Modular Cleanroom Design: Complete Guide to Layouts, HVAC & FFU Placement

Optimize your modular Cleanroom design for compliance, efficiency, scalability, and low maintenance. Access layout diagrams, checklists, and expert design principles.

This guide provides comprehensive modular Cleanroom design strategies focusing on regulatory compliance, operational efficiency, scalability, and reduced maintenance costs. You'll find practical layout diagrams, downloadable checklists, and key design considerations for prefabricated CleanRoom implementation across various industries and cleanliness classes.

Modular Cleanroom Design- Complete Guide to Layouts, HVAC & FFU Placement.jpg

Design Principles & Goals

Successful modular cleanroom design balances multiple competing requirements while maintaining flexibility for future changes:

Personnel & Material Flow Separation: Design distinct pathways to minimize contamination
Pressure Control: Implement proper negative/positive pressure gradients between zones
Maintainability: Ensure easy access for filter changes and equipment servicing
Modular Scalability: Design for future expansion with minimal disruption
Energy & Cost Balance: Optimize HVAC systems for operational efficiency
Cleanliness Class Alignment: Match design to specific ISO 14644 requirements

Module Types & Component Selection

Type	Materials	Pros	Cons	Best Applications
Hardwall	Aluminum honeycomb, steel sandwich panels	Durable, excellent isolation, stable pressure control	Higher cost, less flexible for changes	iso class 5-8, pharmaceutical, biotech
Softwall	Clear PVC strips, vinyl curtains	Cost-effective, quick installation, flexible	Limited pressure control, less durable	ISO Class 7-8, packaging, Electronics assembly
Semi-Modular	Mixed panel/curtain systems	Balance of cost and performance	Complex integration	ISO Class 6-8, R&D, pilot plants

Additional Considerations: flooring (ESD vinyl, epoxy), door types (sliding, interlocking), window placement, and utility passthroughs should align with operational needs and cleanliness requirements.

Layout Examples & Best Practices

Small Lab (20-50 m²)

Ideal for research or testing applications with limited space:

Single personnel entry with gowning area
Material pass-through or small airlock
Unidirectional workflow from dirty to clean
Equipment placed along perimeter

Production (200-1000 m²)

Optimized for manufacturing with high throughput:

Separate personnel and material flows
Multiple airlocks and gowning stages
Zoned cleanliness (ISO 5-8)
Equipment integration areas

Key Layout Principles

Position gowning rooms as contamination barriers
Use airlocks to maintain pressure differentials
Place pass-through windows between adjacent clean areas
Design equipment zones with service access
Include sufficient storage for materials and supplies

Airflow & HVAC Design

FFU Configuration & Placement

Fan Filter Units (FFUs) provide localized Clean air delivery:

Ceiling coverage percentage based on ISO class
Uniform distribution to prevent dead zones
Strategic placement over critical processes
Integration with return air pathways

air changes Per Hour (ACH)

ISO Class	Minimum ACH	Typical ACH Range
ISO 5 (Class 100)	240-480*	240-600
ISO 6 (Class 1,000)	90-180*	90-240
ISO 7 (Class 10,000)	30-60*	30-90
ISO 8 (Class 100,000)	10-20*	10-30

*Varies based on activity level, particulate generation, and room usage

Pressure Cascade Design

Maintain proper pressure differentials between zones:

Cleanest areas have highest pressure
Minimum 10-15 Pa between adjacent classes
Use pressure-resistant walls for high differentials
Monitor continuously with alarms

Common HVAC Mistakes

FFU Overcrowding: Wasted energy and turbulent airflow
Insufficient Return Air: Pressure imbalances
Short-Circuiting: Supply and return too close
Poor Sealing: Leaks compromise cleanliness

ACH Calculation Tool

Estimate required air changes Per Hour based on your cleanroom parameters:

Electrical, Lighting & Services

Power Distribution

Dedicated circuits for critical equipment
Proper grounding for ESD protection
Emergency power for HVAC systems
IP-rated outlets in clean areas

