99% dust-tight containment for live food manufacturing at Kerry Group

Hygienic production for food manufacturing plant

Kerry Group operates globally across the food, beverage, biotechnology, pharma and proactive health sectors, supplying customers in more than 140 countries. Their production environments must meet strict national and international safety and contamination-control standards. 

When Kerry needed to relocate a production line within their Berlin facility, the work had to be completed while the factory remained live. The work created a high-risk challenge. Dust generated during installation must not be allowed into active production areas, where it could compromise product quality and strict global production standards.  

Kerry needed a solution that would keep production moving, maintain safety and quality standards, and minimise disruption, while the installation work continued just metres away.  

99% dust tight seal for compliant manufacturing

Having worked together in the past, Kerry Group knew that Westgate Global had the solutions and expertise to meet the challenge. Following a full site survey, the Westgate team designed, manufactured and installed a temporary Flexiscreen dust control barrier to separate the live production environment from the installation zone.  

A 7m high x 47m wide Flexiscreen was suspended from a tensioned cable fixed to the building’s concrete structure. The screen was then fully tensioned, sealed and secured to the concrete floor, creating an air-tight physical and environmental barrier between the works and ongoing production.  

Flexiscreen is engineered to control dust, temperature, noise and contamination in live, high-risk environments, so critical production can continue safely while work progresses close by. Its unique v-overlap joining method delivers an over 99% dust-tight seal, and is suitable for creating ISO Class 7 cleanroom areas, making it ideal for food and regulated manufacturing environments where contamination control is critical. 

To maintain safe access without compromising protection, the installation also included a Flexistrip curtain access point to allow staff to move in and out of the production area. A Flexicurtain access point was also installed to maintain hygiene compliance while moving new plant and manufacturing equipment into the installation area.  

Westgate Global took responsibility from survey through to final compliance checks, minimising risk and operational impact. The team turned the design and manufacturing around in under four weeks, then deployed experienced, certified UK installation teams to deliver the project safely and efficiently. The full installation was completed in just five days, ensuring Kerry’s production could continue with minimal disruption.  

Throughout the project, Westgate Global’s contracts team maintained constant communication with Kerry stakeholders to keep milestones on track. A further site visit, including a full Health and Safety compliance audit, was also conducted by the experienced Westgate Global team.  

The success of this project reinforced Westgate Global’s role as a dependable delivery partner in live, high-risk environments, leading to further Flexiscreen installations at the Berlin site, as well as at Kerry’s Manchester (Hyde) plant.