Cleanroom Terminology: What Is an Airlock?

Cleanroom Terminology: What Is an Airlock?

by | Nov 22, 2023 | Cleanroom Design

When entering the world of cleanroom design, many people are overwhelmed by the new vocabulary, which can be quite complicated. Suddenly, you have to understand classifications and all sorts of design features and figure out which are right for your application. 

We’re here to break down one of the most common terms you’ll hear in cleanroom design – airlocks. So, what is an airlock, and how does an airlock work? Let’s get jump in.

What Is an Airlock?

An airlock is a system of two doors that are electronically interlocked so that both cannot be opened at the same time. This prevents contamination and prevents particles from outside the cleanroom from entering the cleanroom when personnel enter or exit the cleanroom. 

In addition to its role in contamination control, airlocks can serve as security features, controlling and monitoring access to the cleanroom. An airlock system will also help maintain the controlled temperature of a cleanroom space. They are vital components in various industries, adapting to specific cleanroom requirements while offering emergency features to ensure personnel safety.

How Does an Airlock Work?

An airlock creates a controlled, enclosed space with two interlocked doors. They make a controlled transitional space between an external environment and a cleanroom, with the primary goal of preventing contamination, maintaining cleanliness, and preserving the specified environmental conditions within the cleanroom.

Here’s how airlocks typically operate:

  • Two-Door System: An airlock consists of two doors, one leading to the outside environment and the other to the cleanroom. These doors are electronically interlocked, ensuring that both doors cannot be opened simultaneously.
  • Pressure Differential: The cleanroom typically operates at a higher pressure than the surrounding area. When personnel need to enter or exit the cleanroom, they first enter the airlock. The outer door is closed behind them, sealing off the outside environment.
  • Controlled Environment: Once inside the airlock, the system may initiate a series of processes to maintain the controlled environment. This can include adjusting temperature, humidity, and pressure levels to match the cleanroom’s specifications.
  • Personnel Procedures: Personnel inside the airlock may need to follow specific procedures, such as donning cleanroom attire, which includes specialized garments, headgear, and shoe covers. 
  • Interlocking Doors: After the necessary preparations and checks are completed inside the airlock, the inner door can be opened. This allows personnel to enter the cleanroom while ensuring that the outer door remains closed, maintaining the pressure and cleanliness of the cleanroom.
  • Security Features: Some airlocks include security features like access control systems to authenticate and authorize individuals. 

What Kinds of Airlocks Are There?

There are two types of airlocks: secure and non-secure airlocks. In a secure airlock system, all doors remain locked until a request to enter is granted. This generally occurs through a “request to enter device,” like a button or keypad. A non-secure airlock means that the doors remain unlocked until the first door is opened; then, the other doors lock.

You also have the option of making your airlocks supervised or unsupervised. For high-security areas, you may have a supervised airlock, where personnel must press a “request to access” button. The request must be approved via a CCTV or viewing panel verification system. 

An unsupervised cleanroom could control access through a biometric reader or keypad to gain access. Such systems are useful where only authorized personnel may enter the cleanroom environment.  

Enhancing Cleanroom and Airlock Security

Depending on the classification and application of your cleanroom, you might want additional security features in place on your airlock. These considerations aim to enhance security and monitoring within the airlock system to minimize the risk of contamination and maintain the pristine conditions of the cleanroom.

  • Breach Alarms: Depending on the sensitivity and cleanliness requirements of the cleanroom, it may be essential to implement breach alarms within the airlock system. These alarms serve as a critical safeguard, alerting personnel when the airlock has been breached. Breach alarms are triggered when unauthorized access or contamination may have occurred. 
  • Door Open Duration Alarms: Cleanrooms often require swift and controlled access, and extended open-door times can compromise the cleanliness and environmental conditions. Door open duration alarms provide a mechanism to ensure that doors are not left open for too long, thereby preventing prolonged exposure of the cleanroom to the outside environment.
  • Door Status Indicators: Door status indicators are visual or electronic displays that provide real-time information about the current state of the airlock doors. These indicators offer a quick and easy way for personnel to confirm whether the outer door is securely closed before opening the inner door. 

Cleanrooms to Fit All Your Needs From Angstrom Technology

If your cleanroom requires an airlock, Angstrom Technology is well-equipped to design a custom cleanroom that perfectly aligns with your specific needs. Our team of seasoned design engineers possesses the knowledge and expertise required to create a cleanroom solution tailored to your industry’s unique cleanliness standards and environmental demands.

Contact Angstrom Technology today, and let’s embark on the journey towards a tailored cleanroom solution that precisely fits your requirements, enhancing your controlled environment for optimal operations.

