Modular clean room/booth

What is a Modular Clean Room/Booth?

Definition: A modular clean room, also known as a cleanroom booth, is a controlled environment where pollutants like dust, airborne microbes, aerosol particles, and chemical vapors are kept at specific limits. They are called “modular” because they can be easily assembled, disassembled, and reconfigured, offering great flexibility and adaptability to different needs.

Construction: These cleanrooms are typically constructed with non-shedding, non-particulate generating materials to maintain cleanliness and minimize contamination. Common materials include stainless steel, laminated panels, and anti-static PVC among others.

Filtration System: Modular clean rooms utilize air filters, usually HEPA (High Efficiency Particulate Air) or ULPA (Ultra-Low Particulate Air) filters, to remove particles from the air. The air pressure in the clean room is often kept higher than the pressure outside to prevent unfiltered air from entering.

Classification: Cleanrooms are classified based on the cleanliness level of their air, specified by the number of particles per cubic meter at a specified particle size. The ISO 14644-1 standard classifies cleanrooms from ISO Class 1 (the cleanest) to ISO Class 9.

Uses: They are used in a variety of industries that require stringent control of environmental conditions, including pharmaceuticals, biotech, medical device, electronics manufacturing, and more.

The Necessity of Modular Clean Rooms/Booths

Controlled Environment

The primary reason for the necessity of modular clean rooms is the requirement for a tightly controlled environment. Many manufacturing processes, particularly in the fields of pharmaceuticals, electronics, and scientific research, require very specific environmental conditions to ensure product quality, safety, and efficacy.

Regulatory Compliance

Many industries are regulated by government bodies or other standard-setting organizations that require certain processes to be carried out in clean rooms. Having a modular clean room allows these entities to meet regulatory requirements, ensuring the safety and quality of their products.

Quick Installation

Modular clean rooms can be designed, manufactured, and installed more quickly than traditional clean rooms, enabling businesses to get their operations up and running more swiftly.

Reduced Contamination Risk

By controlling access and utilizing advanced filtration systems, modular clean rooms reduce the risk of contamination, leading to more reliable results and higher-quality products.

Flexibility and Scalability

Compared to traditional fixed clean rooms, modular clean rooms offer the benefit of flexibility and scalability. They can be easily expanded, reduced, or reconfigured as per the needs of the organization. This makes them a highly efficient choice for businesses that expect their needs to change over time.

Cost-Effectiveness

Modular clean rooms are typically less expensive to install and modify than traditional clean rooms. This cost-effectiveness, combined with their flexibility, makes them an attractive choice for many businesses.

Increased Productivity

With a controlled environment tailored to specific production or research needs, productivity can often be improved as conditions are optimized for efficiency. This contributes to the overall success and profitability of the operation.

Working Principle of Modular Clean Rooms/Booths

The basic principle of a modular clean room revolves around air filtration. Air inside the cleanroom is repeatedly passed through High Efficiency Particulate Air (HEPA) or Ultra Low Penetration Air (ULPA) filters to remove particulates and impurities.

Many modular clean rooms use a concept known as laminar flow. In a laminar flow system, filtered air is introduced into the room in a steady stream, moving in the same direction at the same speed. This continuous flow of air “sweeps” particles out of the room. Laminar flow can be either horizontal or vertical, depending on the design of the room.

Another critical principle is the use of positive air pressure. The cleanroom is kept at a higher pressure than the surrounding environment. This means that any leaks or openings will result in air flowing out of the room, rather than unfiltered air flowing in, thus maintaining the cleanliness of the room.

The cleanliness of a cleanroom is also maintained by ensuring a certain number of air changes per hour. This means the total volume of air in the room is replaced with fresh, filtered air a certain number of times every hour.

In addition to controlling particulate contamination, some cleanrooms also control the temperature and humidity levels within the room. This is important for certain manufacturing processes or scientific experiments that require specific environmental conditions.

Benefits and Usage of Modular Clean Rooms/Booths

Flexibility and Scalability: Modular clean rooms can be easily expanded, reduced, or reconfigured based on changing needs. This flexibility makes them a valuable asset for businesses and institutions that expect to grow or shift their operations.

Cost-effective: Compared to traditional cleanrooms, modular clean rooms are often more cost-effective to install and maintain. They can be quickly assembled and disassembled, reducing labor costs. Additionally, because they’re not part of the permanent structure, they can be depreciated over a shorter period, providing tax benefits.

Controlled Environment: Modular clean rooms provide a high degree of control over the room’s environmental conditions, including temperature, humidity, and particulate contamination. This level of control is vital in various industries, including pharmaceuticals, biotechnology, medical device manufacturing, and food processing.

Fast Installation: As pre-fabricated structures, modular clean rooms can be installed much faster than traditional cleanrooms, minimizing disruption to operations.

High Standards Compliance: Modular clean rooms can meet the stringent standards set by organizations like the ISO (International Organization for Standardization) and FDA (Food and Drug Administration). They are a suitable solution for industries where contamination control is critical.

Versatile Usage: Modular clean rooms can be used in a wide variety of applications. This includes manufacturing facilities, laboratories, hospitals, and any other environment where a clean, controlled environment is necessary. They can be customized to meet the needs of different industries and applications.

Selecting the Right Air Shower

First, understand your specific application requirements. Consider factors like the level of cleanliness required, the size of the clean room, the type of work being done, and any specific industry standards or regulations that need to be met.

The ISO 14644-1 standard defines different levels of cleanliness for clean rooms (ISO 1 to ISO 9). Select a modular clean room that can achieve the level of cleanliness required for your operations.

Modular clean rooms come in different sizes and layouts. Choose a size and design that fits your space and accommodates your workflow. Remember, you need enough space not just for the equipment, but also for operators to move around comfortably.

The materials used in the construction of the clean room should be durable, easy to clean, and resistant to the chemicals used in your operations. Stainless steel and high-pressure laminate are commonly used materials.

The clean room should have efficient air filtration systems (like HEPA or ULPA filters) and HVAC systems to control temperature and humidity.

Consider additional features like pass-through boxes for transferring materials in and out of the clean room, or anteroom spaces for gowning and degowning.

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