Hardwall Modular Cleanroom

What is a Modular Hardwall Cleanroom?

A Modular Hardwall Cleanroom is a highly controlled environment designed to limit airborne contaminants, commonly used in industries that require strict cleanliness, such as pharmaceuticals, electronics, and biotechnology. It is built using rigid panels, often with insulating cores, and features sealed walls and ceilings to maintain positive pressure and ensure air cleanliness. These cleanrooms are modular, meaning they can be customized in terms of size, layout, and functionality, allowing for easy expansion or reconfiguration.

The cleanroom's construction uses hardwall panels, which are durable, rigid, and offer superior structural integrity compared to softwall alternatives. These cleanrooms are commonly equipped with HEPA or ULPA filters for air filtration and can be integrated with HVAC systems for precise control of temperature, humidity, and airflow.

How does a Modular Hardwall Cleanroom differ from a Softwall Cleanroom?

The primary difference between a Modular Hardwall Cleanroom and a Softwall Cleanroom lies in the wall construction. A hardwall cleanroom is made of rigid panels, usually composed of materials like aluminum, stainless steel, or composite materials. These panels offer more structural integrity, durability, and ease of cleaning, providing better contamination control. They are also generally more suitable for environments that require positive air pressure.

In contrast, a softwall cleanroom uses flexible walls made from plastic or PVC materials, making it a more cost-effective option. While softwall cleanrooms can be easily assembled and reconfigured, they tend to be less robust, have more seams for contamination to potentially enter, and may not offer the same long-term durability and thermal insulation as hardwall cleanrooms.

What materials are used in Modular Hardwall Cleanroom panels?

Modular Hardwall Cleanroom panels are typically made from composite materials like aluminum, steel, or stainless steel, often with an insulating core such as polystyrene, polyurethane, or mineral wool. The outer panels are usually coated with a smooth, non-porous surface to make them easy to clean and resistant to contamination.

These materials are chosen for their durability, insulation properties, and ease of maintenance. The insulating cores help to maintain thermal stability, reducing energy consumption, while the metallic outer layers provide a rigid structure that contributes to the cleanroom’s structural integrity and airtight seals.

What are the benefits of a Modular Hardwall Cleanroom?

One of the key benefits of a Modular Hardwall Cleanroom is its customizability. These cleanrooms can be easily configured to meet specific requirements, such as room size, airflow patterns, and equipment layout, and can be expanded or reconfigured as needed. This makes them ideal for companies that anticipate changes in their production needs.

Another advantage is the structural strength of hardwall panels. They offer better contamination control by preventing the ingress of particles and maintaining positive air pressure. Additionally, the rigid construction of hardwall cleanrooms ensures they remain stable over time, reducing the risk of leaks or damage that could compromise air quality.

How do Modular Hardwall Cleanrooms maintain cleanliness and control contaminants?

Modular Hardwall Cleanrooms maintain cleanliness through air filtration systems like HEPA or ULPA filters, which continuously remove particles from the air. These filters can capture particles as small as 0.3 microns, ensuring the environment remains free from airborne contaminants. Additionally, positive pressure is maintained to prevent unwanted particles from entering the cleanroom.

The rigid wall panels provide airtight seals, reducing the risk of contamination from outside the room. The smooth, non-porous surfaces of the panels make cleaning more efficient, preventing the buildup of dust or contaminants. Combined with regular maintenance and proper airflow management, this helps to maintain high cleanliness standards in the cleanroom.

How do you design a Modular Hardwall Cleanroom?

Designing a Modular Hardwall Cleanroom begins with identifying the cleanliness standards required for the specific industry (ISO class). The next step involves selecting the appropriate layout, size, and modular panel configuration to accommodate the necessary equipment, workspaces, and air handling systems.

Key considerations during the design process include ensuring that the HVAC system can support the required air changes per hour (ACH) and airflow patterns (laminar or turbulent), as well as ensuring that the room is properly sealed to maintain positive pressure. The room must also be designed for easy maintenance and accessibility to clean and replace filters, check airflow efficiency, and maintain environmental conditions.

What is the typical cost of building a Modular Hardwall Cleanroom?

The cost of building a Modular Hardwall Cleanroom varies depending on several factors such as size, cleanliness classification, and specific features required. On average, the cost can range from $100 to $500 per square foot. For a basic cleanroom, the cost may be on the lower end, while more specialized cleanrooms with additional features like temperature control, humidity control, or advanced filtration systems will fall on the higher end.

Other factors that influence the cost include installation complexity, room configuration, and whether the cleanroom needs to be built from scratch or can be customized from pre-existing modules. Ongoing operational costs, such as energy consumption and maintenance, should also be considered.

How do Modular Hardwall Cleanrooms meet ISO cleanliness standards?

Modular Hardwall Cleanrooms meet ISO cleanliness standards by adhering to the required levels of airborne particle contamination, as outlined in ISO 14644-1. This is achieved through the installation of HEPA/ULPA filters, which remove particles from the air, along with a precise HVAC system that ensures the correct number of air changes per hour (ACH) to maintain the desired air quality.

The rigid walls and airtight seals prevent contaminants from entering the cleanroom, while positive pressure is maintained to push contaminants out. These design features, combined with routine monitoring and maintenance, ensure that the cleanroom meets the necessary ISO classification for specific industries.

What industries use Modular Hardwall Cleanrooms?

Modular Hardwall Cleanrooms are widely used in industries that require stringent environmental controls, such as pharmaceuticals, biotechnology, electronics manufacturing, and medical device production. These cleanrooms provide the necessary sterile conditions for drug manufacturing, precision assembly of electronic components, and the production of high-quality medical devices.

They are also used in aerospace, food processing, semiconductor manufacturing, and research labs, where maintaining a controlled environment is essential for product quality and safety. The versatility and flexibility of modular designs make these cleanrooms suitable for various applications.

How is air pressure and airflow controlled in a Modular Hardwall Cleanroom?

In a Modular Hardwall Cleanroom, air pressure is controlled through a combination of HVAC systems and air handling units (AHUs). The cleanroom is typically maintained at a positive pressure relative to surrounding areas, ensuring that air flows out of the cleanroom rather than entering, which prevents external contaminants from entering the space.

Airflow is managed through the HVAC system, which provides filtered, conditioned air and ensures the correct air changes per hour (ACH). The system is designed to create unidirectional airflow (laminar flow) in some cleanrooms, pushing contaminants toward exhaust points. This helps maintain a consistent and controlled environment, ensuring the cleanliness standards are met.

Clean room purification ventilation duct system