Clean Room Design

Clean Room Design: The Complete FAQ Guide

The cold and heat source of the air conditioner is provided by the power room in workshop 2. The temperature of supply and return water is 7/12℃ in summer. In winter, the temperature of supply and return water is 48/40℃.

Zonsteel take 4 measures to save energy.

(1).A central control system is set up in the workshop to monitor and control the central air conditioning system.

(2).General air-conditioning systems use a full heat exchanger to recover the waste heat in the exhaust air.

(3).Heat and humidity load of air conditioning is treated separately.

(4).The selected equipment in the design is energy saving and environmental protection.

Fire proofing is very important in clean room design, the air duct and its insulation materials are non-combustible, air supply and return air supply lines of air conditioning system are equipped with fire valves (closed at 70℃).

This is an EPC project, considered all aspects to support electronic paper display production, based on safety, energy and cost saving. The design start on 2017 year, all finish and move in to start production on 2019.

If you have any project, big or small, feel free to contact us to make it come true with our specialty. Zonsteel values all our business partners!

 

 

Clean Room Design: The Complete FAQs Guide

 

Clean rooms are usually found in manufacturing or research facilities. Clean room is a room with controlled environment that has little pollutants. In scientific terms, a clean room is a room with a controlled level of contamination that is specified using the amount of particles per cubic metre. The regular air humans breathe in contains 36,000,000 particles per cubic metre. This is the lowest standard for a clean room.

Figure 1 Clean Room Design

A clean room design can be found in different industrial companies where small particles affects their manufacturing process negatively. There are different sizes and functions of a clean room. You can start your clean room design from Zonsteel for clean rooms we can design and build in these industries; biotech, pharmaceuticals, medical devices, military, and energy. The personnel that work in the clean room go through extensive training in contamination control theory. The main component in any Zonsteel clean room design is the air handling system.

 

Types of Clean Room Design

There are different materials and different techniques that you can use as your cleanroom design, and you should constantly review the cleaning chemicals to ensure that they would perform effectively. The type of cleaning technique you would use depends on the type of clean room design. There are three types of clean room design, and they are;

1,Softwall clean room design:Softwall clean room designs are made to ensure that there would be little or no distraction to you or your staff. It is very affordable.

2,Rigidwall clean room design:A rigidwall clean room has the durability of a hardwall clean room, and the low price of a softwall clean room. It provides a contamination of class 10 to 100,000. Standards. This clean room is mobile, so it can be moved around.

3,Hardwall Clean room design: With this clean room, you would be able to provide the highest control level over contamination, static, pressure, and humidity. Hardwall clean rooms have been designed to comply with different standards.

 

Clean Room Design Calculation

When customers want any clean room design, they always have a specific model in mind when they approach clean room design companies. However, what they fail to realize is that the layout of the room is not determined by its class. It only defines the level of cleanliness. To get the calculation of your clean room design, you should contact an HVAC cleanroom design specialist.

Figure 2: Regular Clean Room Design

Though there are clean room design calculators that can help you get the calculations online, they are not as reliable as consulting a clean room design specialist. Here are some of the things that the calculator does not account for; number of people working in the room, the equipment and furniture in the room, the way people move out of the room. Difference in pressure, heat gain, temperature and humidity. Clean room design calculators are suitable for only positive pressure clean room design not a negative pressure clean room design.

 

Types of Clean room design

Correctly designing and engineering your cleanroom design airflow is very important, and this is what ensure that you comply with regulatory standards like ISO, cGMP, USP 797, and FDA. Air change rates also have an effect on the maintenance and operational requirements and costs. However, this depends on the type of cleanroom design and where it is located.

The airflow also determines the heat load, relative humidity, static, temperature, and gradients of the cleanroom. These factors are dependent on the amount of treated air in the cleanroom, the number of times the air is changed, and the total heat load of the environment, considering equipment, personnel, and level of lighting.

Here, two types of clean room designs would be explored the single pass design and the recirculating air design. There is not much difference between the two designs, it is only the preciseness in control that tells them apart from the other. The regular clean room design would push the air down into the room, and then transfer the air out of the clean room. The difference between the two models is what you do with the air. Do you let it return to surrounding areas or you let it return back to the plenum?

