PolySto develops stronger wall protection using its own production surplus
The new generation of CleanRock® kerbs combines circular materials, an innovative foot design and improved food safety.
PolySto, a specialist in hygienic construction solutions for the food industry, is launching a new generation of CleanRock® kerbs for wall protection. Whilst sustainable construction has long focused primarily on energy performance, there is now a growing focus on the materials used and the environmental impact of building components. By reusing production waste from its own manufacture of glass fibre-reinforced polyester panels (FRP, or Fibre Reinforced Polymer) as raw material and introducing a new patented base design, the company has developed a stronger and more sustainable solution for one of the most critical areas in food production environments: the transition between wall and floor.
From production surplus to raw material
The renewed composition of CleanRock® kerbs is the result of several innovation projects focusing on circular composite materials. A research project with Sirris, supported by the FPS Public Health, demonstrated that recycled composites can contribute to stronger and more sustainable end products. This insight prompted PolySto to reuse production surpluses from its own glass fibre-reinforced polyester (FRP) panels as raw material.
With the support of the Province of East Flanders, PolySto took the step towards the effective use of recycled material in a new generation of products. By grinding down waste streams and reusing them as raw materials, the company developed an updated CleanRock® formulation containing recycled content.
“This project demonstrates how collaboration between industry, research institutions and regional partners can lead to tangible innovations with an international impact,” says Linde De Vriese, project leader for the Circular Economy, Composites and Renewable Materials at Sirris.
According to Koen Horsten, COO at PolySto, the project also demonstrates that circularity and product performance can go hand in hand: “What began as research into circular materials has evolved into an innovation that is both more sustainable and delivers better performance. By reusing production surpluses from our own FRP panels as raw material, we can preserve valuable materials and further improve the performance of kerbs.”
A fresh take on the wall-to-floor transition
The joints between walls and floors are among the most critical areas in food processing facilities. They are exposed daily to internal transport, heavy use and aggressive cleaning procedures. Damaged or porous surfaces shorten a building’s lifespan and pose a risk of hidden contamination, with potential consequences for audit results, production downtime or product recalls. Kerbs protect walls from impact damage and contribute to a sustainable, easy-to-clean production environment.
The new generation of CleanRock® kerbs combines high impact resistance with a non-porous structure that does not absorb water and can withstand intensive cleaning. In addition, PolySto is introducing a new, patented base design that channels rinse water in a controlled manner towards the drainage system and minimises uncontrolled splashing.
“Food safety starts with the details of a building”, says Jasper De Jaeger, CEO of PolySto. “The wall-to-floor transition is one of the most underestimated risk areas in a production environment. That is why, with the new generation of CleanRock® kerbs, we have focused not only on strength and durability, but also on hygienic design. From material selection to water drainage: every detail has been developed to help food companies make their production environments safer and easier to clean.”
An integrated construction solution for food safety
The new CleanRock® kerbs form part of PolySto’s broader vision for hygienic construction. Combined with CleanSheet® wall and ceiling systems and HygiSeal® joints, they provide an integrated solution for food-safe production environments.
From its base in Lokeren, PolySto has been developing and manufacturing integrated solutions for food production environments for over 30 years, treating walls, floors, ceilings and finishing details as a single, cohesive whole. The company currently carries out projects in more than 100 countries worldwide and has been part of the portfolio of investment firm Sofindev since 2025. With the launch of the new generation of CleanRock® kerbs, the company is reaffirming its ambition to help shape the future of hygienic construction.
