A portable cleanroom is no longer optional. Here’s why you need one today.
In recent decades, cleanrooms have become an indispensable part of several industries. Traditionally associated with healthcare or biopharmaceuticals, cleanrooms have far wider applications across manufacturing, research and service delivery. They are critical elements in the biotechnology, medical device, electronics, aerospace, defence, automotive, and other industries. Not using cleanrooms for sterile or high-precision processes in these industries compromises product quality and consumer safety, both of which are sure-shot ways to lose business and public trust.
Today, every business that needs ultra-clean operations relies on cleanrooms to get the job done. Cleanroom technology, however, has made tremendous advances in the past few years – as have technologies in the construction and building industries. Together, these developments have put portable cleanrooms at the cutting edge of the industry today.
Portable cleanrooms – also referred to as modular cleanrooms or prefabricated cleanrooms – offer all the benefits of traditional cleanrooms, and then some more. From a cost, convenience, and compliance perspective, portable cleanrooms are superior to their traditional counterparts.
If you are in a sterile or high-precision industry and you aren’t using portable cleanrooms, you risk falling behind your competitors. On the other hand, if you are leveraging the best that modular cleanrooms have to offer, you are poised to lead the industry, with the tools and agility you need to keep up with consistently evolving regulations, market demand, and advancements in manufacturing technology.
Isolation medical examination pods: A study in leveraging portable modular cleanroom systems.
During the Covid-19 pandemic, portable cleanrooms began to be used as isolation medical exam pods. These pods enabled the testing and examination of both patients and workers while minimizing exposure risks for others.
Seamless flooring allowed for effective disinfection, integrated HVAC systems permitted the use of HEPA filters for air cleaning and adequate ventilation, and overhead lighting ensured sufficient illumination.
Portable cleanrooms were the go-to choice for this application because of their self-contained electrical systems and condenser units. These integrations, along with the modular construction of the cleanrooms, meant that installation was quick and easy – just what was needed for a rapid response during a global pandemic.
Isolation pods such as these, also referred to as alternative care facilities for infection control, gained popularity during the Covid-19 pandemic. Today, even a couple of years after the end of the pandemic, they continue to be used, particularly in industrial settings to address injuries and illnesses that may occur as occupational hazards.
So, what are portable or modular cleanrooms?
The isolation medical examination pods described above are only one application of portable cleanrooms.
Cleanrooms are specialised spaces with highly controlled internal environments. They are designed to have ultralow concentrations of contaminants and have environmental conditions that meet specifications regarding temperature, humidity, etc.
Portable cleanrooms are fully equipped, high-performance cleanrooms designed to be movable, flexible, and easily deployable. They are factory-built, independent systems that come enclosed in shipping containers and must simply be assembled and plugged into an electrical supply to function – “plug and play”, as we like to call it.
Traditional cleanrooms are typically fixed in one location. Their portable counterparts, however, can be set up temporarily (or permanently) in a location, with the option to move them as and when needed.
Portable modular cleanroom systems meet the same rigorous cleanliness and air quality standards as brick-and-mortar ones. Additionally, they offer the benefits of being flexible and cost-effective (more on this below). They are the perfect solution for companies that need cleanrooms for short-term projects. They are also ideal during times of expansion, temporary shutdowns, or maintenance. Nowadays, businesses or projects that aren’t in any of these phases are also relying on portable cleanrooms as a strategic decision – they give the business the flexibility needed to keep up with dynamic market demand, evolving manufacturing technologies, and potential upgrades in cleanroom classification.
Advances in modular cleanroom technology.
There are many reasons why portable modular cleanroom systems are so popular – even non-negotiable to some – today. Modular cleanroom technology has advanced leaps and bounds in recent years. So biopharma manufacturers, clinical researchers, nanotechnology companies, and aerospace players are drawn to portable cleanrooms not only because they are portable, but because they represent the next frontier in what is possible for innovation, manufacturing, healthcare delivery, and sustainability in the industry.
