Business Challenges
Otis Spunkmeyer is known as a pioneer in the
fresh-baked cookie business, and a leader in the
sweet baked goods industry servicing customers in
over 56 countries around the world. One specific
location needed attention. The Pennsylvania 80,000
square foot facility that bakes cookies and muffins
was in a state of disrepair. The plant’s flooring was no
longer safe and sanitation was becoming an issue.
Eric Tonsetic, plant manager for the Pennsylvania
facility was new to the Company, but was not new to
addressing and rectifying safety and sanitation issues.
With only a week on the job, Eric took on the
responsibility of the flooring project and worked with
his team to set the company's goals.
The project was divided into two sections: cookies
production area would be completed first, followed
by muffins. Each would take place over the course
of 5 days, from Friday through Tuesday with
production beginning on Wednesday morning. This
would minimize downtime and allow for complete
wash down and sanitation of all equipment.
The Evaluation
Otis Spunkmeyer's evaluation resulted in the choice
between two floor surfacing companies. One
company which outsourced its installation crew and
the other which retained in-house talent. Otis
Spunkmeyer decided on Concare for its all employee
based-company with highly knowledgeable and
experienced staff.
Concare and Otis Spunkmeyer worked together on
the details of the implementation schedule.
Goals for a New Flooring System
•
•
•
•
Get the job done quickly for minimal
impact to production
Minimize dust from installation
Floor must have a better way to release
water
Chemical resistant from frequent wash
downs
Removal of the old
topping system
Preparation
The preparation began with the removal of certain
equipment, while conveyor belts and other forms of
equipment that were not to be removed were
thoroughly covered in plastic to protect from dust and
debris. A plastic sheet was hung from the top of the
ceiling down to the floor clearly defining and
protecting the work area. A section in the facility was
defined as the "Prep Area" for materials, clothing and
safety equipment such as hair nets and masks.
Installation - Solution
The preparation began with the arrival of the Concare
crew at 4:14 a.m. Within 20 minutes, the crew began
the all important preparations with 2.5 days of grinding,
chipping and demolition and completed these tasks on schedule. Next, Concare installed its Guardright CU-Q
solution consisting of Protective Industrial Polymers cemetitious urethane flooring and high performance stain
resistant polyurethane finish. There were special considerations made to the installation to ensure it met the
needs of Otis Spunkmeyer. For example, the texture had to be slip resistant when dusted with flour, yet
cleanable with power cleaning equipment.
•
•
•
Traction or non-slip flooring to identified critical safety areas supporting people and cart traffic
Pitching and leveling to allow for proper drainage
Coving around the legs of unmoved equipment to keep bacteria and insects from accumulating
Otis Spunkmeyer broke the traditional red color floor surface opting for a lighter gray color. The benefits were
unexpected. The lighter gray color brightened the facility, added lumens and boosted morale.
Clean Up
Preparation is crucial to an efficient and quick clean up. Once
Concare completed its routine clean up and removed the plastic
coverings, Otis Spunkmeyer had only its usual wash down
procedures to perform. Debris and excess dust were removed by
the Concare team as installation was being performed minimizing
potential clean up issues by Otis Spunkmeyer. In addition,
careful entry and exit from the work area was tightly controlled by
Concare contributing to the easy clean up.
Results
A year after installation, the floor continues to perform with employees taking pride in
the investment with consistent care. Concare left a floor repair kit in the event an
emergency situation arose. The repair kit continues to sit unused on the shelf.