When you’re commissioning a new cleanroom, it can feel like a necessary evil. You need a cleanroom to start operations, but it costs a lot of money that you might not have available in the budget at the time. It’s a bit of a Catch-22. At this point, you’re probably looking for anything that will get you the cleanroom you need in the time frame you have. Luckily, there are a variety of design options that can solve some of the most common budget concerns. Here are a few cost-cutting design options to keep in mind when you’re looking for a cleanroom now:
One of the absolute quickest and easiest ways to save money on a cleanroom design is to opt for a modular cleanroom over a traditional cleanroom. In most cases, this is a perfectly valid solution, as modular cleanrooms can perform to almost all of the highest cleanroom standards. Additionally, modular cleanrooms can be modified to accommodate business expansions. And most importantly, they’re cheaper and quicker to build than your traditional cleanroom. When you opt for a modular cleanroom, you can get the cleanroom you can afford now without barring yourself from expanding to the larger cleanroom you really want in the future. If budget is an issue, modular cleanrooms are the way to save.
Make it Smaller
Sure, you want a cleanroom that’s big enough to handle the processes you plan on implementing in the future, but can you get by with something smaller for the time being? In the case of modular cleanrooms, there’s a lot you can do to get by with a smaller cleanroom. For example, you can use an existing wall and build your modular cleanroom off of that, which will reduce building and material costs. Remember, you can always build off of that existing cleanroom, or move it to a larger space down the road.
Additionally, by choosing a cleanroom design with a lower ceiling, you’ll also save money when it comes to energy and material costs. The smaller your cleanroom is, the less money it will cost to run it, and the less energy you’ll need to keep it to your ISO standard. If you can get by with a cleanroom with a lower ceiling and a more conservative size, and you need a cleanroom right now, then it’s not a bad idea to start small and expand later on. It’s good to note, though, that if you plan on expanding, to make sure you tell your cleanroom expert. They’ll be able to walk you through the best way to construct a cleanroom that works for you now, but will be compatible with additional processes when you do expand in the future.
Consider LED lighting
Cleanroom lighting makes up a large portion of the money spent on maintaining a cleanroom. Cleanrooms often require super-bright lighting options. While these lights are great at keeping the room well lit for employees, they’re often responsible for adding a surprising amount of additional heat to a cleanroom. This forces your AC unit to work even harder, which results in a spike in overall energy costs.
Today, there are a variety of LED cleanroom lighting options on the market that solve this problem. You can choose from a standard panel style to a strip style LED light that adheres to directly to the ceiling grid, without interfering with your cleanrooms’ laminar flow. LED lights produce little to no additional heat, and have an exceptionally long life, ensuring that you don’t have to constantly replace light bulbs and keeping your cleanroom cool.
Use your existing AC unit
Another great way to save money is to design a cleanroom that will function on your building’s existing HVAC or heating and cooling unit. This is an efficient way to control the temperature of your cleanroom, so long as your building’s unit can handle the extra load that your new cleanroom will add. Consult with your building’s heating and cooling expert to ensure the unit can handle that much energy, and if it can, you’re in luck!
It is good to note that some cleanroom class standards do require a cleanroom have its own AC module, in case the central unit fails. In this case, or in the case that your central unit is already overworked, you’ll need to ensure your cleanroom is properly ventilated to the outside. Though it’s usually cheaper to ventilate a cleanroom into the larger building, this puts a lot of additional stress on both your cleanrooms AC unit and the HVAC unit in the building. Avoid this if possible, to keep both units working in top condition for their intended lifespan.
We get a lot of questions from clients wondering if pre-filters are an acceptable option to use in conjunction with heavy duty HEPA and ULPA filters. The answer is definitely yes! Pre-filters are put in front of the larger filters and can be up to 80% efficient at capturing larger dust particles before they reach the HEPA and ULPA filters. This keeps your larger, more important filters cleaner for longer. Pre-filters are relatively inexpensive and easily cleaned and reused. By using pre-filters in addition to your HEPA or ULPA filters, you extend those more expensive filters’ lifetime and save yourself quite a bit of money.
