Food production facility, Southall, anti-bacterial pre-finished steel used to create anti-bacterial food factory.

Food production facility, Southall, anti-bacterial pre-finished steel used to create anti-bacterial food factory.

Noon Products Ltd, Southall

Client: Noon Products
Type of works: anti-bacterial pre-finishes steel from Corus used to create anti-bacterial food factory.

When leading ethnic food producer, Noon Products Ltd was considering the design of its prestigious new facility in Southall, providing an environment of the highest cleanliness was at the top of the agenda. Specifying Assure™ pre-finished metals with Microban® anti-bacterial protection was a natural choice to help support the company's risk management systems.

At 108,000ft², the building is the largest of its kind in Europe and has been built to meet the increasing demand for ready-made meals. Noon Products, the number one ethnic food supplier in the UK, manufactures ready meals for Sainsbury's, Waitrose, Morrisons, Safeway and Birds Eye Walls'. The building utilises a steel portal frame design with composite-steel panels on the exterior. The interior of the building is compartmentalised into cooking and packaging areas, using insulated panels. Due to the nature of ready meal production, the majority of the processing and packaging areas are considered high-risk. In these areas, all ceiling and wall panels have Assure™ pre-finished steel with Microban® anti-bacterial protection.

Sir Gulam Noon MBE, Chairman and Managing Director of Noon Products Ltd explains, "Given the requirements for first-class hygiene, we saw an opportunity to provide our customers with a kitchen environment which not only has the highest levels of cleanliness, to help protect our manufacturing process, but which also incorporates new technology to help reduce the risk of bacterial growth. This is particularly beneficial between clean downs and other standard operating practices. We chose to work with Corus and use Assure™ panelling as it addresses all the necessary requirements for maximum anti-bacterial protection."

Specifically, Assure™ is used to help reduce the potential for listeria monocytogenes in overhead ceiling condensation reduce mould growth on walls and ceilings and to tackle cross-contamination from walls caused by hand contamination.

The management team at Noon Products places technology and innovation at the core of its business values. The company was an early adopter of Microban-protected products, previously using them in flooring, clothing and machinery.

To have protection in the walls and ceilings of high-risk areas created the opportunity to provide a holistic anti-bacterial solution; thereby helping to minimise the risk of cross-contamination. Given growing public concern and stringent requirements for hygiene-critical environments, particularly in the food supply chain, this places the factory firmly at the cutting edge of industrial food manufacturing.

On this project, Assure™ was used as the facing material on insulated panels, which were fabricated and supplied by Eurobond Laminates. The insulated panels provide a cost-effective way of compartmentalising this type of building due to the ease of installation, thermal insulation properties and the cleanability of the installed panel. Food production creates a demanding environment for surface coatings, and, for this application, Assure has been produced in the Stevlvetite CES anti-static format.

Stevlvetite CES has an impressive track record in food production environments, as it is cleanable, non-tainting and provides good resistance to corrosion. Corus has developed Assure™ to utilise the benefits of Microban® anti-bacterial protection without affecting the properties already associated with the pre-finished steels.

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