Modular panel production factory for cleanrooms

Modular panel production factory for cleanrooms

Clean rooms are designed to remove dust, sand, salt particles and bacteria that enter the room through clothing and human skin. Because cleanrooms are sealed from the outside air, the entry and exit of items, people, and equipment must be strictly controlled. Anyone entering a clean room must often wear a rabbit suit that covers the person from head to toe. This prevents the introduction of foreign contaminants.

Due to the contamination-free nature of modular cleanrooms, they have become an essential product for industries such as aviation, aerospace, electronics, hard drive manufacturing, military component manufacturing, medical and pharmaceutical laboratories, meat processing and packaging, veterinary clinics, hospitals. became. , medical offices and operating rooms. Finally, they are used by scientists in the fields of microtechnology and biochemistry.
Therefore , modular cleanroom panel manufacturing plants are constantly striving to ensure that modular cleanrooms meet the standards of the industries they use.
Modular panel production factory

Modular clean room industry

Modular cleanrooms are enclosures designed to facilitate research, manufacturing, and other sensitive operations that must be performed in the absence of dust, moisture, and other airborne contaminants.

The measure of cleanroom cleanliness is the number of air pollutants found in an air sample. Many clean rooms are not intended to be completely sterile environments. Instead, experts worry about the amount of airborne dust, or dust that can be kicked up from the ground when you step on it. This dust is microscopic and can sometimes only be measured with specialized machinery. Typically, particles are measured in microns - a unit of measurement equal to one millionth of a meter.

There are cases where sterility is a requirement for cleanroom equipment suppliers. Many medical research operations and testing procedures must be performed in a sterile environment. Pharmacological studies, infectious disease testing, and other highly sensitive procedures associated with medical research often require the complete elimination of microbes that may be present in their surroundings. The cleanliness of the clean room is determined by the presence of contaminants with a size of more than 0.5 micrometers.

Modular cleanroom panel manufacturing plants , hard wall cleanrooms use paneled wall structures that support the ceiling grid. These panels are made of different materials. Pharmaceutical compounding chambers, USP 797And medical device cleanrooms often use panels made of reinforced plastic or high-pressure laminate because these materials can withstand repeated cleaning and sterilization without breaking. Aluminum honeycomb panels are most popular for electronics industry because it is gas free, particle shedding, anti static and non combustible. Other material options for hard wall construction include pre-painted aluminum, 24-gauge pre-painted steel, vinyl-coated drywall, structural aluminum, paper or plastic honeycomb, expanded polystyrene, and polyurethane.

Cleanroom modular panel manufacturing plants are soft wall structures made up of tubular steel frame structures that support a ceiling grid. This construction uses pressurized vinyl curtains with sealable inlets and outlets to provide maximum cleanliness.

Both chamber structures are designed to allow only filtered air to enter the chamber. The air is filtered by filter units installed in the ceiling. These devices filter the outside air through a HEPA filterAbsorbers filter the air before it enters the clean room.
Modular panel production factory 5

Modular clean rooms

Modular cleanrooms are often used in manufacturing and research facilities, but thanks to their versatility and ease of installation, they are being used every day in new industries. Any industry or application where small particles can negatively impact production, manufacturing or packaging processes can benefit from using a modular cleanroom.

By definition, a clean room is a controlled environment with low levels of contaminants such as dust, airborne microbes, aerosol particles, and chemical vapors. Strictly speaking, a cleanroom maintains a controlled level of contamination, defined by both particles per cubic foot and allowable particle size.

Modular cleanrooms are used in critical clean processes in several markets, including:
  • Semiconductor production
  • Pharmaceutical processing
  • Production of biotechnology and medical equipment
  • Military and aerospace
  • Production of optical components
  • automobile manufacturing
  • Hospital clinics
  • Food and beverage processing
  • Production of cosmetics

And countless other cleanrooms are of permanent construction - that is, they are built into the same building. But more and more cleanroom users are looking for a solution that offers more flexibility than a standard cleanroom.