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Building a battery dry room

Building a battery dry room

by | Dec 16, 2022 | Air Circulation, Cleanroom Design, Cleanrooms

Many materials and processes used in battery production are susceptible to moisture damage. For that reason, humidity control is critical in a battery dry room. The experts at Angstrom Technology can create a stable low dewpoint production environment to meet your requirements. In this blog post, we explain how.

 

Battery dry room construction

Battery dry rooms require a constant supply of ultra-dry air to create and maintain low-humidity conditions for the R&D and production of solid-state and lithium-ion batteries.

We can develop an energy-efficient dry room to protect your critical process in any of the following applications. We do this by combining airtight envelope systems, dehumidification systems, and HVAC design.

Small-scale battery research

Pilot plants

Mega / Giga-factory

Single-zone facilities for testing the chemicals and processes during battery R&D.Multi-zoned facilities for scaling up production to manufacture at volume.Large-scale battery production facilities for high-volume battery production.

 

Battery dry room manufacturers

As battery dry room facility manufacturers, we deliver complete dry room systems. Working with specialist humidity control partners, we provide bespoke solutions that include industry-leading energy-efficient HVAC systems.

A typical clean room environment operates at 20.0°Cdb, 50% Relative Humidity — which is a dewpoint of 9.3°Cdp. Due to the materials’ sensitivity in the process, solid-state battery dry rooms can require control to minus 40.0°Cdp at the room’s exit point. A lower dewpoint of minus 50.0°Cdp is required for Lithium-ion battery dry rooms, and the next generation may have even tighter requirements. The battery chemistry may need the environment to reach minus 80.0°Cdp at the point of supply into critical areas, such as Electrolyte Fill.

Look at how we can custom-build your perfect battery dry room.

 

Footprint & zones

Establish a suitable layout for your process, featuring multiple zones, each with the optimum dew point temperature and ISO class.

 

Dehumidification systems

Single or multi-rotor low dewpoint AHU options to suit your budget, space, and specification needs.

 

Internal airflow distribution methods

Horizontal unidirectional airflow with a supply and return air plenum or a high-level distribution system with uni or non-unidirectional airflow.

 

Airflow modelling

Using Computational fluid dynamics (CFD) studies to verify HVAC design with equipment and furniture layouts.

 

Scalable HVAC designs

With specialist AHUs designed for deployment in battery facilities, airflows range from 2,000 m³h to 50,000 m³

 

Energy-efficient design

Airtight envelope systems and recirculated air manage energy efficiency.

 

Battery dry room design & build projects with Angstrom Technology

As Angstrom Technology are cleanroom specialists, our dry rooms can also achieve ISO classification. Not only that, but they can also meet any applicable international engineering and building standards and regulations.

We’ve developed proven envelope solutions and reliable cleanroom HVAC designs for many applications. The Angstrom Technology group pride ourselves on our in-house expertise and capability to deliver over 100 cleanrooms annually across America, the UK, and Europe.

Tell us about your new dry room project!

Whitepaper: Dry room design guide for lithium battery manufacturing

DOWNLOAD OUR HANDY GUIDE:

 

 

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Post-and-Panel vs. Seamless Cleanroom Wall Systems

Post-and-Panel vs. Seamless Cleanroom Wall Systems

by | Aug 17, 2022 | Cleanroom Design

The materials you use to build your cleanroom have a lasting impact on its cleanliness, performance, durability, and appearance. Arguably the most important of these materials is the cleanroom wall system you choose. 

Let’s take a look at two of the most common types of cleanroom wall systems: post-and-panel and seamless. 

Post-and-Panel vs. Seamless Wall Systems: What’s the Difference?

First, some definitions. Learn more about what post-and-panel and seamless wall systems are, and how they differ below. 

What Is a Post-and-Panel Cleanroom Wall System?

A post-and-panel cleanroom wall system utilizes a series of non-progressive posts and panels that are joined together to create a modular enclosure. The posts and panels are “stitched” together with a corrugated roof deck that keeps them in place. 

The end result? A modular enclosure that’s self-supporting, reconfigurable, and isolated from its surrounding environment. It stands alone and is separate from the existing building structure. 

What Is a Seamless Cleanroom Wall System?

A seamless cleanroom wall system utilizes studless, flush wall or liner panels to create a modular enclosure. These wall panels can be either progressive or non-progressive but are tightly sealed so that no seams are exposed. They also have coving (a curved covering that connects a wall to a ceiling) on both horizontal and vertical intersections. 