Scalability. Portable cleanrooms are not only moveable. They are reconfigurable, scalable, and flexible such that businesses can remove or add cleanroom sections depending on their needs. This makes them perfect not only for temporary cleanroom setups but also for businesses that anticipate expansion, changes in manufacturing technologies, fluctuating demand, or modifications in regulatory requirements.
Advanced filtration systems. Modular cleanrooms today come with inbuilt HEPA and ULPA filters. This has dramatically improved indoor air quality in portable systems, making contamination control a lot more efficient.
Energy efficiency. New technologies have made the installation and operation of portable cleanrooms extremely energy efficient. Without compromising the safety and quality of cleanroom operations, portable cleanrooms today can reduce energy consumption and consequently operating costs as well.
Integrated monitoring. The latest portable modular cleanroom systems also come with integrated advanced monitoring systems. These permit real-time tracking of humidity, temperature, air quality, etc. This is critical for maintaining desired environmental conditions as well as compliance with regulations. Some of these systems also support remote monitoring and automation. This translates to continuous monitoring, fewer human errors, and increased accuracy in contamination control, making such cleanrooms attractive to most businesses across industries.
Advanced materials. Advances in material science have had knock-on effects on contamination control in portable cleanrooms. Materials like nanocoatings lend modular cleanrooms superior antimicrobial properties and consequently, greater sterility. Some new construction materials are also cleaning solution-resistant, non-outgassing and non-particle shedding, resistant to specific chemicals, and resistant to scratches. All of these advances lend portable cleanrooms superiority over their brick-and-mortar counterparts.
For any business that wants to stand the test of time in their industry, a portable cleanroom – with its capacity for mobility, adaptability and scalability – is no longer optional. The next part of this article will tell you why.
Portable cleanrooms are self-contained units that are often not connected to a traditional building’s air conditioning or ventilation systems. With built-in HVAC, air filtration, plumbing, electrical wiring and building management systems, they simply need to be connected to a power supply to be up and running.
These prefabricated isolation enclosures – assembled and installed on-site – are customizable to project needs. From size and configuration to temperature, humidity and air quality, everything can be adapted to a project’s requirements.
In general, there are two types of modular cleanrooms: softwall modular cleanrooms and hardwall modular cleanrooms.
Softwall cleanrooms are lightweight, extremely cost-effective, and easy to assemble cleanrooms, typically designed as positive pressure enclosures. They’re ideal for small- to medium-sized operations, especially when a project needs a simple, immediate cleanroom solution. Compared to hardwall cleanrooms, softwall cleanrooms are even more adaptable and affordable, though they do not have the robustness of a hardwall space. Additionally, they usually require support from existing infrastructure, which means they are not as location-agnostic as portable hardwall cleanrooms.
Modular hardwall cleanrooms, meanwhile, are far more impact-resistant and durable than their softwall counterparts. With rigid walls, they can operate at higher internal pressures than softwall cleanrooms. They are also free-standing, without the need for support from existing infrastructure and are better equipped for large-scale operations than softwall cleanrooms.
Whether it’s a softwall cleanroom or a hardwall one, having a modular cleanroom is non-negotiable in today’s world. Here’s why.
Why you need portable modular cleanroom systems.
Reason #1. They are versatile. Portable cleanrooms are extremely versatile. As we’ve just described, you could opt for either softwall cleanrooms for their unparalleled portability and expandability. Or you could opt for a hardwall portable cleanroom for its durability. Or you could go for a hybrid cleanroom which adopts both types of construction.
Regardless of the type of modular cleanroom, they are scalable to meet expanding market demand; they can even be scaled back to account for lowering demand for some products, say, the Covid-19 vaccine. They can be modified to include the latest manufacturing technologies, to adhere to a stricter ISO class if required, or to manufacture a new product.
Essentially, portable modular cleanroom systems support continuous improvements and innovation in operational procedures. You can rest assured that if and when technologies in your industry evolve, your cleanroom is capable of quickly adapting to incorporate these new changes. With a portable cleanroom, your business is better equipped to thrive, even in the face of unforeseen challenges.
