Impact Protection for Food Environments at Keohane Foods, Bantry
Keohane Foods is a well-established food distribution business based in Bantry, Co. Cork. With a busy operational facility handling daily food production and distribution, protecting both personnel and infrastructure while maintaining the highest standards required in a food environment was a key priority.
Polybar was engaged to design and supply a suitable impact protection solution for the facility, with a particular focus on perimeter door protection across key operational areas.
Installation Project Overview
Polybar worked closely with our installation partner to assess the facility layout, understand the specific risks within each zone and design the most suitable protection solution for the environment. We attended the site during the installation to provide technical support and ensure the system was installed correctly and to the highest standard.
The installation included a combination of:
These products were selected for their proven performance in food production and distribution environments, where safety, hygiene and material suitability are all critical considerations.
Our Client Challenges Addressed
Keohane Foods required a protection solution that could perform reliably in a working food facility without compromising hygiene or creating contamination risk. This ruled out steel-based systems, which corrode over time and shed paint and metal particles on impact, both of which present serious contamination hazards in food environments.
The facility also required protection at perimeter doorways and high-traffic access points, where forklifts and pedestrians regularly converge and where the risk of impact to door frames, structural elements and personnel is at its highest.
Key challenges included:
Protecting doorways and perimeter access points from forklift impact without restricting operational flow.
Selecting materials fully suitable for a food production and distribution environment.
Designing a layout that addressed the specific traffic patterns and risk zones of the Bantry facility.
Completing the installation with minimal disruption to ongoing operations.
Our Impact Protection Solutions
Polybar's P-FLEX range was specified for this project due to its unique suitability for food environments. Unlike steel barriers, P-FLEX products are manufactured from resilient synthetic polymer that does not corrode, does not require painting and does not shed particles on impact. This makes the range the most appropriate choice for any facility where hygiene standards must be maintained alongside operational safety.
P-FLEX Goalposts were installed at key doorways to protect door frames and the surrounding structure from forklift contact, while allowing vehicles to pass through without restriction. P-FLEX Bollards were positioned at critical points to define safe zones and prevent vehicle encroachment into pedestrian and structural areas. P-FLEX Barrier Rails were installed along high-risk vehicle routes to create clear physical separation between forklift traffic and facility infrastructure.
The system was designed in full collaboration with the installation team, with Polybar providing on-site support throughout the installation process to ensure every element was positioned correctly and performing as intended from day one.
Impact Protection Results
The completed installation provides Keohane Foods with a durable, hygienic and fit-for-purpose impact protection system across their Bantry facility.
Doorways and perimeter access points are now protected against forklift contact, reducing the risk of structural damage and costly repairs.
Clearly defined vehicle and pedestrian zones improve day-to-day safety for the full operations team.
The polymer system requires minimal maintenance and will not corrode, chip or shed particles in the food environment.
The installation was completed without significant disruption to the facility's daily operations.
Polybar's on-site presence throughout the installation ensured quality and accuracy at every stage.
How Can We Help You?
If you manage a food production, food distribution or hygiene-controlled facility and are reviewing your current impact protection setup, Polybar are here to help. We provide bespoke specification support, including layout guidance and product selection tailored to the specific demands of your environment.
Get in touch with our team today to arrange your first consultation.
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