Pass-thru chambers are another sneaky way to save money on your cleanroom. They’re a lot smaller than an access door, and they allow employees to transfer supplies or materials without having to gown up. This saves both money and time: money because in using a pass-thru chamber instead of a full door, you eliminate the possibility of contamination from foot-traffic and maintain a stable pressure during the interaction; and time because your employees won’t have to properly gown up to enter the cleanroom via the access door. In installing a pass-thru chamber as part of your new cleanroom design, you’ll save money by lowering energy costs and increasing employee productivity.
We hope that this list helps you find a cleanroom that works both for your application and your budget. If you have more questions regarding a cleanroom design that works for you, make sure to give the experts at Angstrom a call! We’re always here to help answer any cleanroom questions you can throw at us, so get in touch with our office at 888-768-6900, or request a cleanroom quote online today!
Cleaning a cleanroom seems a bit counterproductive, doesn’t it? By name, a cleanroom is already supposed to be clean, so what would the point of actually sterilizing it be? Unfortunately, no cleanroom, regardless of its ISO standard, is 100% effective. By having people move about in the cleanroom, particles are bound to fall and contaminate your cleanroom from time to time. That’s why it’s important to ensure that you and your employees are regularly cleaning your cleanroom. If you’re new to cleanrooms, there are a few methods you can use, as well as a few precautions to keep in mind. We’ll start with standard cleanroom sterilization methods:
For regular, routine cleaning, dry cleaning – or dry transfer – is the most common method of sterilization. This type of cleaning refers to the polishing or wiping of a surface with an absorbent or collective cloth. There are a variety of cleanroom-approved materials well-suited to this sort of sterilization, but the one you choose will depend on your cleanroom’s class. At the very least, you’ll want to ensure that whatever wipes you choose for routine dry transfer cleanings are lint-free. This will decrease the amount of lint and particles left behind from the dry transfer cleanroom sterilization. Dry transfer is commonly used on a daily basis to remove the minimal amount of particulate buildup that occurs in a short period of time.
Wet cleaning, the process of cleaning with an approved solution or cleaning fluid, is necessary when a standard dry transfer cannot remove the particulate that’s accumulated over a period of time – generally once a week. There are a variety of cleaning solutions suited to removing cleanroom particulate, but the one you choose for your cleanroom will depend on the surfaces you’re cleaning as well as the class rating of your cleanroom. It’s important to note that you’ll want to choose a product that’s approved by the EPA and is suitable for use in a cleanroom. EPA-approved products are often safer for your employees, as they emit less toxic fumes.
Instating Your Cleaning Process
Before you begin assigning employees to sterilize your cleanroom, you’ll first need to take a few initial organizational steps:
Standard Operating Procedure
You’ll need a clear, outlined procedure for each type of cleanroom sterilization process you plan on implementing: daily, weekly, and monthly. This procedure will ensure that every employee knows exactly what they’re responsible for at each cleaning. Your SOPs should include proper dilution techniques for any cleaning solutions used and should give an outline of which order employees should clean surfaces and appliances.
After creating the necessary SOPs, it’s time to train the employees who will be responsible for sterilizing the cleanroom. It’s a good idea to have a few designated employees who will always handle the cleaning. This ensures that the process is completed consistently each time. Employees should know exactly what to do from the point of entering the cleanroom with sterilized cleaning products and equipment to discarding of any waste after the cleaning is complete. By training and regularly observing the employees responsible for sterilization, you’ll be better able to ensure that your cleanroom is always cleaned properly.
Additional Cleanroom Sterilization Tips
Clean From Top to Bottom
No matter what sterilization process you’re using, it’s important that employees always clean from top to bottom. In a thorough monthly cleaning, this means that employees should start with the ceiling, move to walls, and then tackle surfaces like tables and chairs, saving the floor for the absolute last. In cleaning the area from least contaminated sections to the dirtiest, you will ensure that minimal particulate is left behind.