Lighting Requirements

800-1000 lux at work surface level
Sealed, smooth fixtures to prevent particle accumulation
ESD-safe materials in construction
Emergency lighting per local codes

Service Integration

Plan conduit and raceways during design phase
Use sealed penetrations for pipes and cables
Include service chases for future expansion
Design for easy maintenance access

Data & Communications

Network connections for monitoring systems
Wireless access points with proper sealing
Intercom systems for personnel communication
Integration with building management systems

Control & Monitoring

Comprehensive monitoring ensures continuous compliance with cleanliness standards:

Critical Parameters

differential pressure: Continuous monitoring between zones
Particle Counts: Multiple locations based on room size
Temperature & Humidity: Tight control for sensitive processes
Airflow Velocity: At filter face and critical locations

System Integration

BMS/SCADA connectivity for centralized control
Alarm escalation protocols for out-of-spec conditions
Data logging for regulatory compliance
Remote access for troubleshooting

Sensor Placement Guidelines

Pressure sensors on both sides of critical barriers
Particle counters at working height and return air streams
Temperature/humidity sensors away from equipment influence
Airflow monitors at filter face and room exhaust

Installation, Maintenance & Scalability

Installation Best Practices

Proper sealing of all panel joints and penetrations
Level installation to ensure proper door operation
Verification of pressure integrity before occupancy
Documentation of as-built conditions

Routine Maintenance

HEPA/ULPA filter replacement schedule
Surface cleaning protocols and frequencies
Gasket and seal integrity checks
Calibration of monitoring instruments

Scalability Considerations

Design for future expansion with removable walls
Oversize utility connections for additional capacity
Modular components that can be reconfigured
Documented interface points for future connections

Access for Maintenance

Sufficient space above ceiling for filter changes
Service corridors around critical equipment
Easy access to valves and control points
Clear labeling of all system components

Case Studies & Photos

Pharmaceutical Cleanroom Image.jpg

Pharmaceutical ISO 7 Cleanroom

Challenge: Rapid deployment for new drug production with strict regulatory requirements.

Solution: Modular hardwall system with integrated HVAC and monitoring.

Results: Achieved ISO 14644 certification in 6 weeks, 30% faster than traditional construction.

Electronics ISO 6 Manufacturing.jpg

Electronics ISO 6 Manufacturing

Challenge: ESD protection combined with particulate control for microelectronics.

Solution: Custom modular system with ESD flooring and ionization.

Results: Yield improved by 15% while reducing energy costs by 20%.

Key Performance Metrics

40-60%

Faster Installation

15-30%

Energy Savings

100%

Regulatory Compliance

50%

Easier Reconfiguration

Frequently Asked Questions

Can modular cleanrooms meet ISO Class 5 requirements?

Yes, properly designed modular cleanrooms with hardwall construction and appropriate HVAC systems can achieve and maintain ISO Class 5 (Class 100) conditions. Critical factors include adequate FFU coverage, proper sealing, and appropriate air change rates.

How do I determine the number of FFUs needed?

FFU quantity depends on room size, target ISO class, ceiling height, and internal heat loads. As a general guideline, ISO Class 5 typically requires 25-40% ceiling coverage, while ISO Class 8 may only need 5-10%. Use our ACH calculator above for preliminary estimates.

What's the optimal gowning room design?

Gowning rooms should include a two-stage process: pre-gowning for storage of personal items and initial gowning, followed by a final gowning area. Maintain proper air pressure cascade (increasing cleanliness toward the cleanroom) and include mirrors, benches, and adequate lighting.

How long does modular cleanroom installation take?

Installation time varies by size and complexity, but modular cleanrooms typically require 40-60% less time than traditional construction. A small lab (20-50 m²) might take 2-4 weeks, while larger production facilities (200-1000 m²) may require 8-16 weeks from design to certification.

Can modular cleanrooms be relocated?

Yes, one of the key advantages of modular cleanrooms is their relocatability. Most components can be disassembled and reinstalled at a new location, though this requires careful planning and may involve replacement of some seals and filters.