Upgrading Factory Surfaces: Switching from Steel to PE500 Sheets

Introduction

In the fast-paced world of industrial operations, factory surfaces endure relentless wear and tear. Whether it’s heavy machinery, chemical exposure, or strict hygiene demands, the materials used underfoot and around production lines must meet incredibly high standards. For decades, stainless steel has been the go-to option  valued for its strength and clean finish. But as factories evolve, so too must the materials they rely on.

Enter PE500, also known as High Molecular Weight Polyethylene (HMWPE)  , a powerful alternative that’s quietly revolutionising how factory environments are built and maintained. From food production lines to pharmaceutical plants, more and more UK businesses are making the switch from steel to PE500. Why? Because it’s lighter, quieter, corrosion-resistant, and tailored for the realities of modern industry.

This blog explores exactly why switching from steel to PE500 sheets can deliver major benefits for your factory  including improved safety, lower maintenance, and long-term cost savings. We’ll also show you how this smart, future-proof material is helping companies across the UK modernise their facilities with confidence.

What Is PE500 (HMWPE) and Why Is It Used in Industrial Settings?

Key Material Properties of PE500

PE500, also known as High Molecular Weight Polyethylene (HMWPE), is a premium-grade engineering plastic that’s earning its place as a steel alternative in many industrial environments. It’s a mid-range material in the polyethylene family, denser and tougher than HDPE (PE300), but more cost-effective than UHMWPE (PE1000). This balance makes it a favourite for applications where durability, hygiene, and low-friction performance are essential.

One of the standout features of PE500 is its exceptional impact resistance, even at sub-zero temperatures. It performs reliably in environments ranging from −100 °C to +80 °C, making it suitable for cold storage, food processing, and chemical-heavy zones. Unlike steel, PE500 doesn’t corrode, rust, or react to moisture  meaning no flaking, no paint, and no surface degradation over time.

It also offers:

• Low coefficient of friction – ideal for sliding surfaces and conveyor systems.
  
• Excellent chemical resistance – perfect for factories using cleaning agents or acidic substances.
  
• Noise-dampening properties – quieter than steel when handling parts or machinery.
  
• Food-safe compliance – available in colours like blue and white for easy industry coding.
  

How PE500 Compares to Other Plastics (HDPE, UHMWPE)

Compared to HDPE (PE300), PE500 is tougher and more wear-resistant, with superior load-bearing capabilities. It can handle high-impact tasks where basic plastic sheets would fail. Meanwhile, UHMWPE (PE1000) offers even higher performance — but at a premium price. For most factory applications, PE500 strikes the ideal middle ground: affordable yet highly durable.

That’s why PE500 is widely used in:

• Cutting boards and food prep stations
  
• Conveyor line wear strips
  
• Sliding chutes and packaging tables
  
• Bin liners and silo linings
  

If your factory needs material that’s strong, safe, and easy to maintain, PE500 is a smart upgrade  and it’s available cut-to-size from PrimePlasts.co.uk.

Why Upgrade from Steel to PE500 for Factory Surfaces?

Corrosion-Free and Hygienic for Food & Pharma

Steel surfaces may be strong, but they come with a major drawback: corrosion. In high-moisture or chemically aggressive environments, steel can rust or degrade, leading to contamination risks, safety hazards, and expensive repairs. That’s a big issue in sectors like food processing and pharmaceuticals, where cleanliness and compliance are non-negotiable.

PE500, on the other hand, is naturally resistant to moisture, acids, and cleaning chemicals. It doesn’t rust, warp, or flake  even after years of intensive use. Its smooth, non-stick surface makes cleaning effortless and prevents bacterial build-up, giving it a major hygiene advantage over steel or wood. Many versions of PE500 are certified food-safe, and its colour options (such as blue for food contact) make it easy to integrate into colour-coded environments for audit compliance.

Noise Reduction and Workplace Safety

Factory floors can be noisy  especially when metal parts move across steel surfaces. Over time, this noise pollution adds up, increasing stress and reducing workplace comfort. PE500 significantly reduces this issue. Its low-friction surface absorbs vibration and impact, making material transfer quieter and safer.

Whether you’re running a busy conveyor line or loading chutes, PE500 helps reduce metal-on-metal contact, protecting both your equipment and your ears. It also offers better grip for feet and wheels in some applications  reducing slip risks and contributing to a safer, more compliant workplace.

Lightweight, Durable & Low Maintenance

Steel may be durable, but it’s also heavy, costly to install, and time-consuming to replace. PE500 is around seven times lighter than steel, making it far easier to handle, fit, and transport. It also doesn’t need coatings, sealants, or ongoing treatments  just install and go.

With exceptional wear resistance, PE500 lasts for years, even in high-impact areas. That means fewer shutdowns for maintenance, fewer component replacements, and a lower total cost of ownership over time.

Ready to make the switch? Explore PE500 options at PrimePlasts.co.uk – custom sizes, food-safe sheets, and UK-wide delivery available.

Where Can PE500 Sheets Be Used in Industrial Environments?

Conveyor Wear Strips, Chutes & Sliding Pads

One of the most common uses for PE500 sheets in factories is in conveyor systems. Thanks to its low-friction surface and impact resistance, PE500 is ideal for wear strips, guide rails, sliding surfaces, and chutes  all of which experience constant movement, pressure, and contact with materials.