Many cleanrooms utilize sticky flooring to minimize the amount of particulate released into the cleanroom via shoes and dirt that collects on the floor. This is a great way to keep your cleanroom as sterile as possible, but it will require a different cleaning procedure. Ensure that your Standard Operating Procedure includes proper manufacturer instructions on the cleaning process for this sticky flooring.
Preparation of Cleaning Materials
It is paramount that employees follow proper preparation procedure for cleaning materials. In many cases, cleaning solutions must be diluted with water before they can be safely used on cleanroom surfaces. Improper dilution can result in 1) ineffective cleaning processes if there is too much dilution, and 2) the erosion and damage of cleanroom surfaces if solutions are not fully diluted. Most cleanroom sterilization products are caustic and require an adequate amount of dilution to ensure that they are removing only the particles that contaminate your cleanroom, and not corroding cleanroom surfaces. You’ll also want to double check that the cleaning materials you choose are suited to the surfaces within your cleanroom.
Beware of Fumes
Cleaning materials can cause a buildup of fumes, which contaminates your cleanroom and can be harmful to employees. To avoid fume buildup, ensure that fans and filter units are always left on during the cleanroom sterilization process.
Disinfect Cleaning Equipment
To protect from bringing in additional contaminants, it’s important to disinfect all cleaning equipment before it enters the cleanroom. This includes replacing old or disintegrating mop brushes and using new, uncontaminated cloths and wipes.
Follow Proper Gowning Procedure
In sterilizing the cleanroom, staff must follow standard gowning procedure. They should also treat cleaning as they would any other normal cleanroom operation. This means slow, controlled movements that limit the introduction or disturbance of contaminants.
With these basic sterilization tips, you can ensure that your cleanroom is always performing at its best by protecting your procedures, and reducing any possible contaminants in the area. Make sure you’re following a regular cleaning schedule, and keep your employees up to date if you ever make changes or adjust your cleaning SOPs. And if you have any other questions about sterilizing your cleanroom, give the experts at Angstrom a call. We’re always happy to help! Contact our office by phone at 888-768-6900, or request a quote online today.
Updating your cleanroom can be daunting. After all, there are so many factors that need to be considered when it comes to any change to the cleanroom environment. You have to consider the specification you need to meet, cost, durability, and maintenance requirements of additions or replacements. But investing in some smart upgrades can really improve the cleanliness, ease of maintenance, efficiency, and ergonomics of your cleanroom space.
LED lighting is a no-brainer when it comes to upgrading your cleanroom. When compared with fluorescent lighting it’s easy to see why: LED lights are very efficient, emit little heat, and require little maintenance, whereas fluorescent lights are fragile and need replacing often. LEDs have the longest lifespan of any commercially available light source, which makes them worth investing in.
LED lighting also beats fluorescent lighting in system efficiency (greater than 50 lumens/watt for LEDs, less than 30 lumens/watt for fluorescents). This is because fluorescent lighting is omnidirectional, emitting light for 360°. Fixture housings are required to redirect fluorescent light to the desired area. LEDs emit light for only 180°, which makes it easy to target light over the desired area–more light actually reaches it.
If your cleanroom wall panels are damaged, it can be costly to replace them. If the damage isn’t too extensive, it’s possible that panels can be repaired instead of replaced. Repairing damaged panels will improve the aesthetic of your space, but most importantly, it will help maintain the integrity of the cleanroom. Damaged panels could give off particulate matter or allow contaminants to breach the cleanroom.
Vinyl Walls and Ceilings
Vinyl is a smart upgrade for two reasons: cleaning and surface resistance. Vinyl is easy to clean and allows complete removal of particles, in addition to its low particulate emission. Vinyl can also have dissipative or conductive levels of static resistance, making it ESD safe, if that’s something your cleanroom requires.