Advantages of modular clean rooms

Perhaps the greatest advantage of modular cleanrooms is that they can be modified or even relocated with minimal cost and downtime. Many prefabricated modular cleanrooms are almost 100% reusable.
In general, modular cleanrooms are much cheaper than standard sheetrock construction and can be installed in a fraction of the time.
Many prefab cleanrooms are factory-built, with UL -classified pre-wired walkways.which provides a smooth interior surface for electrical outlets and telephone/data wiring. These raceways can also be used as service chases to maintain deionized water, compressed air or nitrogen lines. Built-in corridors eliminate the mess of cutting and sanding drywall on site, minimizing construction time and facility disruption.
Many modular cleanrooms have an insulated wall system that provides a thermal barrier and improves the efficiency and performance of the cleanroom's mechanical system. This reduces energy costs and maintains temperature levels far better than uninsulated systems.

Depending on the level of classification or function of the cleanroom, entry and exit through anterooms or cloakrooms may be required. Many modular clean rooms can be built with facilities for these rooms to reduce contamination from external environments. Airlocks, air showers and transit boxes can be integrated to safely bring personnel, products and materials into and out of the cleanroom without the risk of contamination.
Modular clean room systems are flexible and affordable.
Modular cleanroom systems are highly customizable as they are made from hard or soft panels with a hard top. Soft panel cleanrooms have walls made of transparent PVC and a small opening for entering and exiting the area. Rigid wall cleanroom systems consist of prefabricated panels that are joined together to create a square or rectangular room. This style of prefab cleanroom is fully enclosed and can be installed with doors, windows, and transition vents like a permanent cleanroom.

Some of the advantages of modular cleanroom systems over permanent cleanrooms are:

Versatility: A modular cleanroom can be easily assembled, disassembled and moved, often in just a few days or less.
Easily Reconfigurable: A modular cleanroom layout can be rearranged, expanded, retrofitted, or upgraded as the user's cleanroom needs change.
Cost-effective and time-saving: Modular cleanrooms are designed and manufactured off-site at a fraction of the cost of permanent construction and installed on-site in a fraction of the time.

Reduced downtime: A modular cleanroom installation causes far less disruption to daily operations, allowing many users to keep some or all of their processes active during the start-up process.

Rental: If you rent your space, the modular option allows you to remove the cleanroom you need and take it with you when you relocate.

ROI : Because it can be taken down, moved and erected again, a modular cleanroom is considered a piece of capital equipment and can be treated as such for tax purposes.

Cleanliness: Modular cleanroom is a better option for cleanroom requirements above ISO 6 classificationIs. The materials used in these systems do not shed like drywall or metal studs and reduce the level of pollution.

Modular panel production factory
Modular clean room systems
A modular cleanroom is an easy way to achieve climate control and regulatory compliance. From semiconductors to medical devices, manufacturers and researchers in all markets can use modular cleanrooms to meet strict cleanliness standards.

Modular clean rooms
There are two types of modular clean rooms: hard wall modular clean room and soft wall modular clean room.

Hardwall modular clean rooms
Designed for flexibility, hard wall modular cleanrooms are easy to assemble and move. Modular cleanrooms are affordable and a great option for when you need a cleanroom or want to expand in the future. We equip all modular cleanroom systems with windows, doors, electrical outlets and full insulation for temperature control.

Clean rooms and softwall curtain dividers
Soft wall clean rooms like Hard wallThey have a wide range of available options based on customer needs. Dressing rooms can be easily added to the clean room. They are easily portable and can be transported along the outer perimeter of the cleanroom for rotation or adaptation to production processes. Softwall cleanrooms can be mobile if specified. Once equipped with the optional braked wheels, they can be easily moved to a new location in the same facility.
Softwall cleanrooms work well in an existing controlled environment where increased airflow or clean points may be required. Available with castors, the Softwall cleanroom can be easily moved around your premises for use in different areas. We equip our software modular cleanrooms with HEPA filtersand air conditioning, available for ISO level 5we put. Curtain dividers can be used in place of doors to either divide up your cleanroom space, or to direct airflow to tighter areas.