The decision on which method to use depends on the level of your control’s preciseness. If you want to control humidity and temperature tightly, you should use the recirculating system so that the conditioned air would not escape. When you remove the air from a single pass cleanroom design, it fills the surrounding environment.

If you want to make a decision on the clean room design to use, you should consider the tightness or control of the humidity and temperature over the tightness or control of the particle count.

Clean Room Design companies provide a number of services led by professionals to use and maintain a high performance production facility. Their services include; clean room design, blueprinting, mechanical, and engineering. You can contact any cleanroom design companies to help with proper care and maintenance.

1, Single pass clean room design: When you use the single pass clean room design to remove the air that is in your clean room design, it presses the air down and releases it into the surrounding environment. This allows you create an external environment that is cleaner using the air from the cleanroom design. They are usually smaller than the recirculating air design. In a Zonsteel hardwall single pass clean room design, the air is usually let out through the low exhaust grills.

Figure 3: Single Pass Design

The HEPA modules that is in the single pass clean room design has speed controllers, to help ensure that the air change rates meet the standard classification level. The conditioning of the clean room design should be low enough to counter the heat loads coming from the HEPA fan filter motors, process equipment, air change rates and light fixtures.

1, Recirculating air clean room design: When you use a Zonsteel recirculating air clean room design, this would allow you trap the conditioned air, and not release it into the surrounding environment. The air is filtered using a dedicated air handling system that is designed to keep the clean room design at the appropriate environmental tolerance level. This type offers; pressurization, relative humidity, and temperature. The Zonsteel systems are paired with a static HEPA filtration modules instead of the fan powered modules.

Figure 4: Recirculating Air Design

The single directional airflow is created using careful placements of the HEPA filtration modules. This directs airflow, and also removes heat load in some areas of the cleanroom design that need higher airflow. There are instances where lower ISO-class recirculating cleanroom designs are filtered using HEPA units with the supply air from the HVAC system. This would help reduce maintenance cost and requirements in the long run.

 

Benefits of a Clean room Design.

1, Zero contamination: Airborne contamination is usually a bug problem in several manufacturing industries. For example, dust from boots could damage a CPU worth $400. Complete control of your environment is the only way that you can have zero contamination. An appropriate Clean room design offers appropriate airflow control rate, direction, temperature, and pressure.

2, Customized solution: Clean room design can be customized to fit the taste and regulations of different industries. Whether it’s the medical device industry or pharmaceutical industry, clean room design provides customized solutions by ensuring production is made in the right environment to meet up with quality standard.

3, Improver products and ranking: When you use clean room design for your production process, you would be certain that they would meet and surpass the industry standards. This would boost your product portfolio and boost your ranking on the global market.

4, Compliance with regulations: Working with a clean room design ensures that you meet up with the government’s standard for safety precautions, and also ensure that all products made are quality and safe for use. This is a one-time investment that would help improve your products, brand image, ranking, and sales.

 

Choosing a clean room design system

Selecting a clean room design for a new business or product is not really difficult. Though there are different features and brands that you can select from, but keeping in mind the essential requirements would help make your job easier. Here are the things you should consider when you want to get a clean room design;

1, Rules and regulations: You should know the rules and regulations, guidelines and customer requirements before you use any clean room design. The regulations determine the cleanliness level and required ratings. This is a good place to start from when you want to get a clean room design.

2, Cost: You should consider the cost of the clean room design especially if you just want to start a business. Prices of clean room design vary from fixed wall, to modular, to hardwall clean room design. Fixed wall rooms are the most expensive, and softwall clean room design are the most affordable. The size, application, and configuration are all determinants of the cost.

3, Other considerations: The location of your clean room in the building, the number of employees that would come in and out daily are the determinants of the size and structure of your clean room design. A nice clean room design would help project your product to customers has a high quality product.

 

Common Design Configurations

Here are the 4 types of clean room design configurations that can be used for different clean room design applications.

1, Panel-post clean room design:This design is very common because the system can be moved, expanded, cleaned, and reconfigured easily. All the materials can be used for new configurations. There is also easy access to this facility without causing an increase in the number of particles.