Due to a variety of factors (gravity, for example), floors are often the dirtiest part of a cleanroom. Just like walls and ceilings, vinyl is also a good flooring choice for the same reasons: chemical resistance, static dissipative or conductive resistance, low particulate emission, and easy cleaning. There are also a variety of other flooring types such as rubber, epoxy coating, urethane, etc., with different characteristics to meet specific purposes. Cleanrooms with heavy vehicle and wear traffic may benefit from ultra-durable rubber flooring, whereas cleanrooms with the need for chemical and stain resistance might require urethane.
There are many ways to spend money while updating your cleanroom, but smart upgrades can help you make the most of your renovations, and your cleanroom. If you’re looking to upgrade your modular cleanroom, be sure to call Angstrom Technology at 888-768-6900 or request a quote online today!
One of the most difficult considerations when designing a cleanroom is determining how big or small it needs to be. The goal is to create a cleanroom that is big enough to house operations, but only just. If your cleanroom is considerably larger than you actually need it to be, then you end up wasting a lot of money by keeping that extra space clean as well. If your cleanroom is too small, you won’t reach required production levels and you may not have enough space for all of your machinery. So, how do you decide what your dimensions should be? Here are a few things to take into account:
Sure, maybe you have a warehouse with a ton of empty space, but that doesn’t mean you should use all of it for the cleanroom proper. You need to make space allowances for both big HEPA, ULPA, and pre-filters, and you have to consider the installation of the cleanroom itself. Regarding the ceiling, you’ll need at the absolute minimum 6 inches of clearance. Less than that, and you risk starving your filters for air, defeating the purpose of the cleanroom in the first place. We recommend you leave about three feet, if you have the room, to allow for hassle-free changing of your filters. They’re not small, and it will make the job much easier if your employee has a little room to move up there.
When it comes to the walls, we understand that most people like to build against existing walls to conserve space. While this is fine if you absolutely need the space, the installation, and any future maintenance, will be considerably easier if you leave a three-foot perimeter around your cleanroom. This gives you more room to work with, and it makes any future expansions, updates, and even the initial installation go a lot faster.
As a final point on clearance, if you do have a ton of space, it’s important to remember that your cleanroom doesn’t need to take up the entire room. In order to be cost-effective, your cleanroom should be the right size for your operations, and no larger. The more dead space, the more money you pay for no reason.
Another key consideration is to estimate exactly how much space any machinery or appliances will take up. If you already have the machinery, we suggest placing it on the floor of your existing area to get an idea of how much space the machines alone will take up, and how far apart they’ll need to be to provide employees safe and convenient access. Any kind of machinery is going to be your biggest factor in determining cleanroom size.
Once you figure out how much space your machines need, you’ll next have to decide how many workers your operation will require, and how much space they will need to function efficiently within the cleanroom. This should include any workspace required within the cleanroom. If they need to use a table, desk, computer, or chairs, these should all be taken into account when you’re thinking about your cleanroom size. Your employees should have enough room to access the machinery, and comfortably walk from point A to point B, without running into, or interrupting, other workers.
The final consideration regarding cleanroom space has to do with temperature. While the majority of cleanrooms are modular, any type of cleanroom structure you create will trap heat. This means that if you have a lot of machinery running within the cleanroom or a lot of employees, you may have to factor in a greater amount of space to keep the cleanroom from overheating. Since you can’t – like other rooms – just open a window or door, there has to be enough space built into the design to allow your air conditioner to keep the room at a stable temperature. This is imperative to the function of the cleanroom itself, as well as the productivity of your employees.
It’s also important to note that if you opt for a modular cleanroom, you can always expand along with your production. Modular cleanrooms are highly adjustable, which means you can add on to your existing cleanroom whenever you need the extra space, and if production slows for any reason, it’s relatively simple to bring your cleanroom in a bit. For optimal flexibility, we always advise those in search of a cleanroom to go for a modular option. This way, even if the cleanroom ends up the wrong size, it can easily and affordably be re-fitted for your current business operations.
