Flexicurtain delivers hygienic line separation for Birds Eye

Meeting hygiene standards on food production line

Food manufacturing operates under some of the most stringent hygiene and safety standards of any industry. For producers such as Birds Eye, operating multiple production lines, managing the risk of cross-contamination is non-negotiable. As manufacturers face increasing pressure to maximise output, staggered production schedules are becoming the norm — when one line is being washed, an adjacent line remains in production — making adequate and hygienic separation between the two absolutely vital.

This was precisely the challenge facing Birds Eye at its Lowestoft facility. Changes to production schedules and staff shift patterns meant that cleaning two production lines could no longer be done simultaneously. Where different product types are handled across adjacent lines, overspray during washdown carries a serious risk of introducing undeclared allergens or cleaning chemicals into active production, which is one of the most common triggers for product recalls. With Birds Eye’s reputation and regulatory compliance on the line, a reliable, proven solution was essential.

Westgate Global proposed the Flexicurtain system, a fully retractable industrial curtain solution that provides instant space separation without requiring permanent construction or costly downtime.

Flexiwall prevents overspray during washdown

Manufactured from reinforced, fire-rated PVC with antibacterial coatings, the system is resistant to cleaning chemicals, making it suitable for food, beverage and washdown environments. For Birds Eye, the option of antimicrobial finish meant the solution could meet the facility’s strict hygiene and compliance requirements. 

The Birds Eye installation required drilling into the ceiling structure, which meant careful scheduling was needed to avoid any impact on production. Westgate coordinated all installation work over the Easter Bank Holiday weekend, ensuring the facility was fully operational and compliant when staff returned. 

Westgate Global installed 40 linear metres of curtain to the full height of 4.5 metres. A vision panel was incorporated across the curtain, allowing production staff to monitor activity on both lines simultaneously without compromising the protection barrier. Once in place, the retractable design allowed areas to be opened or closed in seconds, giving Birds Eye production teams the flexibility to adapt instantly to changing operational demands. 

The result was a practical, scalable solution that eliminated the contamination risk, preventing overspray from the washdown process from reaching the active production line, while allowing both areas to continue functioning as normal. 

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