Food-safe Flexiscreen enables food production to continue alongside active construction

Flexiscreen enables food production to continue alongside live works

Charlie Bigham’s is one of the UK’s premium food brands, crafting high-quality, oven-ready meals that have earned a loyal following in major retailers across the country. Their production facility operates around the clock, with hygiene, contamination control, and uninterrupted output fundamental to regulatory compliance and commercial success.

Food production environments are among the most demanding settings for any construction or installation project. Strict hygiene standards, controlled environments, and zero tolerance for contamination mean that any work taking place must be meticulously planned and executed. When Charlie Bigham’s required ongoing construction works adjacent to an active production area, it was critical that dust, debris, and airborne particles from the construction zone did not impact food safety standards.

Over 99% dust containment

With decades of experience delivering segregation solutions in complex, live environments, Westgate Global were well placed to meet the brief. The team specified Flexiscreen in PL665, a translucent, reinforced PVC-coated fabric screen designed specifically for applications where dust containment, structural integrity, and light transmission are required. The translucent material was a deliberate choice, ensuring that natural light could continue to pass through the screen and into the production area, maintaining the working environment on both sides of the barrier. Flexiscreen’s unique panel connection method and tight seal meant that the screen could be engineered around ducts, pipes, and steelwork and still deliver over 99% dust containment. 

End-to-end project management 

The project came with considerable logistical complexity. Installation had to take place out of hours to avoid interfering with production schedules, and it fell during one of the client’s busiest periods, so there was no room for delay or disruption. Access was restricted, working space was tight, and the technical demands of the installation were substantial: fixings needed to pass through fridge-panel ceilings and connect securely to the building’s steelwork. Full structural calculations were also required to verify the screen’s ability to withstand wind loads generated when warehouse loading doors were opened. Westgate Global provided full structural calculations to support the installation, giving the client confidence that the screen would perform safely and reliably throughout the project.

The completed installation was managed end-to-end by the Westgate Global team, providing a robust, food-safe barrier between their live production environment and the ongoing construction works. When the construction phase was complete, the screen could be demounted and reused, offering long-term value beyond the immediate project.

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