2, Panel-panel clean room design: This is more popular in the pharmaceutical industry. The system provides non-progressive construction for removing the single panel without disturbing the adjacent panels. It is not load-bearing, and it requires an internal support structure.

3, Double-wall clean room design: This unique design provide solutions to some problems encountered in the pharmaceutical sector. The panels are directly connected, and this would create a smooth transition across the wall surface of your clean room design.

4, Furring-wall clean room design: This design can be easily attached to any wall or surface, and it is a great update for already existing areas. There are various methods of securing the panel to already existing walls. The non-progressive construction allows easy removal of panels without disturbing the adjacent panels. The essential materials used for a furring-wall clean room design are; aluminium honeycomb, gypsum, and XP board.

Components of a Clean Room Design

There are several equipment that you would need for your clean room design. Some of these equipment are; Lights, terminal filters, paints, pass-through, and many more. You can get all of them from clean room design and manufacture company Zonsteel.

1, Ceiling tiles:

Figure 5: Clean Room Ceiling Tiles

These tiles are used for different environments and applications, they must provide optimum sanitary conditions. They can be used in environments like; hospitals, restaurants, and laboratories. They have to meet the required sanitary requirements.

2, Cleanroom filters:

Figure 6: Clean Room Filters

There are several sizes of filter available, and you can get them in stainless steel, galvalume steel. You can also get custom-made cleanroom filters. They go well with other components, light, and flooring to help create a clean environment.

3, Cleanroom pass-through:

Figure 7: Clean Room Pass-through

Including a pass-through in your clean room design would provide an easy way to transfer equipment and materials into the clean room. This would eliminate unnecessary traffic in the clean room and also prevent cross-contamination.

4, Clean and plastic strip doors:

Figure 8: Clean Room Strip Doors

You can get this from any clean room design and build company. These air tight clean room design doors are made from different materials like virgin vinyl. They are effective and durable. There are different types of doors, and they are the; double door, the single door, the interlock door, the auto door, the emergency door, and the fast door.

5, Vinyl Flooring:

Figure 9: Clean Room Design Vinyl Flooring

There are different types of vinyl flooring, and they offer different resistance levels. You should get a quality wax also, because it would help to get a good clean room design.

6, Talk-through Window:

Figure 10: Clean Room Design Talk-through Window

This window allows for easy communication without spending any extra cash on communication gadgets. A talk through window would allow for easy communication with the personnel in the clean room. It allows for both oral and visual communication. You can buy from clean room design and manufacturer Zonsteel.

7, Paint:

Figure 11: Clean Room Design & Paint

There are clean room floor and wall paints, and the paint of your clean room design must be up to the clean room design standards. Paints help provide the durable, stain-resistant finish. It is durable for interior use in your clean room design.

8, Lights:

Figure 12: Clean Room Design & Lights

LED light. The lamp body is designed easy to clean with a beveled edge, the appearance is simple, the mirror reflector is installed inside, and the lampshade and the lamp body are connected by a high-quality sealing strip. Suitable for lighting in electronic, pharmaceutical, and high-standard clean workshops.

9, Terminal Filters:

Figure 13: Clean Room Terminal Filters

There are different varieties of cleanroom design terminal filters, the replaceable, disposable, and the one that incorporates light fixture in the filter structure. Terminal filters would facilitate the flow of uniform purified air.

 

Methods of reducing contamination in the clean room

The reason why there is a clean room design is to ensure that you have a clean, contamination free zone for continuous work flow and maintaining productivity, profitability, and quality. In a manufacturing firm, the employees are usually the most common source of contamination. However, there are some simple steps that you can take to help prevent that.

 

How to maintain a clean room

1, Practice good hygiene: If you want to maintain your clean room when do the clean room design, you and your employees have to practice good hygiene. Humans always shed contaminants off, it could be lotions or cosmetics. Good hygiene would reduce the level of contamination spread in the clean room design.

Figure 14: Changing Room

2, Be mindful of hands: Most of the cleanliness violations in the clean room are always hand related. To prevent your employees from contaminating any clean room design equipment, you can install no-touch sensors.