A seamless cleanroom wall system can be tied into steel stud walls and/or the existing building structure that surrounds it. It also typically features a flush, walkable ceiling. Its seamless design allows for durable performance and sleek aesthetic appeal for the most stringent applications. 

Pros & Cons of Post-and-Panel Cleanroom Wall Systems

Now let’s take a look at some of the advantages and disadvantages of these cleanroom wall systems, specifically highlighting distinguishing factors between each type. We’ll start with post-and-panel. 

The main advantages of post-and-panel cleanroom wall systems are: 

  • They can be reconfigured easily. Due to their non-progressive nature, post-and-panel wall systems are the easiest type to reconfigure. The-two piece stud post allows removal and replacement of a wall panel without disturbing adjacent panels. They also accomodate quick and easy vertical installation of electrical, data, and communication lines in the raceways, which are accessible from the removable cover plate. If your facility is expecting growth or changes in the future, this is an important benefit to consider. 
  • They’re self-supporting. Post-and-panel wall systems can stand alone. The structural-grade, extruded aluminum acts as a structural column on spaces with long clear spans or load bearing roofs. The stud system will accommodate steel tube inserts for additional load bearing capability. They don’t need to be integrated into an existing building structure, giving you a bit more versatility with placement and layout. 

The main disadvantages of post-and-panel cleanroom wall systems are: 

  • They’re harder to clean. Because they’re not fully seamless (the panels will fit within studs creating an ⅛” protrussion or less) and have no coving integrated into their system, post-and-panel wall systems can be more difficult to clean. There are more seams and crevices where particles can accumulate. 
  • They’re not FM-approved. Post-and-panel wall systems are Class A non-combustible, but they’re not FM-approved. This may be a deal breaker for certain applications, depending on industry-specific requirements. 

Pros & Cons of Seamless Cleanroom Wall Systems

Now for some advantages and disadvantages of seamless cleanroom wall systems — which are basically the opposite of what we mentioned about their post-and-panel counterparts. 

To start, the main advantages of seamless cleanroom wall systems are: 

  • They’re easy to clean. Seamless wall systems have tight, chemically cold-welded uPVC seams and coves so there are no crevices for contaminants to build up in or air leakage. This makes them much easier to clean, wash down, and fumigate. For higher ISO classifications with stringent cleaning requirements, this is the best option.
  • They feature a floating flush ceiling. Their floating flush ceiling offers the same fine line seams and finishes as the modular wall system. The flush ceiling platform utilizes 5’ x 10’ ceiling panels and 5’ x 10’ hanger spacing, allowing the installation of FFUs and lights without changing the ceiling panel orientation. Interior wall panels are attached to the bottom surface of the ceiling panels and wall/ceiling covings can be run at any location making it integral to the cleanroom system. The walkable ceiling is capable of supporting a wide variety of mechanical systems and accommodating components and small equipment.
  • They’re FM-approved. Seamless wall systems are both Class A non-combustible and FM-approved, meaning they offer the considerable level of fire resistance that some cleanroom applications require. 

The main disadvantages of seamless cleanroom wall panels are:

  • They’re not as easy to reconfigure. While it’s definitely not an impossible task, reconfiguring a seamless cleanroom is a bit more difficult. This is especially true if it’s built with progressive wall panels where replacement is done through the use of rotating splines.
  • They can’t stand alone. Seamless cleanroom wall systems aren’t self-supporting. They must tie into the existing building structure, or you’ll have to build a steel superstructure for support.
  • They’re a bit more expensive. Since the system isn’t structurally sound on its own and must be supported by a steel superstructure or existing building, seamless cleanroom wall systems are generally the more costly option.  

What Type of Wall System Is Best for My Cleanroom?

Both post-and-panel and seamless cleanroom wall systems are great options that can meet varying specifications you need them to, so there’s not really a “wrong” answer to this question. A better way of looking at it is there might be one option that’s better for you than the other. That can vary for you based on a few factors, including:

Our recommendation is that before deciding anything, you should connect with a cleanroom specialist. They’ll be able to listen to your unique needs and recommend a solution that will work best for you. 

Start Your Cleanroom Design & Build Project with Angstrom Technology

Thinking about installing a new cleanroom in your facility? We can help! At Angstrom Technology, our cleanroom specialists have extensive experience designing, building, and installing cleanrooms with high-quality materials. 

From deciding which type of cleanroom wall system is best for your application to ensuring you have enough air filters and handling units to maintain a controlled environment, we’ll help you work through the details of your project. Then we’ll make your vision come to life! 

To get started working with us, give us a call at (888) 768-6900 or contact us online.

