Case Study: Food Factory Strip Curtain Installation — HACCP Compliant, Sheffield

Last updated: April 2026

Client Background

Northern Provisions Ltd is a Sheffield-based food manufacturer producing cooked meat products, pies, and pastry items for foodservice and retail distribution. The factory holds BRCGS Global Standard for Food Safety Grade A accreditation. The facility operates clearly defined raw, high-care, and packing zones in accordance with BRCGS Clause 4.3. A production line reconfiguration created two new internal openings requiring physical barriers, and a BRCGS pre-audit identified three existing external-facing openings needing attention.

The Challenge

Opening A: Raw Pastry Store to Packing Hall (Critical Control Point)

A 2.2m wide × 2.8m high opening between the raw pastry ingredient store (unclassified zone) and the cooked product packing hall (high-care zone). Classified as a critical control point in the HACCP plan — any contamination route between raw and cooked product areas had to be physically controlled.

Opening B: Pastry Production to Packing Hall

A 3.0m wide × 2.8m high opening between the baking area (22–28°C) and the packing hall (12–16°C). Primarily a transit route for baked product; physical separation required to control airborne contamination and the temperature differential.

Three Existing External Openings

Goods inward door (damaged strips), waste disposal area door (no pest exclusion), and canteen delivery entrance (inadequate pest proofing) — all identified in the BRCGS pre-audit as requiring action.

Solution Selected

Opening A (Critical Control Point)

  • 200mm × 3mm food-grade anti-microbial PVC, made-to-measure; stainless steel twin track rail
  • Floor clearance: 15mm; Blue strips on raw zone side, clear strips on cooked side
  • Daily strip wipe with food-safe sanitiser; weekly removal and wash
  • Strip curtain specification formally entered as a critical control measure in the HACCP plan

Opening B

  • 200mm × 3mm food-grade clear PVC, made-to-measure; stainless steel hook-on rail, 3.0m; 50% overlap

Three External Openings

  • All fitted with food-grade ribbed anti-insect PVC, 200mm × 3mm (goods inward and canteen) or 200mm × 2mm (waste disposal), on stainless steel hook-on rails

Total material cost: £2,140 + VAT. Installation: in-house maintenance team, one day.

Results Achieved

BRCGS Audit Outcome

The BRCGS audit conducted two months after installation awarded Northern Provisions an AA grade (up from A). The auditor specifically noted the appropriate physical barrier at the raw/cooked product boundary with documentation in the HACCP plan, and the closure of the previous minor non-conformance regarding external opening pest proofing.

Fly Control

Fly trap monitoring in the packing hall: average 12 trap counts per week pre-installation; reduced to average 2 counts per week post-installation — an 83% reduction.

Temperature Compliance (Packing Hall)

Packing hall temperature maintained at 12–16°C target range 97.3% of monitored time (improvement from 91.2% prior to Opening B strip curtain installation).

Key Learnings for Food Manufacturers

  • The strip curtain specification must be formally entered into the HACCP plan, not just installed
  • Monitoring procedures and corrective actions (immediate strip replacement) must be documented
  • Cleaning schedules must be specific (frequency, method, chemicals) with records kept
  • Staff training on the purpose of barriers must be documented

View our food-grade and anti-microbial PVC strip curtains.