A ‘can-do’ attitude for Frucor Beverages
With a large amount of equipment waiting to be installed in their new canning and pasteurising area, Frucor Beverages was working to a precise deadline.
That’s why they chose to work with the expert team at Topcoat Specialist Coatings – and a revolutionary quick-curing concrete system – that saw the job roll out exactly to schedule, on time and on budget.
The challenge
Frucor Beverages makes some of New Zealand’s most well-known drink brands; including Fresh Up, Just Juice, Mizone, V energy drink, and others.
In October 2010, Frucor introduced a new production line at their site in Wiri, South Auckland. The equipment, which was second hand, had been reconditioned by the German manufacturer Krones.
The project was 12 months in the planning – and as Frucor Beverages Technical Services Manager, Tony Fisher explains, it had some very specific end dates.
“We knew what dates we were aiming for when we ordered the equipment, and the floor had to be ready,” says Tony.
“We had thirty 40-foot shipping containers arriving from Germany, and a team of six people coming from overseas to complete the installation.”
One of the key factors in meeting the deadline was the fast-curing concrete solution recommended by Topcoat. UCRETE® DP is a unique heavy-duty polyurethane resin technology, supplied by chemical company BASF New Zealand Ltd.
“Topcoat finished on the Friday, and the equipment was installed on Monday,” says Tony.
“We literally drove a 40-tonne crane across it to position a tank two days later.”
BASF Ucrete features
Frucor had originally specified an epoxy paint system for the main packaging area. However after recommendations from Topcoat, Frucor decided to invest in the Ucrete MF 4mm system.
“We know it will give us a longer-lasting solution, than if we just used an epoxy paint system.”
“We liked the fact the product was non-odorous, and that it would save us time,” says Tony.
UCRETE® DP is specifically developed for the food and beverage, pharmaceutical and chemical industries; and is used in many such facilities worldwide.
As part of the selection process, Frucor had also visited the new Lion Breweries site in East Tamaki. During the massive building project over the last two years, Topcoat Specialist Coatings has installed approximately 8,000m² of Ucrete DP6 at the new brewery.
“We were happy with what we saw there, as it’s a similar use to our facility,” says Tony.
“The speed and ease of application made Ucrete an attractive option.”
On this project, BASF also offered advantages when forming the falls to drains over the top of the old existing concrete floor in the warehouse. Specified BASF concrete additives allow falls in the floor to be laid in low shrinkage, high early strength concrete. Topcoat was laying the Ucrete DP6 polyurethane flooring 4 days later.
“The BASF Ucrete DP system is one of the only products that can adhere to green concrete,” explains Brett Wheeler, New Business Manager for Topcoat Specialist Coatings.
“We can lay BASF Ucrete over new concrete. Normally with green concrete we wait 28 days before putting a topping over it, but with Ucrete it’s just 3-4 days.”
Other advantages
The Ucrete product offers outstanding resistance to aggressive chemicals and heavy impact, and is designed to withstand temperatures ranging from -40ºC up to 120ºC.
According to Brett, UCRETE® DP offers flexibility to suit the varying needs of a processing plant.
“In most food and beverage plants, there are usually areas within the plant that have different flooring requirements. At Frucor, for instance, the flooring was divided into wet and dry areas. We used 6mm in the filling room and pasteurisng area, where there’s a wash down section with strict hygiene standards that had to withstand 60-80ºC hot water. In the packing area, which is dry, we used 4mm.”
Frucor’s new floor also has a non-slip surface to meet health & safety requirements; and a minimum of control joints to minimise contamination and unsightly joints, ensuring a seamless finish.
Superior service
With the tight time-frame on this project, Topcoat’s responsiveness of service was a key asset. In fact the Topcoat team not only worked to schedule – they worked ahead of schedule.
“We actually started the building process a couple of week’s further out than we’d planned,” says Tony.
Fortunately, Topcoat was able to recoup some of that time.
“We shortened our time frame, used our large labour force and managed to gain one week, allowing Frucor access to the floor earlier than expected,” says Brett.
Although it was the first time Frucor had worked with Topcoat, the two businesses now have a trusted partnership.
“The other thing that was notable about this job was that everything happened quite smoothly – and the Topcoat team was really good to work with,” says Tony.
“There were some solutions that were needed ‘on the go’. Topcoat worked well with everyone, including their sub-contractors, to fine-tune the solution as they went.”
Client: Frucor Beverages Ltd
Location: Wiri, South Auckland
Architects: BECA Group
Main Contractors: Cassidy Construction
Flooring team: Topcoat Specialist Coatings Ltd
Products: BASF UCRETE® DP 6mm,
BASF UCRETE® MF 4mm,
BASF High Early Strength, Engineered Concrete
Total Square Meters: 1600m2
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