Hygienic Wall Cladding for UK Food Facilities: BioClad vs Altro Whiterock
Hygienic wall cladding in UK food manufacturing facilities provides a seamless, non-porous, and chemical-resistant surface that complies with BRCGS Food Safety Issue 9 and EHEDG standards. Systems like BioClad antimicrobial PVC and Altro Whiterock prevent microbial harbourage, withstand continuous caustic chemical washdowns, and are installed using thermoformed corners around live production lines.
What are the BRCGS requirements for hygienic wall cladding in UK food facilities?
Under Clause 4.4 of the BRCGS Global Standard for Food Safety (Issue 9), facility walls must be designed, constructed, finished, and maintained to prevent the accumulation of dirt, minimise condensation and mould growth, and facilitate easy and effective cleaning. Traditional ceramic tiles with cementitious grouting fail modern audit criteria because grout joints degrade under caustic washdowns, creating moisture traps where bacteria thrive.
Modern food facilities deploy continuous semi-rigid PVC sheet cladding. As an established commercial food manufacturing facility contractor, Norfolk Building Group ensures every cladding installation meets stringent audit readiness, combining high impact resistance with seamless thermoformed corners.
BioClad vs Altro Whiterock: Specification and Performance Comparison
Both BioClad and Altro Whiterock represent the gold standard in UK food and beverage wall systems. The following engineering matrix outlines their technical parameters and typical investment thresholds:
| System / Material | Thickness | Antimicrobial Tech | Fire Rating | Indicative Cost |
|---|---|---|---|---|
| BioClad Antimicrobial PVC | 2.5mm | BioCote silver-ion technology impregnated throughout | Class 0 / Class 1 (BS 476 Parts 6 & 7) | £85 to £135 per m² |
| Altro Whiterock White PVCu | 2.5mm | Non-porous high-density virgin polymer surface | Class 0 / Class 1 (BS 476 Parts 6 & 7) | £90 to £145 per m² |
| Standard Commercial PVC Cladding | 1.8mm - 2.0mm | None (standard surface finish) | Class 1 (BS 476 Part 7) | £55 to £80 per m² |
How is hygienic cladding installed around active food production shifts?
Decommissioning an entire food production line for building maintenance is rarely viable. Our commercial teams employ active shift containment protocols:
- Negative Pressure Containment: Active construction zones are isolated with heavy-duty polythene airlocks fitted with industrial HEPA filtration units to capture airborne particulates.
- Off-Site Thermoforming: External and internal corners are pre-formed using specialist heat blankets, reducing on-site cutting and dust generation.
- Solvent-Free Polyurethane Adhesives: Low-odour, non-taint adhesive systems are utilised to eliminate any risk of organoleptic food product contamination.
- Out-of-Hours Delivery: Hot-welding and high-impact operations are scheduled during sanitation changeovers or weekend shutdowns.
Frequently Asked Questions
What is the primary difference between BioClad and Altro Whiterock cladding?
BioClad incorporates BioCote silver-ion antimicrobial technology impregnated into the entire panel during extrusion, killing up to 99.9% of microbes on contact. Altro Whiterock is manufactured from dense, impact-resistant virgin PVCu with seamless thermoformed corners, offering exceptional surface durability under continuous high-pressure hot water washdowns.
Can hygienic wall cladding be installed without stopping food factory production?
Yes. Using temporary negative pressure poly-sheeting, airlock gowning chambers, and HEPA air extraction, works are physically segregated from operational lines. Cladding panels are thermoformed and hot-welded out-of-hours or during scheduled weekend sanitation windows to prevent any cross-contamination.
Why is thermoforming external corners required by BRCGS standards?
Thermoforming uses heat blankets on site to fold solid PVC sheets around corners, creating a continuous curved radius. This eliminates mechanical joint trims, corner silicone beads, and crevices where listeria or salmonella bacteria could otherwise harbour during facility washdowns.
What fire safety ratings must hygienic cladding achieve in commercial food facilities?
Hygienic cladding in UK commercial food premises must satisfy Building Regulations Approved Document B, achieving a minimum of Class 1 surface spread of flame under BS 476 Part 7, and ideally Class 0 under BS 476 Part 6 to reduce fire propagation along escape corridors and production halls.
Food Manufacturing & Industrial Environments
Norfolk Building Group delivers complete food-grade fit-outs, cold-store construction, Grade 316 stainless drainage, and rapid sub-zero floor repairs nationwide.
Explore Food DivisionAll food facility works are executed under direct director supervision with accredited CHAS health and safety compliance and full RAMS documentation.
Comprehensive specification benchmarks, indicative cost matrices, and British Standards guidelines.