Modular panel production factory
Clean wall panel system

What is a modular clean room?
Modular clean rooms are often used in production and inspection facilities. Thanks to their strength and ease of installation, they are useful every day in other new and fast-growing industries. Industry or applications where fine particles may have an adverse effect on production or manufacturing or packaging processes can benefit from the use of a modular clean room. A clean room is defined as a controlled environment with reduced levels of contaminants such as aerosol particles, airborne microbes, dust and chemical vapors.
These modular cleanrooms are sometimes referred to as modular wall cleanrooms to distinguish them from wall-mounted cleanrooms because of the solid walls used in construction.

Among the reasons for using a modular room
  • Fewer people on site during a project with multiple parallel workflows
  • Modular walls can be removed to accommodate new and larger equipment as needed
  • Design flexibility
  • Install the cleaner
  • Faster installation
  • No dust, debris or mess is generated from last minute changes on site
  • Save up to 40% on project costs if you have to relocate your cleanroom
  • Can be sold as an asset
  • Higher and stable quality, because production under ISO 9001 quality management systemis done

Types of modular clean rooms
PVC Softwall Panels: Clear PVC Softwall Panels: These provide a durable and excellent barrier against the uncontrolled environment outside the cleanroom as well as excellent resistance to solvents and liquids. The main advantage during use is that only a small opening is created when exiting or entering the cleanroom. Softwall panels can be used as complete softwall cleanrooms or as entrances for hardwall cleanrooms. Soft wall panels are also used for the internal division of the modular clean room.

Panel System: The ceiling and wall panel system has the advantage of being an additional structural option to their custom modular cleanroom range. The panel system is an off-site pre-fabricated solution that increases the level of customer choice during the planning of cleanroom solutions. The panel system provides strong connection lines for fully colored finishes that ensure a structure that can be customized to include all parts of the cleanroom including transfer vents, steel doors, windows, etc.

Modular clean room designs
The type and design of the clean room largely depends on the production requirements and the standards that must be met and maintained. The design of the cleanroom and the specification of components, surface finishes and materials are done at an early stage and may be done in consultation with a supplier such as Cleanroom-Solutions.be done. Then, the construction of the clean room includes the construction, assembly and operation of these parts according to the detailed design.

The plans are divided into different categories, which include:

Single block system: Can be made from two metal sheets facing a wall or ceiling, machined to tight tolerances, then powder coated and finished to meet cleanroom design requirements. This type of clean room walls are mostly used for pharmaceutical cleanrooms, heavy construction, and mostly for the fixed arrangement of different rooms.
Modular wall system: This is a single-shell or double-shell framed wall system. Modular structures made of glass containers, aluminum or other different types of panels are more ideal for semiconductor applications. A key advantage of modular cleanrooms is that they can be easily adapted to any layout or change in production requirements.

The advantages of single block systems are:

They are used in high level clean rooms
Made of solid structures
They have insulating properties
They have smooth surfaces and can have smooth joints

The advantages of modular systems are:
  1. The production cost is relatively low
  2. They are used in upper clean room classes
  3. They are modular and therefore, can be easily changed based on production needs
  4. NGS horizontal pipes can be included in the panel to build a turnkey modular clean room
  5. Clean room ceiling system and vinyl flooringNGS modular construction clean room
  6. Cleaning the pharmacy wall
  7. Large pharmacy wall cleaning room
  8. Clean room with fan and return filter units
  9. A view of the clean room showing the return air grilles and fan filter units in the ceiling

The basic building block of Softwall 's modular cleanroom design is a split roof structure made of tubular steel beams with T-bar cross units.Composed. This interlocking ceiling grid enables simple assembly and cleanroom expansion. The roof is braced by tubular steel struts at each of the four corners and secured by a substantial gauge, triangular steel extension. HEPA filter unitsElectrical, ceiling panels and lighting systems are bolted to the frame using washers. HEPA filtersThey also provide an additional block against particles found in cleanrooms, while the controlled airflow design works against contamination.

Customized solution is our standard
Raymon Group's modular cleanroom walls are built for your needs. Our customizable modular cleanroom wall system allows us to provide cost-effective custom cleanroom design for any modular cleanroom application.

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