We hope this helps you determine what size cleanroom you need! If you have any more questions regarding cleanrooms, from installations to maintenance, Angstrom Technology is happy to help. We’ve been in the industry for decades, so we’re confident that we can address any issue you’re having quickly and effectively. Whether you’re interested in a cleanroom, or you just have a few questions, make sure to get in touch. You can call our office at 888-768-6900, or contact us online today!
If you have a cleanroom, you probably already know that humans are the biggest source of cleanroom contamination. The fact is that you do need people in the cleanroom to be able to manufacture your product. This means that your employees have to be gowned properly in order to reduce the amount of particles that are released into the air inside your cleanroom. The difficult part is deciding how they should gown, and ensuring that all employees are properly gowned, at all times.
Depending on what type of cleanroom you have, your employee requirements for gowning will be different. In some cases, they may just have to put on a lab coat and goggles, where in others they’ll need a full bunny suit. Generally, these requirement correspond with the level of cleanliness your cleanroom has to meet. The higher the standards, the more gear your employees will have to wear.
Once you know what your employees are required to wear, you can easily design a protocol for them to follow. It’s a good idea to keep a mirror in the gowning station, so employees can make sure garments are properly tucked in. You may also post a picture of someone properly gowned, as a “how to” reference for employees.
Here is a general list of things to consider when teaching employees proper gowning technique, to help you establish a simple, step by step process that your employees can follow every time they enter the cleanroom:
Remember that proper cleanroom attire starts outside the gowning room: Employees should be discouraged from wearing makeup, jewelry, hairsprays or perfumes, as these can all give off unnecessary particles and fumes, endangering the balanced state of your cleanroom.
Consider footwear: It may be a good idea for employees to have shoes dedicated only to the cleanroom, in the interest of minimizing contamination. If employees change shoes before even entering the gowning room, you’re minimizing the amount of dirt and dust particles tracked into the cleanroom.
No food: While this may seem like a no-brainer, make sure you’re reminding employees never to eat in the cleanroom. It may seem like a hassle for them to leave for lunch, and then redo the entire gowning process, but it’s a greater concern to have any kind of food or gum in the cleanroom. It’s a good idea to put up a sign outside the door to remind anyone entering the cleanroom of this rule.
Top to bottom gowning: When you’re developing your gowning protocol, it’s important to know that gowning should be done from top to bottom. That means that employees should start with hoods, then move to tops, then pants, then shoe covers. This method of dressing prevents any particles from falling down to already-gowned pants or booties.
Don’t touch: Employees should be aware that most cleanliness violations happen as a result of a garment being touched by dirty hands, or the floor. You should stress the importance of regularly washing and drying hands and gloves, as well as ensuring that garments do not touch the floor. A good way to minimize these issues is to make sure that surfaces are ultra-clean, and that no-touch washers and dryers are readily available.
Minimize motion: Believe it or not, people emit thousands of particles a minute even when they’re dressed in cleanroom gowning gear, and sitting still. As soon as people begin to move, that number of particles increases exponentially. This is why both your gowning room and your cleanroom itself, should be set up to minimize movement as much as possible.
With these considerations in mind, it shouldn’t be too difficult to come up with a thorough, step-by-step gowning procedure for your employees. Once you design the protocol, it’s important to make sure you train, and retrain it. Your personnel should attend a formal training program, but don’t stop there. Post reminder posters outside the gowning room, and make sure that your employees understand how important the gowning process is to maintaining the standards of your cleanroom. The best way to keep your cleanroom clean is to have a unified program for gowning procedure that everyone follows.
If you’re in need of gowning supplies, or if you’re looking for more information on cleanrooms, give the experts at Angstrom a call! We’ve been in the business for more than 20 years, and design, repair, and supply every kind of cleanroom. At 888-768-6900 we’re here to help answer any cleanroom question.
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Angstrom Technology 901 Northland Drive, NE Rockford, MI 49341 Phone: 888-768-6900 Fax: 616-866-0080