Flexible Polyurethane Filler Solution for EssilorLuxottica

Project Summary

About the Client

EssilorLuxottica is a global leader in the design, production, and marketing of ophthalmic lenses, optical equipment, instruments, prescription glasses, and sunglasses. As a multinational company with advanced production and operational environments, EssilorLuxottica requires flooring and surface solutions that support precision, safety, equipment movement, and long-term facility performance.

For a facility using robotic systems and heavy operational equipment, even a small floor gap or uneven transition can create challenges. Smooth movement, equipment stability, and surface durability are critical to keeping operations efficient and safe.

Flooring Requirements & Pain Points

EssilorLuxottica had a significant gap on the 3rd floor that needed to be properly filled and levelled to support a robotic system. The surface needed to allow machines and equipment to move across the area smoothly without obstruction, impact, or angle-related disruption.

The client required a solution that could meet two important performance needs at the same time:

1. Flexibility to absorb movement and prevent cracking or separation over time.
2. Hardness and strength to support machine and equipment traffic without creating uneven transitions.

The floor area had to be corrected in a way that allowed the robotic system and equipment to move across the surface with a smooth, zero-angle transition.

Challenges

The main challenge was the presence of a large gap on the 3rd floor where robotic systems and operational equipment needed to pass.

This created several practical concerns:

• The gap could interfere with smooth robotic movement.
• Machines and equipment needed a flat, stable transition.
• The filled area had to be strong enough to handle traffic.
• The material also needed enough flexibility to adjust with floor movement.
• A rigid solution could crack, while a soft solution could fail under equipment pressure.
• The final finish needed to support operational safety and long-term durability.

Finding the right balance between flexibility and strength was the key challenge.

Our Objective

Sealwell’s objective was to provide a flooring repair and gap-filling solution that would create a smooth, durable, and functional transition for EssilorLuxottica’s robotic system.

The solution needed to:

• Fill the large floor gap properly.
• Create a smooth and level transition.
• Support robotic equipment movement.
• Allow machines and equipment to pass over the area without disruption.
• Maintain flexibility to handle movement.
• Provide enough hardness for operational traffic.
• Reduce the risk of cracking, chipping, or premature failure.
• Deliver a clean and professional finish suitable for an advanced facility environment.

Proposed Solution

Sealwell recommended a flexible polyurethane filler as the most suitable product solution for this project.

The flexible polyurethane filler was selected because it could provide the right balance between elasticity and strength. Unlike a standard rigid filler, this solution was designed to remain flexible enough to accommodate movement while still becoming hard enough to support machines, robotic systems, and equipment traffic.

This made it ideal for the client’s requirement: a surface that could support equipment movement with a smooth, zero-angle transition.

Implementation Process

Sealwell’s team followed a practical, performance-focused installation process to ensure the gap was filled correctly and the surface could support operational needs.

1. Site Review and Gap Assessment

The team first reviewed the 3rd floor area to understand the size, depth, location, and movement requirements of the gap. This helped determine the best filler approach and preparation method.

2. Surface Preparation

The surrounding area was prepared to ensure proper bonding and long-term performance. Any loose material, dust, or weak surface areas were addressed before applying the filler system.

3. Product Selection and Planning

Sealwell selected a flexible polyurethane filler that could meet the client’s dual requirement: flexibility and hardness. The goal was to avoid a brittle repair while still creating a strong load-supporting surface.

4. Gap Filling Application

The gap was filled carefully using the selected polyurethane material. The application was performed to ensure the material settled properly and created a consistent support layer.

5. Leveling and Transition Control

The filled area was finished to create a smooth transition, allowing robotic systems, machines, and equipment to move across the surface without hitting an angle or uneven edge.

6. Final Quality Review

After installation, the area was reviewed for finish quality, smoothness, surface stability, and suitability for operational use.

Results

Sealwell successfully provided a custom floor gap-filling solution that met EssilorLuxottica’s operational needs.

Key results included:

• The large 3rd floor gap was properly filled.
• The surface was improved for robotic system movement.
• Machines and equipment could move across the area with a smooth transition.
• The solution delivered both flexibility and strength.
• The filled area was hard enough to support operational traffic.
• The repair helped reduce the risk of movement interruption.
• The final surface supported a safer and more efficient working environment.

The flexible polyurethane filler solution allowed Sealwell to solve a technical flooring challenge where both movement tolerance and load support were required.

Client Feedback

“Sealwell’s team understood the operational importance of this repair from the beginning. The gap on the 3rd floor was affecting how our robotic system and equipment could move across the area, and we needed a solution that was both flexible and strong. The polyurethane filler system provided a smooth, stable transition, allowing our machines to move over the repaired section without disruption. The final result met our facility requirements and helped improve movement, safety, and overall floor performance.”

Facility Manager