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A modular cleanroom is a flexible, prefabricated system designed to create a controlled environment with stringent requirements for cleanliness, air quality, and temperature. Unlike traditional cleanrooms that are built on-site, modular cleanrooms are made up of standardized, prefabricated components that can be quickly assembled, reconfigured, or expanded as needed.
Modular CleanRoom Classifications
Modular cleanroom grade standards are based on the level of airborne particle contamination, classified by ISO Standards (ISO 14644-1). The most common classes are:
ISO Class 1: Highest cleanliness, with less than 10 particles per cubic meter (0.1 microns).
ISO Class 5: Suitable for pharmaceutical and biotech, with up to 3,520 particles per cubic meter (0.5 microns).
ISO Class 7: For less sensitive environments, with up to 352,000 particles per cubic meter (0.5 microns).
ISO Class 8: For general industrial use, with up to 3.5 million particles per cubic meter (0.5 microns).
These grades determine the filtration, airflow, and environmental controls required for different industries.
Features of modular cleanrooms
Modular cleanrooms are flexible and customizable systems that use pre-engineered components for easy assembly, reconfiguration, and expansion. This design allows for efficient airflow control and contamination management, making it ideal for industries like pharmaceuticals, biotechnology, and Electronics. Modular cleanrooms offer both high performance and adaptability, which is essential in environments where stringent cleanliness standards are required.
Key Features of Modular Cleanrooms:
Quick Installation & Flexibility: Components can be rapidly assembled, reconfigured, or dismantled to meet changing needs.
Scalability: Easily expandable to accommodate increasing production requirements or changes in process.
Efficient Maintenance: Individual modules and components can be replaced or serviced without disrupting the entire cleanroom.
Cost-Effectiveness: Modular design is often more affordable compared to traditional cleanrooms, offering greater resource efficiency.
Modular cleanroom working principle
A modular cleanroom operates on the principle of maintaining a controlled environment where airborne particles, temperature, humidity, and other contaminants are carefully regulated. It uses a combination of filtration systems, such as HEPA or ULPA filters, to remove particles from the air, and an HVAC system to maintain constant airflow and pressure. This ensures that the space remains free from contamination, which is crucial for industries like pharmaceuticals, biotechnology, and electronics manufacturing.
The modular cleanroom is designed for flexibility, with pre-fabricated panels that can be easily assembled and reconfigured. The system maintains the desired level of cleanliness by continuously circulating air through the filters and keeping surfaces sanitized. The modular design allows for quick adaptation, making it easy to expand or modify the cleanroom as requirements change, all while ensuring compliance with strict industry standards.
Modular Cleanroom wall systems
Modular cleanroom wall systems consist of key components designed to maintain cleanliness and adaptability:
Wall Panels: Made from materials like stainless steel or aluminum, these panels are smooth, non-porous, and easy to assemble or modify, ensuring contamination control and insulation.
Doors: Airtight doors with self-closing mechanisms prevent contamination. They are made from the same materials as wall panels and may include airlocks for added protection.
Windows: Clear, easy-to-clean windows allow monitoring of the cleanroom while maintaining the sterile environment. They are often made of acrylic or tempered glass.
Ceiling: The ceiling supports the HVAC system and air filtration, ensuring proper airflow and air pressure. It is made from cleanable materials and integrates with the overall system design for uniform cleanliness.
These components work together to provide a flexible, sterile environment for industries requiring strict contamination control.
Modular cleanroom airflow systems
Modular cleanroom airflow systems are crucial for maintaining a sterile environment by ensuring proper air circulation and filtration. Two key components of these systems are HVAC and FFU, both of which help control temperature, humidity, and airborne particle levels.
HVAC (Heating, Ventilation, and Air Conditioning): The HVAC system in a modular cleanroom is responsible for regulating the air quality, temperature, and humidity levels to meet the specific requirements of the cleanroom environment. It maintains a continuous flow of filtered air, ensuring that the space stays at the required temperature (typically 20-25°C) and that the humidity is controlled. The HVAC system works to create positive pressure inside the cleanroom, preventing contaminants from entering through doors and other openings.
FFU (Fan Filter Unit): FFUs are essential for maintaining air cleanliness within the cleanroom. These units contain a fan and a high-efficiency filter (usually HEPA or ULPA) to remove airborne particles and contaminants. The FFU units are typically mounted in the ceiling grid of the cleanroom, where they supply a laminar flow of filtered air into the space. This setup helps create a uniform air distribution, ensuring that contaminants are effectively removed and maintaining the desired cleanliness level across the cleanroom.
Together, HVAC and FFU systems ensure the proper functioning of a modular cleanroom, creating an optimal environment by regulating airflow, temperature, humidity, and particle contamination.
The costs of a modular cleanroom
The costs of a modular cleanroom depend on factors like size, design, and cleanliness requirements. Basic modular cleanrooms, typically with lower cleanliness standards (ISO Class 7 or 8), can cost between $100 to $300 per square foot. For more advanced systems with higher specifications (ISO Class 5 or 6), the price can range from $400 to $800 per square foot, depending on the complexity of the filtration and HVAC systems.
Additional costs may include installation, specialized equipment, and ongoing maintenance. While modular cleanrooms are generally more affordable than traditional built-in cleanrooms, the total cost can increase with customization, additional features (such as gowning rooms or air showers), and the specific technical requirements of the cleanroom environment.
In summary
These cleanrooms are ideal for industries such as pharmaceuticals, biotech, electronics, and manufacturing, where maintaining a sterile and contaminant-free environment is critical. The modular design allows for easy customization to meet specific cleanliness standards (such as ISO grades), and components can be adjusted or replaced with minimal downtime, making it a cost-effective and scalable solution. Cleanroom components include walls, ceilings, filtration systems (such as HEPA or ULPA filters), and HVAC systems to control temperature, humidity, and air pressure.
