Disinfection — Factory Floor, Shah Alam Industrial Zone

Factory Floor Disinfection — Shah Alam Industrial Zone Case Study

The facilities manager of a mid-sized manufacturing company in Shah Alam Industrial Zone contacted us after a cluster of staff absences linked to a suspected gastrointestinal illness in the production area. The company was also preparing for a scheduled audit by their overseas client and needed documented professional disinfection as part of their hygiene compliance record.

The Problem

The facility occupies approximately 8,000 sq ft and operates two production shifts daily, six days a week. The layout includes a main production floor, a raw materials storage area, a finished goods warehouse section, a staff changing room, and a loading bay. With dozens of workers moving through shared spaces and equipment every day, maintaining a hygienic environment is both a regulatory requirement and a practical necessity.

The specific concerns raised by the facilities manager included:

• Five staff members had reported illness symptoms over a two-week period — suspected gastrointestinal in origin
• Shared equipment including conveyor surfaces, workbenches, and pallet handles had not been professionally disinfected in over six months
• The loading bay and storage area had visible organic residue accumulation in floor joints and corners
• An upcoming client audit required documented evidence of a professional hygiene programme
• The canteen and changing rooms had not been included in any prior cleaning contract

Our commercial disinfection service was recommended as the appropriate solution — a single comprehensive treatment covering all zones, scheduled during the overnight window to avoid any disruption to production.

Our Approach

Before the treatment date, our team conducted a site walk to map all zones, identify high-touch surfaces, and confirm the correct disinfectant formulations to use — particularly important given that the facility handles materials that may have specific chemical compatibility requirements.

We divided the facility into treatment zones:

• Zone A — Production floor: Conveyor lines, workbenches, equipment surfaces, control panels, floor drains
• Zone B — Raw materials storage: Shelving units, floor surfaces, wall-floor junctions, ventilation grilles
• Zone C — Finished goods area: Pallet staging areas, forklift high-touch zones, roller shutter interior surfaces
• Zone D — Staff facilities: Changing room lockers, toilet fixtures, canteen tables and surfaces
• Zone E — Loading bay: Floor surfaces, door handles, loading dock edges, waste collection point surrounds

The Treatment

Our three-person team arrived at 11:00 PM after the final production shift had ended. The treatment was completed in a single overnight session, with the facility cleared for re-entry by 4:00 AM — well ahead of the 6:00 AM start of the early morning shift.

The disinfection process followed a structured sequence:

1. Pre-cleaning sweep: Loose debris and surface contamination was removed from production floor drains and storage floor joints before disinfectant application to ensure maximum product contact with surfaces.
2. Surface disinfection — high-touch points: Hospital-grade quaternary ammonium disinfectant was applied to all shared equipment surfaces, door handles, control panels, and workbench tops using microfibre application cloths with a dwell time of 10 minutes.
3. Electrostatic spray — open areas: An electrostatic sprayer was used to apply disinfectant across the production floor, storage shelving, loading bay surfaces, and staff facilities. Electrostatic application ensures the product wraps around surfaces — including underside areas and shelving rear panels — for comprehensive coverage.
4. Floor treatment: All floor surfaces were treated with a disinfectant solution applied at manufacturer-recommended dilution, with particular attention to floor-wall junctions and drainage channels where microbial loads tend to concentrate.
5. Ventilation and aeration: Upon completion, all roller shutters were opened and ventilation fans activated to ensure the facility was fully aired out before staff entry in the morning.

A treatment completion certificate was issued on-site, documenting the products used, dilution rates, treatment zones covered, and technician credentials — suitable for inclusion in the client's hygiene audit file.

Results

The facilities manager reported no further staff illness cases in the four weeks following the treatment. The client audit was completed successfully, with the disinfection certificate accepted as part of the hygiene compliance documentation.

The company subsequently signed up for a quarterly maintenance disinfection programme — scheduled to coincide with their internal audit cycle. Each quarterly session covers all five zones and includes an updated completion certificate for record-keeping. The loading bay and storage areas are now included as standard, having previously been omitted from the facility's regular cleaning scope.

For manufacturing facilities in the Shah Alam Industrial Zone and surrounding areas, maintaining a documented professional disinfection schedule is increasingly expected by overseas clients and local regulatory bodies alike — and is one of the more straightforward hygiene measures a company can put in place.

"Very efficient team. They finished on time, the certificate documentation was exactly what we needed for our audit, and there was no chemical smell left behind by the morning shift. Will be using them on a quarterly basis going forward."
— Facilities Manager, Shah Alam Industrial Zone