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Dedicated vs. Integrated Cleanroom HVAC Design

Dedicated vs. Integrated Cleanroom HVAC Design

by | Aug 10, 2022 | Cleanroom Design

Environmental control is the staple of effective cleanroom design and performance. In order to ensure safe and controlled operations can take place, airborne particles of a certain size must be caught and removed from the cleanroom environment. 

However, there’s more to the equation than just air filtration. Regulating temperature and humidity within your cleanroom is also an important factor in maintaining a high level of environmental control and to protect customer products. A well-equipped and strategically configured HVAC system can get you there.

What Does an HVAC System Do?

HVAC systems are air handling units engineered for precise control over temperature and humidity within an enclosed space. They complement filtration systems like HEPA and ULPA filters which sit in your cleanroom’s ceiling grid. 

When it comes to choosing an HVAC system for your cleanroom, you have two options: dedicated or integrated. Below, we’ll discuss what each of these options means so you can make an informed decision about what will help your cleanroom reach peak performance. 

Dedicated vs. Integrated Cleanroom HVAC Design: What’s the Difference?

So what are dedicated and integrated HVAC systems? Their definitions have to do with how each one is designed and implemented within the cleanroom environment, and possibly within the larger facility as a whole. 

  • Dedicated cleanroom HVAC design is when an HVAC system is designed specifically for the cleanroom and utilizes its own system. It operates independently from the rest of your facility’s existing HVAC system.
  • Integrated cleanroom HVAC design is when the facility’s existing HVAC system is used to service, tie into, and maintain the cleanroom. It operates in utilizing the larger facility’s system.

After reading and understanding those descriptions, you may get a sense of the advantages and disadvantages related to each design choice. In the following sections, we break that down a little more clearly.  

Pros & Cons of Dedicated Cleanroom HVAC System

Dedicated cleanroom HVAC system is a smart choice for many facilities. In fact, it’s usually the only configuration that can meet a cleanroom’s specifications. In terms of design, air changes per hour, heat loads, air filtration, and environmental control over temperature and humidity, this is the choice that can meet the most stringent HVAC requirements. 

A dedicated cleanroom HVAC system can also help a facility balance the load put on their various operational systems. Since it’s independent of the rest of the building’s HVAC system, it carries its own load and doesn’t take anything away or starve other external spaces. This is a big deal when you think about how much energy and air cleanroom HVAC systems circulate on a daily basis. 

A few disadvantages here? 

Dedicated cleanroom HVAC systems can cost more and require a more involved process upfront. Since an entirely new system is being installed, site details, existing facility drawings,  design, coordination with other engineers, and installation time is usually necessary. 

But after installing an HVAC system that’s reliable, meets the required specifications, and performs well, most facility managers find that the upfront cost was well worth it — making the dedicated HVAC system a more cost-effective choice in the long run. 

Pros & Cons of Integrated Cleanroom HVAC System

When you look at an integrated cleanroom HVAC system, the advantages and disadvantages are basically the opposite of those described above. 

The biggest benefit of integrated cleanroom HVAC system is that it requires less design and installation time because you are tying into the existing facility’s system. Because of this, it may cost less upfront. However, that lower upfront cost often comes with a lower-performing system or cleanroom. 

Since integrated cleanroom HVAC systems are incorporated into buildings’ existing HVAC systems, they use the same supply air as the rest of the building, which is typically not designed for cleanroom applications. 

For cleanrooms that need a high level of environmental control, need to turn the air over a significant amount of times per hour, and need to protect the safety of the product, this can be detrimental. Air from other areas of the building is designed for creature comfort of their employees, so it’s controlled differently than a cleanroom. Merging the two operations together creates unpleasant environments for one of the two parties. 

Which Type of Cleanroom HVAC System Is Right for My Facility?

No matter your cleanroom’s size or application, a dedicated cleanroom HVAC system is the most effective choice. It’s more capable of meeting requirements related to filtration, temperature, humidity, and more — ultimately providing you will a controlled, high-functioning, cost-effective space. 

If you’re still unsure about how this type of cleanroom HVAC design could fit into your facility, get in touch with a trusted cleanroom manufacturer or technician. They’ll be able to listen to your concerns and provide you with recommendations that are customized to fit your needs. 

Ready to Start the Cleanroom Design Process? Contact our Experts

Your cleanroom’s HVAC system is essential to the safety and efficiency of your operations. If you’re looking for a cleanroom manufacturer that can deliver a well-designed, high-performance solution, contact Angstrom Technology for more information or request a quote today. 

Our cleanroom design and engineering specialists have experience working with customers in all kinds of industries, achieving great results time and time again. We’d love to work with you as well!

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