Engineered Foam Products needed to carve out a secure, contained area within their existing facility where products could be manufactured without being affected by temperature fluctuations or dust from the surrounding factory floor. We designed, manufactured, and installed a bespoke U-shaped factory partition measuring 9m wide by 20m deep, fitted with two high-speed doors for regular vehicle and material traffic, along with two pedestrian access doors for staff.
The result is a dedicated production zone that separates the manufacturing process from the wider factory environment, helping maintain more consistent conditions while still allowing people and vehicles in the area to move around efficiently.
Engineered Foam Products was producing a product that couldn't tolerate the conditions of the open factory environment. Temperature fluctuations and airborne dust from the surrounding production floor were both potential risks to product quality.
This is a common challenge in manufacturing. Most factories are designed as large, open spaces to make it easier to move machinery, materials and people around. While this works well for general production, it can become problematic when a particular process requires more controlled conditions.
Dust can travel across an open factory floor, temperatures can fluctuate throughout the day, and the regular opening of large doors for forklifts and materials can allow air from the wider building straight into the production area.
A factory partitioning system provides a way to separate these areas without permanently changing the building. Instead of constructing a traditional room or permanent wall, a partition can be designed to fit the existing factory layout and the intended use of the space.
For Engineered Foam Products, the layout itself presented another challenge. The available space and constant movement of vehicles and staff meant a straightforward straight-line partition wouldn't work. The area needed to remain accessible and fully operational throughout the day, while still providing a contained production environment.
The key consideration wasn't simply creating a physical barrier. The factory partitioning system needed to maintain conditions inside the production area while allowing people, vehicles, and materials using the space to continue moving efficiently.
The project started with Engineered Foam Products looking for a practical way to protect their production process from the conditions on the open factory floor. A site survey was carried out by Dale to accurately measure the available space and determine how the factory partition would fit within the existing layout, structures, and traffic routes.
This was an important part of the project because the solution couldn't simply be designed around the space's dimensions. It also needed to reflect how the factory operated every day.
The U-shaped design allowed the partition to enclose the required production area while making use of the available floor space. Rather than forcing the customer to change its existing workflow, the factory partitioning system was designed around it.
The entire project was completed in-house, from design and manufacture through to installation. This meant we could move quickly once the site survey was complete, with the factory partition and doors turned around and installed within five days.
The finished factory partition measured 9m wide by 20m deep, creating a dedicated production zone within the existing factory. The U-shaped design was a deliberate choice based on the site requirements. A straight partition would have been easier to install, but it wouldn't have provided the same enclosed area without interfering with other parts of the factory. By wrapping the partition around the production area, we created an enclosed space on three sides while leaving the surrounding factory floor available for normal operations.
Two high-speed doors were incorporated into the factory partitioning system to allow forklifts, materials and other vehicle traffic to move in and out of the enclosed area.
For a production environment like this, the doors are an important part of the overall solution. Creating a contained area is only effective if it can remain contained during normal operation.
A large door that remains open for extended periods while a forklift passes through can allow dust and ambient factory air to enter the area, affecting conditions inside.
High-speed doors minimise this exposure by opening and closing quickly, allowing vehicle movements to continue without leaving the production area open for longer than necessary.
Two pedestrian access doors were also installed as part of the factory partitioning system.
Having dedicated pedestrian access means staff don't need to use the larger vehicle doors each time they enter or leave the production area. This keeps pedestrian and vehicle movements separate while also reducing the amount of time the main access points need to remain open.
It is a relatively simple addition, but one that makes a significant difference to the practicality of the factory partition in everyday use.
Engineered Foam Products now has a dedicated, enclosed production area that provides greater separation from the conditions of the wider factory.
The factory partition helps reduce the impact of airborne dust and temperature fluctuations on the manufacturing process, creating a more controlled environment without requiring a permanent alteration to the building.
The U-shaped design also means the system works with the existing factory layout rather than against it. Forklifts and materials can continue to move through the area using the high-speed doors, while staff have separate pedestrian access.
The result is a factory partitioning system that does more than simply divide one part of a building from another. It has been designed around the actual requirements of the production process, the available space and the way people and vehicles move through the facility.
Because the complete system was designed, manufactured and installed in-house, the project could also be delivered quickly, with the full solution completed within five days.
For manufacturers looking to create a more controlled production environment without committing to a permanent construction project, a bespoke factory partition can provide a flexible and practical alternative.