Why your next facility needs a future-ready cleanroom system
The cleanrooms of today don’t look like the cleanrooms of some years ago – and how fortunate we are for that!
Today, cleanroom systems are far from simple sterile spaces. They are designed and built with great care to meet sustainability needs, incorporate novel technologies, and address the growing demand for contamination control and precision across industries. From pharma and biotech to aerospace, electronics and defence – organisations across these industries are adopting cutting-edge technologies and practices in their cleanroom systems.
Particularly, they are investing in modular cleanroom systems as part of a future-ready approach in which their infrastructure can evolve with their business needs, ISO classifications, advancements in science and technology, and sociopolitical happenings.
Modular construction – while it’s been around for several decades – is yet to become the mainstay of the cleanroom industry. Nonetheless, it should – and will – be the number one choice in the coming years because of advancements in cleanroom tech that have made modular cleanroom systems unparalleled in operational efficiency, reliability, safety, and ensuring long-term competitiveness.
From the past to the future: Understanding the history and evolution of cleanroom systems
Rewinding to the past: The origin of cleanroom systems
Responding to these needs, early cleanroom systems were simple controlled environments where temperature, humidity, and contamination levels could be regulated to suit the nature of the process being executed inside. Their designs comprised basic ventilation systems to control airflow. Cleanroom classifications had not yet been standardised. And cleaning processes were highly rigorous, with manual cleaning required to maintain the desired hygiene levels.
Most importantly, in the early phase of cleanroom systems, laminar airflow systems were introduced, transforming how contamination control was carried out. By directing air in a uniform flow, laminar air flow systems sweep particulate pollution away from sensitive areas. They quickly became a mainstay in the cleanroom systems industry for their unparalleled contribution to maintaining a pollutant-free space within research or production areas.
Cleanrooms today: ISO classifications, advanced filtration, prefab modular cleanrooms, and more
Most critically, the cleanroom systems of today – whether they are stick-built or modular cleanroom systems – are classified as per the ISO 14644-1 standards. These universally accepted standards provide benchmarks for acceptable contaminant levels for different ISO classes. Depending on the level of precision and environmental control demanded by their industry and processes, organisations choose the most appropriate ISO cleanroom classification for compliance (more on this later).
Beyond the regulatory guidelines for cleanrooms, the cleanrooms of today also boast of advanced filtration systems, including high-efficiency particulate air (HEPA) and ultra-low particulate air (ULPA) filtration, to remove 99.97% of particulate pollutants. They have real-time monitoring systems to track indoor air quality, temperature, humidity, pressure, and other factors impacting cleanroom operations. They have energy-efficient HVAC and lighting systems, sustainable construction materials, and improved systems for material flow.
Vital to the future scalability and adaptability of the cleanroom industry, modular cleanroom systems are also becoming more common. This is an important development as prefab modular cleanrooms are the basis for the future growth and flexibility of any business that relies on environment-controlled spaces. Prefab modular cleanrooms are not only essential parts of the present of cleanroom systems but they are also fundamental to the future of the industry.
What makes a cleanroom system future-ready? Upcoming trends in the cleanroom industry
Let’s explore what cleanroom system manufacturers will focus on to not only stay relevant today but also remain future-ready for the years to come.
Sustainability. Sustainability is already a growing priority within the cleanroom system industry. Cleanroom system manufacturers are integrating energy-efficient HVAC and lighting systems in their cleanrooms. Using recyclable and eco-friendly materials for construction is also becoming a priority, though this is relatively difficult in traditional construction – prefab modular cleanrooms are a much better option for this because fabrication in a factory allows cleanroom system manufacturers to reuse materials and also use more advanced materials.
Moreover, once a particular modular cleanroom system has served its purpose in one location, it doesn’t need to be demolished in polluting ways like with traditional brick-and-mortar buildings. Prefab modular cleanrooms can simply be dismantled and relocated to another project site.
Finally, waste management is an important concern in cleanroom systems, particularly in industries like biopharma, which may generate toxic biochemical waste. In the future, cleanroom system manufacturers and operators will enhance protocols to minimise waste generation and also devise means to better deal with the waste generated during research and/or manufacturing.
Smart cleanrooms. Cutting-edge cleanroom systems today already rely on automation to speed things up, make them more efficient, and reduce manual intervention and human errors. In the coming years, automation and technological intervention in cleanroom systems will only grow. Robots and automation for cleaning, material handling, and other tasks will become more ubiquitous. AI-driven analytics will drive preventative maintenance, predict risks, and recommend steps for operational efficiency and future scalability. IoT sensors which continuously monitor and optimise cleanroom conditions will underlie the implementation of many of these technologies.
Augmented reality (AR) and virtual reality (VR). Though they have become quite popular in other industries, AR and VR are not yet widely used in the cleanroom industry. In the future, however, that’s likely to change. These technologies will be used to simulate cleanroom spaces to virtually train cleanroom personnel, eliminating the health and safety risks that may arise in a physical cleanroom. Cleanroom simulations in AR and VR will also aid cleanroom design, maintenance, and troubleshooting.
Accessibility. As we’ve already seen, cleanroom system manufacturers are stepping beyond niche industries to be relevant for a wide range of applications. As time goes by, more industries may adopt cleanroom systems for their high-precision and low-contamination processes and products. Beyond industry accessibility, cleanroom systems will also become accessible and feasible in emerging markets that previously did not have the resources to enter this space. Overall, the future of the cleanroom system industry will be marked by greater accessibility.
