In a food plant, stopping a production line to replace the floor is almost never an option. The 2025 project at PT Mayora Indah shows how 2,000 m2 of floor was laid while the plant kept operating.
Can a factory floor be coated with epoxy without stopping production? Yes, if the area is split into zones and the schedule is set with the plant team. At Mayora, 2,000 m2 of self levelling floor was finished in 21 working days without stopping operations.
Project data
- Client: PT Mayora Indah
- Year: 2025
- Area: 2,000 m2
- Duration: 21 working days
- System: self levelling epoxy (SL)
The challenge
Working time was limited because the plant stayed in operation. The floor could not be closed all at once, and every closed area meant production or logistics routes had to be diverted for a while.
In a food plant the floor work also must not spread dust into running production, so grinding areas had to be screened off.
The approach: zone by zone
The area was divided into zones worked in rotation. Each zone went through the full sequence, grinding, primer, self levelling coat and cure, before it was handed back to the plant. Extra crew worked the non-production areas so the zones that did not affect the lines could finish faster.
That way each part of the plant was only closed while its own zone was being done, not for the whole project.
What carries over to other plants
The principle works in any plant or warehouse that cannot stop: split the area by workflow, not just by floor plan, agree the zone order with operations, and put cure time into the schedule before an area goes back into use.
The full photo set is on the Mayora project page.