Steel may seem like the default choice, but over time, it wears down, gets noisy, and becomes a maintenance headache. PE500, however, ensures smooth material flow and minimises friction, keeping machinery efficient, reducing part damage, and extending the life of moving components.

Food Processing & Hygiene Stations

Factories working with meat, dairy, bakery, or ready meals often face strict hygiene standards. PE500 is a top-tier option for:

• Cutting tables
  
• Cleaning platforms
  
• Butchery and prep areas
  
• Packaging lines
  

Its food-grade certifications (such as FDA and EU compliance) and non-absorbent surface make it a hygienic, durable material that’s far superior to porous alternatives like wood  or rust-prone steel.

What’s more, PE500 is available in multiple colours (natural, blue, green, red), which makes it perfect for colour-coded food zones to meet BRC or HACCP compliance.

Lining Surfaces & Material Handling Areas

PE500 also excels as a liner for bins, silos, chutes, and walls where abrasive materials are stored or transported. Unlike steel, which can deform or corrode over time, PE500 provides a slippery, abrasion-resistant surface that keeps materials flowing smoothly  especially powders, grains, plastics, or aggregates.

It also prevents material build-up, reduces cleaning time, and minimises wear and tear on containers. Whether you're lining a grain hopper or a metal bin, PE500 will keep things running more efficiently.

 For PE500 cut-to-size sheets ideal for these applications, visit PrimePlasts.co.uk  delivered UK-wide.

Installation Tips for PE500 Sheets

Fixing Methods for Stability and Longevity

Installing PE500 correctly is key to ensuring it delivers long-term performance. While it’s incredibly durable, its low friction surface and slight flexibility mean it needs to be securely fixed to prevent movement or warping under load.

Here are some tried-and-tested installation tips:

• Bolt spacing matters: Use countersunk bolts every 250mm–400mm, depending on thickness and load. Stainless steel fasteners are ideal to avoid contamination or rust.
  
• Allow for expansion: Like most plastics, PE500 expands and contracts with temperature. Pre-drill oversized holes to allow for thermal movement.
  
• Use a solid backing: For floors, tables, or walls, mount onto a rigid base like marine ply or metal to avoid flexing.
  
• Seal edges where needed: In food zones, use food-safe silicone to seal gaps and avoid moisture ingress.
  

If unsure, consult a supplier like PrimePlasts.co.uk for expert advice and fabrication support.

Choosing the Right Thickness, Colour & Size

PE500 comes in a range of thicknesses from 6mm to 50mm+, with guidance as follows:

• 6–10mm: Wear strips, low-impact liners, cutting boards.
  
• 12–25mm: Platforms, tables, medium-duty flooring.
  
• 30mm+: Heavy-duty zones, machinery bases, impact buffers.
  

Colour isn’t just visual. In food or pharma, colour coding supports traceability and audit compliance:

• Blue: Food-contact safe, contamination visible.
  
• Natural: Common for general use.
  
• Red/Green/Yellow: Used in production zones or safety coding.
  

PE500 can be cut to size and pre-drilled for convenience.
  Browse made-to-measure PE500 sheets on PrimePlasts.co.uk.

PE500 vs Steel: Cost, Performance & ROI Comparison

Upfront Costs vs Long-Term Savings

At first glance, steel might appear cheaper than PE500 in terms of raw material cost. But when you factor in installation, maintenance, hygiene risks, and downtime, the real cost story changes.

Here’s how PE500 delivers better ROI:

• Lower installation costs – no welding or coatings.
  
• Fewer replacements – no rust, no corrosion.
  
• No sealants needed – just install and go.
  
• Energy savings – smoother operation in conveyor systems.
  

Many businesses report 30–50% savings over 3–5 years by switching from steel to PE500.

Cleaner Compliance & Lower Risk of Contamination

Contaminated surfaces lead to audits, fines, and product recalls. Steel can pit or rust, trapping bacteria or causing flakes. PE500 avoids all of that with:

• Zero water absorption
  
• No corrosion
  
• Easy-clean finish
  
• Colour coding for safety and compliance
  

These factors protect both your bottom line and brand reputation.

 Need a smart switch that saves money and boosts safety?
Check out custom-cut PE500 sheets at PrimePlasts.co.uk – UK delivery, food-safe options, and expert support.

Conclusion: Is It Time to Upgrade Your Factory Surfaces?

If your factory still relies on steel surfaces, now might be the time to modernise. While steel has long been the industry standard, its downsides: corrosion, weight, noise, and high maintenance  are becoming increasingly hard to justify.

PE500 (HMWPE) offers a powerful, proven alternative. It’s durable, food-safe, impact-resistant, and incredibly easy to work with. Whether you're dealing with wear-prone chutes, noisy conveyors, or hygiene-sensitive food zones, PE500 delivers:

• Superior performance
  
• Lower costs over time
  
• Better compliance and hygiene
  
• Minimal maintenance downtime
  

 Ready to future-proof your surfaces?
Explore PE500 sheet solutions today at PrimePlasts.co.uk – the UK's trusted supplier for high-performance plastics.