Alfaplas Limited, located in Hereford, is a specialist printer of polyethylene, polypropylene, foil, and paper materials. As part of the SP Metal Group, one of Europe’s leading manufacturers of household packaging products, Alfaplas has built a reputation for high-quality production and printing of items such as mailing films, plastic carriers, and food wrap. The company operates in two main areas: the production area, where plastic pellets are processed into film, and the printing area, where the film is printed and finished. Both areas are held to high cleanliness standards to ensure the integrity of the finished products.

The Challenge

While flying insects occasionally posed a risk of contamination during production, Alfaplas’ larger concern was controlling these pests while still maintaining a comfortable working environment for their employees. Closing all doors to the factory was not a viable solution, as it restricted ventilation and natural daylight, which was crucial for operator comfort—especially during warmer days when large access doors were often left open. Alfaplas sought a solution that would effectively block insects from entering while still allowing fresh air and light to flow into the facility.

Solution

Alfaplas turned to Galebreaker Industrial, specialists in weather protection systems that also allow for airflow and light passage. After collaborating with the team at Galebreaker, Alfaplas ordered two 6m x 5m roller doors to fit inside their existing metal sliding doors. These doors were designed to allow sufficient clearance for the outer doors to open and close, ensuring smooth operation.

The key features of the new doors included:

• Fine mesh panels: Made from grey mesh with one-millimeter holes, allowing for 25% permeability. This provided filtered airflow while maintaining a light, pleasant environment for the operators.
• Dense brush seals: Fitted around the sides of the doors to ensure a tight seal, preventing flying insects from entering the production areas.
• Motorised operation: The doors are raised and lowered via a motor with a push button for easy access.
• Lateral wind bars: Reinforced the door within the side guide rails, providing added strength and stability.

The entire installation process was completed in just two days, minimising disruption to daily operations.

Benefits

The new roller doors have provided Alfaplas with several key advantages:

1. Flying insect control: The mesh effectively prevents insects from contaminating the production areas, especially during the night when factory lights attract pests.
2. Improved ventilation: The mesh allows fresh, filtered air to flow into the building, improving air quality and maintaining a comfortable working temperature during warmer weather.
3. Enhanced lighting: Natural daylight can still enter the facility, maintaining a well-lit environment without compromising insect control.
4. Low maintenance and cost-effective: The system is easy to maintain and offers a long-lasting, low-cost solution compared to other pest control methods.

Feedback

John Hodgson, Alfaplas’ Maintenance Manager, praised the solution, saying, “Galebreaker have provided us with a low-cost, easy-maintenance solution. Their installation team was very professional—so much so that you wouldn’t have known they’d been on site. The system works very well, especially at night when the lights in the factory area draw insects. Now the doors can be left open to allow cool air in, and nothing else.”

Conclusion

The installation of the Galebreaker roller doors at Alfaplas Limited has successfully resolved the issue of flying insects entering the production areas while maintaining an ideal working environment. With the added benefit of natural light and fresh air, Alfaplas can continue to operate efficiently while focusing on the quality and cleanliness of their products. As the company expands its operations and continues to introduce new processes, the roller doors will remain a vital part of ensuring a comfortable, pest-free environment for both staff and production.

Find out more about Galebreaker’s door options here.