Why prefabricated modular clean rooms are the future of contamination control | Part 2
Prefabricated modular cleanrooms are at the cutting edge of contamination control because they are a future-proof solution. Whether your business’ or lab’s future involves potential expansions, relocations, operational changes, or any other kind of evolution, a prefabricated modular cleanroom can, in most situations, adapt to your dynamic requirements.
More importantly, prefabricated modular cleanrooms are the future of contamination control because of how diverse their applications are. Modular cleanrooms in and of themselves are not industry-specific. They merely provide a clean, controlled environment that can be used for any operation that requires controlled conditions.
Types of modular cleanrooms.
Regardless of industry, modular cleanrooms will be one of two types: softwall or hardwall cleanrooms.
Softwall cleanrooms are typically made of lightweight vinyl curtains fitted into a metal frame. The translucent curtains are softer than a wall, giving this category of cleanrooms its name. While softwall cleanrooms are not as efficient at contamination control as hardwall cleanrooms, they are much cheaper, more mobile, and extremely easy to install and expand. They can be designed to include HEPA filters, ceiling lights, and downward air circulation. They are usually designated as ISO class 6, 7, or 8. They may also be used within a hardwall modular cleanroom when additional isolation is needed.
Hardwall cleanrooms, meanwhile, are prefabricated with panels made of aluminium, stainless steel, fibreglass-reinforced plastic, or other more robust materials. They are superior to softwall cleanrooms when it comes to environmental control.
Your choice of modular cleanroom type will depend not only on your requirements in terms of moisture resistance, chemical resistance, airflow, etc. but also on your budget and industry standards. Nonetheless, be rest assured that whatever your contamination control requirements, there is a modular cleanroom solution out there for you.
Industrial applications of prefabricated modular cleanrooms.
Modular cleanrooms are, in other words, a one-stop solution for contamination control in any and every industry. So let’s explore the different types of businesses that can rely on modular cleanrooms to ensure process and product integrity.
Pharmaceuticals. Sterility is critical in pharmaceutical research, development, manufacturing, and drug compounding. These activities must be carried out in facilities that comply with stringent regulatory standards and GMP. Otherwise, drugs, vaccines and diagnostics run the risk of being contaminated by dust, microbes, and many other unwanted materials which can adversely affect product quality and consequently, public health.
Why modular cleanrooms as opposed to traditional ones? Well, during the R&D phase, the configuration of research and production facilities may require frequent changes. Modular cleanrooms can easily adapt to these changes. Second, if demand for a particular drug shoots up in a short period of time, production in a modular cleanroom can be easily ramped up with additional modules to meet demand. Most critically, in times of disease outbreaks, geopolitical conflicts, or natural disasters—especially in low- and middle-income countries (LMICs) and/or regions with poor health infrastructure—modular cleanrooms can be deployed quickly to meet a population’s health needs, even when there is limited pre-existing infrastructure.
Prefabricated modular cleanrooms are an important tool for the global health community to overcome disparities in health delivery and population health outcomes.
Biotechnology and medical device manufacturing. Biotechnology companies rely on controlled lab environments to conduct research, develop new products, and manufacture them. Their activities may include genetic engineering, cell culturing, bioprocessing, and many more. Any contamination during the research phase can invalidate results while contamination during manufacturing can adversely impact human health. Cleanrooms are the answer.
Whether it is for medical device manufacturing or any other purpose, prefabricated modular cleanrooms offer an environment for safe and efficient product assembly, testing, and packaging. As the industry continues to evolve and innovate new products, modular cleanrooms can be easily reconfigured, scaled up, or scaled back to keep up with technological changes, manufacturing upgrades, and evolving market demand.
Healthcare. Just like with any other health-related industry, healthcare delivery also needs sterile spaces, like the ones provided by modular cleanrooms. Modular cleanrooms are used in hospitals and laboratories for infection and contamination control while compounding sterile medications, conducting research, and/or handling sensitive medical equipment.
Electronics and semiconductor manufacturing. In microelectronics and semiconductor manufacturing, even tiny dust particles can disrupt the production process, resulting in costly defects and damages. Cleanrooms are key to preventing such contamination and losses. The controlled environments that they provide ensure the quality and reliability of electronic components.
Typically, the electronics and semiconductor manufacturing industries use cleanrooms of ISO class 5 or lower. Cleanrooms in this industry not only use HEPA or ULPA filtration to achieve the requisite level of cleanliness but they also use anti-static flooring and walls to prevent electrostatic discharge.
Aerospace and defence. Precision manufacturing and testing are important activities in the aerospace and defence sectors. These activities require clean, contaminant-free environments within which sensitive aerospace components can be assembled, military research can be conducted, and quality control checks can be performed. These high-cleanliness needs span the building of aircraft components and the development of advanced technologies. Prefabricated modular cleanrooms are well-suited to providing the required environment to these industries.
Automotives. From the initial design phase to final production, modular cleanrooms are used widely and at every stage of the supply chain in the automotive industry to test and validate prototypes and manufacture products.
Cosmetics. The products of the cosmetics industry are directly used by human beings. This means that these products must meet high safety and quality standards to ensure the health and well-being of consumers. No dust, no germs will do. For this reason, the development and manufacturing of cosmetics products require the sterile environment provided by cleanrooms.
Moreover, the sector is very innovation-driven, with new types of products constantly being introduced in the market. Given their flexibility to adapt to new products and to scale up to meet increasing consumer demand, prefabricated modular cleanrooms are ideal for cosmetics research and production.
Others. Beyond these industries, prefabricated modular cleanrooms have applications for contamination control even in food and beverage processing, optical component manufacturing, and several other industries.
At the end of the day, prefabricated modular cleanrooms are an incredibly versatile solution for contamination control. They can either be deployed as standalone facilities or connected to existing factories, warehouses, or other buildings. They can be used across diverse industries. They can fit various budgets and requirements. And they can adapt to changing market demand and production requirements.
In our ever-changing world, where not only health concerns but also industrial activities call for cleanroom solutions, modular systems are the best way to go. With their speed, cost-effectiveness, flexibility, and customizability, they are the future of contamination control.
To get started on your next cleanroom project, reach out to us at PodTech™ today.