3, Wear your gear properly: The way the garment is put on is as important has the garment itself. There are different companies, and they all have different procedures, but the regular clean room design gear is worn from the head to your toes.

4, Limit speaking: When you have a quiet clean room design, productivity is increased and contaminants are also reduced drastically. To limit the contaminant from saliva that come out of your mouth in a clean room, you should wear a mask.

 

How do I clean my clean room?

Before attempting to clean your room, you should ensure that all your experiments are stored away properly, and if any cleanroom specialist forgets an item, they should be contacted immediately because the contents of a clean room are very fragile and could be contaminated.

Figure 15: Clean Clean Room Design

After proper storage of experiments and personnel, the janitors must suit up before entering the clean room design. Disinfectants should be used to clean the surfaces, and any large debris can be swept away. Items that are found in the cleanroom should not be accessed. Zonsteel clean rooms design has a non-abrasive disinfection spray to help keep your clean room environment well controlled. You can also use charged particles that would clean every surface in the clean room design. Items that you need in cleaning your clean room includes; UV lamp, Non-woven fabrics wiping, special chemical reagent, and ozone generator. You can get all these materials from Zonsteel.

 

Things you should know before cleaning the clean room

You should know that regular cleaning of your clean room is quite important. Though the cleaning procedure of your clean room design depends on the procedures offered by the company. However, there are some general steps that we all know. They are;

1, Establish environmental monitoring, and identify viable and non-viable contaminates: You should effectively monitor the environment of your clean room, and also identify the viable and non-viable contaminants.

2, Use the results to get cleaning chemicals and disinfectants: You can get cleaning chemicals and disinfectants to help maintain your clean room design properly, and also use the disinfectant around the clean room design surroundings to prevent an increase in the number of particles.

3, Establish procedures of operation: The procedures of operating the clean room must be made available to everyone, so that they would have the knowledge of what is required of them when they want to enter, approach, or clean the clean room.

4, Train your cleaning staff: Your cleaning staff must be trained effectively to prevent any mishaps in the clean room design that could be disastrous, and to also ensure that they clean the room well enough.

5, Inspect personally to ensure that all orders and regulations are followed: You have to personally inspect the job, to ensure that they meet up with all standards and regulations.

 

Zonsteel

Zonsteel is a professional company that specializes in clean room design, in the production of clean room components like doors, windows, and panels. Zonsteel products can be used in different industries, products would provide complete laminating, production, and assembling. All products are automated, and your clean room design needs just needs a touch from Zonsteeel.

Zonsteel offers two clean room designs, the hardwall and softwall. There are several clean room accessories in design to complement your clean room. You can be assured of buying quality products when you buy from Zonsteel. Our wall panels are made from rock wool core, our ceiling panels are aluminium honeycomb, rock wool, or steel board 2mm, and they are the most durable on the market. Zonsteel clean room panels can withstand 4 hours of fire, using the MGO board on both sides.

Our doors are designed in different varieties. Double door, the single door, the interlock door, the auto door, the emergency door, and the fast door.The material type you choose depends on you, but here are the options available; aluminium, steel, melamine resin, and stainless steel. Door frames are specially designed for clean room design panels.

 

Which clean room can Zonsteel design?

This is an important question to ask yourself. Before buying any product from Zonsteel, you should be aware of the type and category of products that they have. Zonsteel products are available for companies in the following industries; IT, Pharmaceuticals, Laboratories, New Energy, and Food. There are several more on the portfolio, but you should know that Zonsteel provides clean room design for different industries.

Figure 16: Zonsteel Clean Room Panels

Your ceiling needs, tolerances, and air handling system can be handled by Zonsteel. We offer products like wall, channels, and ceiling materials. Zonsteel clean room panels are half-made from machines, and the other half is hand crafted. The four sides are steel sealed, very strong, and effective. Our walls and ceilings can also be reinforced from the inside. You can make the wall longer by making a special order from Zonsteel.

 

Conclusion

If you want to start your business in any industrial like IT, Pharmaceuticals, food, new energy, and lab industries, etc. Contact Zonsteel for EPC project. We can offer you from clean room design, to clean room component, equipment and furniture manufacturing, and clean room installation. Or you just want to buy some clean room parts, feel free to contact us!