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Designing and building an efficient and hygienic cleanroom environment requires careful consideration of the cleanroom wall systems you use. Cleanroom wall panels provide the framework for your controlled environment, ensuring it meets strict standards of cleanliness and functionality. There are a range of wall panel systems tailored to different cleanroom requirements. Lets explore the options available and the advantages they offer.
Types of Modular Cleanroom Wall Panels
Insulated Metal Panels are a common choice for cleanroom environments due to their excellent thermal insulation properties and robust durability. These panels consist of an insulating core sandwiched between metal facings. They provide strong, sturdy walls that can be used to create cleanroom partitions, external walls, and even ceilings. Insulated metal panels offer a high degree of temperature control, making them ideal for environments with specific temperature and humidity requirements.
Honeycomb Panels are known for their lightweight yet sturdy construction. These panels consist of a core made of honeycomb-structured material, typically aluminum, sandwiched between two outer skins of metal. Honeycomb panels offer excellent strength-to-weight ratio, which is crucial for cleanrooms where load-bearing capacity may be limited.
Liner Panels provide a cost-effective solution for updating existing walls. These panels are typically ½ inch thick and consist of steel or aluminum skins bonded to an aluminum honeycomb core. Liner panels are attached to existing facility walls, allowing them to achieve the same finish and appearance as newly constructed walls.
Softwall and Rigid Wall Cleanroom Structures
Softwall cleanrooms are typically constructed using vinyl curtains and are available in antistatic variants when necessary. They are a good option for areas that just need a limited level of containment.
Rigid wall cleanrooms offer several panel types, including acrylic, static dissipative PVC, and polycarbonate. These panels vary in features, such as scratch resistance, impact resistance, and static dissipation, catering to different cleanroom requirements.
Drywall Coated with Epoxy Paint or Cladding
Another option for cleanroom walls, particularly in less strict areas, is drywall coated with epoxy paint. This option can be a more budget-friendly alternative, offering some level of protection and cleanliness. Epoxy paint is known for its resistance to moisture and ability to create a smooth, easily cleanable surface. Its suitable for environments where the cleanliness requirements are not as demanding as other cleanroom settings.
Another option for drywall is covering it with hygienic cladding, which can be sealed using either silicone caulking or a heat seal with a welding rod. There are various types of wall cladding available, allowing you to choose the best fit for different applications.
How Cleanroom Panels are Sealed
The panel seams are commonly sealed either with a silicone caulking or a chemical cold weld.
Chemical cold welding offers a smooth, seamless surface across the entire panel system due to the welded seams. This seamless construction ensures the cleanroom maintains a high level of cleanliness and is ideal for environments with strict cleanliness requirements. Once installed, these panels form a fixed, integrated wall system that provides excellent strength and stability.
Silicone caulking provides a seal at a lower cost and still allows for ease of installation and removal. This design allows for the easy disengagement and replacement of individual panels as needed. This flexibility makes silicone caulking a great choice for environments where access to utilities behind the walls or adaptability to future changes is necessary.
By selecting the right type of wall panel system, you can ensure your cleanroom meets environmental expectations and is compliant with industry standards.
Our team can design, manufacture and install your certified cleanroom in as little as 4 weeks , on-site with minimum disruption.
A Turnkey Complete Cleanroom is when the modular cleanroom company provides beginning to end service, doing all aspects of the cleanroom project. This includes:
A Mask Manufacturing Cleanroom is a cleanroom that is used for manufacturing of K95 and surgical masks during the Covid-19 crisis.
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A Static Dissipative Cleanroom is designed to prevent static from building up within the cleanroom which can damage sensitive electronic components. Features include:
A: A cleanroom (or clean room) is a room that has HEPA filtration to remove particles from the air. Cleanrooms are used for manufacturing where high levels of cleanliness and sterility are required. Common applications are medical devices, pharmaceutical and semiconductor manufacturing. The FDA mandates the use of cleanrooms to create GMP manufacturing factories.
A: Cleanrooms are used for manufacturing where high levels of cleanliness and sterility are required. Common applications are medical devices, pharmaceutical and semiconductor manufacturing. Cleanrooms use HEPA filters to remove particles from the air. It is common to see pharmaceutical cleanrooms, medical device cleanrooms, semiconductor cleanrooms, electronic cleanrooms, aerospace cleanrooms, food cleanrooms, USP797 compounding pharmacy cleanrooms and biotech cleanrooms. Cleanrooms are also used by the government such as national labs, defense industries, and R&D labs at universities.
A: Very clean. A class 100 cleanroom has 100 particles per cubic foot. By comparison your typical office space has between 500,000 and 1 million particles per cubic foot. Cleanrooms come in different classes from class 100 to 100,000.
