Totnes Cheese Factory

Description

This was a full turnkey factory build carried out by the Optimum Flooring team from the ground up. The project spanned over ten individual rooms and incorporated a complete fit-out including hygienic wall systems, environmental controls, drainage, and flooring.

Designed to meet the rigorous demands of food production, the facility required a combination of hygienic finishes, specialist room builds, and durable, chemical-resistant flooring throughout. The end result was a fully fitted environment tailored for production efficiency, safety, and long-term performance.

Project Scope

• Complete Internal Build – Construction of over ten rooms using hygienic Whiterock panelling, tailored for food production zones.
• Environmental Controls – Installation of temperature regulation systems and cold storage facilities.
• Drainage Installation – Integrated stainless steel drainage channels, gullies, basket traps and food-grade gratings.
• Flooring System – Application of a 6mm polyurethane resin screed with 100mm resin coving to all perimeter walls.
• Specialist Doors & Mezzanine – Installation of high-speed, double, and personnel doors, plus a full mezzanine deck structure.

Project Overview

The build began with foundations and mezzanine steelwork, followed by the formation of internal rooms using Whiterock hygienic panelling. Each space had unique requirements for manufacturing, including different door systems to match the specification – high-speed shutters, swing doors, and secure personnel access.

Working in parallel, the drainage team installed stainless steel drainage systems, ensuring all channel connections and backfilling were completed efficiently to maintain programme momentum.

Surface preparation was carried out using an Innovatech three-phase mechanical grinder to create an ideal profile for bonding. A liquid DPM was applied across all floor areas, followed by a 6mm polyurethane screed laid by hand, and finished with 100mm resin coving upstands mechanically fixed to stainless steel perimeter trims. The chosen flooring solution provides excellent chemical, impact and slip resistance — ideal for food factory conditions.