We’ve now explored the past, present and future of cleanroom systems. As the evolution of the industry accelerates, it is becoming more important for cleanroom system manufacturers and their customers to move from rigid, unchangeable infrastructure to more adaptable infrastructure that can keep up with changing times.
In part 2 of this article, we’ll explore the need for future-ready cleanroom solutions and how they can be developed. Stay tuned.
Why do you need a future-ready cleanroom system? Well, the standards for cleanroom systems are already very high. And as product quality expectations rise and technologies to implement them become more accessible, those standards are only going to become more stringent.
Standards for cleanroom systems are already very high
This is incredibly important because some of the main use cases of cleanroom systems are in the health sector – in biopharma research and manufacturing, biotech applications, etc. – where even the smallest contaminant can adversely affect the microbiological, chemical, and physical qualities of raw materials and finished products. Consequently, the smallest contaminant can even adversely affect people’s health and quality of life.
In other industries, like semiconductor manufacturing, even slight deviations from precisely laid plans can cost a business heavily by damaging the functioning and/or quality of the products.
It is imperative, then, that cleanroom system manufacturers and their customers follow globally accepted protocols to control parameters like temperature, pressure, humidity, indoor air quality, and beyond. Particularly in the pharmaceutical industry, cleanroom systems must meet the technical requirements established in the ISO 14644-1 standard, with classes ranging from ISO 1 to ISO 9, each of which has different specifications regarding temperature, pressure, humidity, number of particles per cubic metre, and air change rates.
Ideally, most cleanroom systems in the biotech industry must comply with a classification of ISO 5 or less (ISO 9 is the least strict, while ISO 1 is the strictest). Even though ISO 5 is somewhere in the middle of the cleanroom classifications range, it is considered to be an extremely stringent standard. For industries which require moderate control over particle size and count, even ISO 7 and 8 may be appropriate.
As science and technology progress, cleanroom system standards and expectations will also evolve. New technologies will improve contamination control – the primary concern in cleanroom systems. But they will also enhance operational efficiency, enable compliance with more and more stringent regulations, and improve the cost-effectiveness of cleanroom system construction and operations.
Investing in the future-readiness of your cleanroom systems
If you, too, want to stay ahead of the curve, here are some investments you should consider and discuss with your cleanroom system manufacturer to make sure that you’re ready to adapt to whatever the future may throw at your industry and your business.
The increasing use of automation in cleanroom systems
For starters, robotics is a common feature in future-ready cleanrooms. Cleanroom operators deploy robots for routine tasks like cleaning that call for stringent adherence to rules and protocols. The personnel working in a contamination-controlled space are the biggest risk to cleanliness as their clothes, hair, skin, and nails could all leave contaminating traces in the cleanroom – robots minimise this risk.
Automation is also used in cleaning systems that don’t use robots. This kind of system relies on advanced techniques like ultrasonic cleaning and automated fogging to decontaminate equipment and cleanroom surfaces.
Finally, like in any other industry, AI is also transforming the cleanroom space. AI-driven monitoring is crucial for environmental monitoring and regulation in future-ready cleanroom systems.
Advanced systems for real-time cleanroom monitoring
IoT sensors give cleanroom operators a constant stream of data, allowing them to get a real-time picture of the internal environment. This data is used to feed predictive analytics which help anticipate potential issues and address them before they even occur – this includes environmental drift, equipment wear and tear, and other predictive maintenance tasks that must be carried out regularly and proactively.
This not only ensures product quality and continuous compliance with regulatory standards but also reduces production costs by minimising downtime. Essentially, it gives cleanroom operators the gift of abundant data which can help them identify patterns and make informed decisions about environmental controls, cleaning schedules, equipment maintenance, upgrades, and any other factor which impacts cleanroom efficiency and productivity.
Improvement in decontamination techniques
In our changing world, however, climate change and other socio-environmental factors are leading to the emergence and spread of new contaminants and pathogens. Better decontamination is the need of the hour and fortunately, the scientific community has delivered.
Future-ready cleanroom systems boast of the use of ionized hydrogen peroxide (iHP) as a highly effective decontamination agent. It is effective against diverse pathogens, including many which are resistant to traditional cleaning agents. iHP can also be used in cleanroom systems through novel non-invasive decontamination techniques. This means that you do not need to halt production to decontaminate your cleanroom – novel techniques like iHP fogging can do the job without causing significant disruption to your operations.
Future-ready cleanroom systems also have mechanisms for targeted decontamination, focusing only on specific areas which are more vulnerable to certain contaminants. This reduces the use of chemicals, making the process not only cheaper but also safer for cleanroom personnel.
Prefab modular cleanroom systems to future-proof your facility
That is why modular cleanroom systems are not just a part of a future-ready facility; they form the very foundation of it.
Prefab modular cleanroom systems offer the adaptability, scalability, reconfigurability, and relocatability that underly continuous evolution. They can easily be modified to integrate a new, more efficient HVAC system. Automated systems can be used to control their operations. Since they are fabricated in a factory, they are also more sustainable, more cost-effective, and less time-consuming to set up.
Tomorrow’s world will be characterised by dramatic changes – climactic, scientific, social, economic, and geopolitical. Many of these will be quick and unpredictable. Staying relevant and efficient in such a world will require proactive planning and future-proof facilities. It will require incorporating new technologies, adapting to regulatory changes, and meeting demand in new markets.
Prefab modular cleanrooms are the foundation to address most of these concerns. Regardless of which industry you are in, if your operations call for the use of cleanroom systems, prefab modular cleanrooms are the way to go.