A: Medical device and pharmaceutical manufacturing requires sterile environments to produce their products. Cleanrooms provide this sterile super clean manufacturing space which reduces the chance of contamination getting in your medicine. Semiconductor manufacturers produce devices with ultra small super dense features. Examples are computer chips for your cell or PC. If contamination were to get on the chip during manufacturing, they would not work.
A: ISO is the International Standards Organization. It has created the ISO -1 Cleanroom Standards that describe the allowed number of particles, the allowed size of particles and HEPA filtered air flow changes per hour meet ISO-4, ISO-5, ISO-6, ISO-7, and ISO-8 standard. It relies on measurements per cubic meter. It corresponds to the USA based Fed Standard 209E which relies on measurements per cubic foot. Fed Standard 209E corresponding classes are 10, 100, , 10k and 100k.
A: In pharma a clean room is a controlled environment using HEPA filtration to minimize particulate contamination. Pharmaceutical manufacturers are subject to FDA validation of their manufacturing which typically specify use of a clean room to ensure the quality of the manufactured pharmaceutical product. Sterility is highest priority. Pharma cleanrooms focus on both non viable (inanimate) and viable (live) contamination. They typically use laser particle counters to measure non viable contamination levels and settling plates with culture media to measure viable contamination levels. Pharmaceutical cleanrooms use aggressive chemical and UV light cleaning techniques to maintain sterility.
A: A data cleanroom is a secure isolation virtual platform that typically stores anonymized marketing data from multiple sources. It is used to protect privacy and share data from multiple sources. It is very different from physical cleanrooms used for manufacturing.
A: Cleanrooms rely on HEPA or ULPA filtration to remove particles from the air and create an ultra clean environment. With sufficient air changes per hour and laminar air flow it is possible to reduce particulate count from greater then 500k/ft3in typical office space to as low as 100/ft3(class 100 cleanroom). Airlocks are used to prevent contamination from entering the cleanroom. Workers inside cleanrooms typically wear cleanroom garments such as booties and bunny suits to prevent them from bringing contamination into the room. Eating and drinking are never allowed in cleanrooms.
A: Industries such as pharmaceutical, medical device and USP797 compounding pharmacies are required by the government to manufacture in sterile environment and must use cleanrooms. Other industries such as semiconductor, electronics, aerospace and optics find the ultra-clean environments in cleanrooms are the only way to cost effectively manufacture their products. Other industries that use cleanrooms include food, beverage, e-liquid, CBD and vitamins.
A: Pharmaceutical manufacturers are subject to FDA validation of their manufacturing which typically specify use of a clean room to ensure the quality of the manufactured pharmaceutical product. Sterility is highest priority. Pharmaceutical cleanrooms focus on both non viable (inanimate) and viable (live) contamination. They typically use laser particle counters to measure non viable contamination levels and settling plates with culture media to measure viable contamination levels. Pharmaceutical cleanrooms use aggressive chemical and UV light cleaning techniques to maintain sterility.
A: A class 1 cleanroom refers to ISO standard allowing less than 2 particles greater than 0.3 microns and no particles greater than 1.0 microns per cubic meter. A class 1 cleanroom typically has from 500-750 air changes per hour and typically utilizes ULPA filtration. Other common characteristics are 100% ULPA ceiling coverage and raised floors. It is the cleanest classification.
A: A class 2 cleanroom refers to ISO standard allowing less than 11 particles greater than 0.3 microns and no particles greater than 1.0 microns per cubic meter. A class 2 cleanroom typically has 500-750 air changes per hour and typically utilizes ULPA filtration. Other common characteristics are 100% ULPA ceiling coverage and raised floors. It is the 2nd most clean classification.
A: The most common type cleanrooms are modular cleanrooms, stick-built cleanrooms (or standard), and softwall cleanrooms. Modular cleanrooms utilize prefabricated modular wall systems which allow for faster installation, easy modification(s) and reasonable cost. Stick built or standard cleanrooms rely on conventional steel stud(s) drywall construction. It can be slightly cheaper. Softwall cleanrooms use clear vinyl curtains suspended from metal frames. Small softwall cleanrooms are often mounted on casters so they can be easily moved around.
A: A class 4 cleanroom refers to ISO standard allowing less than particles greater than 0.3 microns and less than 2 particles greater than 5.0 microns per cubic meter. A class 5 cleanroom requires from 500-600 air changes per hour and typically utilizes ULPA filtration. Other common characteristics are 100% ULPA ceiling coverage and raised floors. It is the 4th most clean classification.
A: If you need an ISO-7 cleanroom you should prepare your facility for the modular cleanroom installation. Check that area is free and clear up to height of cleanroom. Frequently existing electrical conduit, lighting, sprinklers, and HVAC ducting need to be relocated. When installing new cleanroom flooring make sure the existing concrete is in good shape. Have any cracks and depressions filled to level the floor.
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