Reason #2. They are cost-effective. Building a traditional cleanroom can cost you about USD 1,500 per square foot. Even constructing a 100-square-foot cleanroom would set you back about USD 150,000. These high costs are not without reason – you need specialised contractors, ductwork specialists, and other highly technically trained professionals for every aspect of your cleanroom, from flooring to plumbing to lighting.
And with highly specific designs and execution, it’s not likely that you will be able to pivot to any other purpose or cleanroom classification other than the one originally intended.
On the other hand, a portable modular cleanroom system of the same size i.e. 100 square feet can cost you as little as USD 10,000 to USD 15,000, depending on your specifications. The cost may increase with stricter ISO levels but will remain significantly more affordable than traditional construction, especially when you consider inclusions like industrial furniture, workbenches, anti-static mats, custom cabinets, and other cleanroom-specific interiors.
A part of the savings is because the cleanroom panels are manufactured in a factory and only need to be assembled on-site, significantly cutting labour costs and construction time. Even in terms of maintenance and repairs, portable modular cleanroom systems are much cheaper than stick-built cleanrooms.
Reason #3. They are quick and easy to install. The speed and ease with which a portable modular cleanroom system can be set up is unparalleled. This quick turnaround time ensures a fairly short time-to-market for your business, whether you are in biopharma manufacturing, healthcare delivery, electronics manufacturing, or aerospace. The speed with which you can set up a portable cleanroom also allows you to adapt to changing requirements, whether that is an emergency or a sudden spike in demand.
The ease and speed of setting up a portable cleanroom are due to how straightforward the process is. The modular cleanroom panels are manufactured – as per your specifications – in a factory setting (all of PodTech™’s modular cleanrooms are manufactured at our facility in the UAE). The modular cleanroom, enclosed in a shipping container, is transported to the project site, where it is installed in a much shorter time than brick-and-mortar construction would take.
No extended downtime for existing operations, no errors or accidents that happen in traditional construction. No extensive on-site electrical work – with fully pre-wired electrical systems, modular cleanrooms have only to be connected to existing power supply, typically 120/208V three-phase systems rated for HVAC, lighting, and essential process automation equipment.
Only quick deployment, one engineering partner to deal with, and no compliance issues.
Reason #4. It’s accessible. Setting up a cleanroom is notoriously difficult in regions which don’t have established infrastructure, labour, and supply chains. But with their “plug and play” nature, portable modular cleanroom systems can overcome this challenge.
Portable cleanrooms can be deployed easily in various locations. The mobility and accessibility of portable cleanroom technology are transforming how not only businesses but entire industries approach research and production. Modular cleanrooms support their aspirations for scale, even in underpenetrated markets with poor existing infrastructure.
Reason #5. Compliance. In sterile and high-precision industries, the standards for compliance are very high. For a cleanroom, you may need to meet FDA, GMP, ISO 14644, and/or other industry-specific regulations. To meet these regulations, you need continuous environmental monitoring, Class II Type A2 biological safety cabinets, pass-throughs, CO2, N2, liquid nitrogen (LN2), Vaporized Hydrogen Peroxide (VHP) sterilization, and many other specifications.
Portable modular cleanroom systems can meet and exceed these requirements. Given that they are manufactured in controlled factory spaces, the risk of contamination is much lower, ensuring product quality and an easier validation process. Overall, compliance is a whole lot easier with modular cleanrooms.
Reason #6. Sustainability. Today, ESG concerns are as important for businesses as financial concerns. Sustainability is at the core of innovations in industry practices, and portable modular cleanroom systems align with this focus. Due to the construction materials used and the nature of their manufacturing and systems, portable cleanrooms are energy efficient, reusable and recyclable, allowing the businesses that use them to add to their sustainability efforts.
Portable modular cleanroom systems: The gold standard in research and manufacturing.
Portable cleanrooms offer more benefits than we can list here. But one thing is for sure – with their flexibility, ease of installation, and reusability, they allow researchers and manufacturers to “fail fast”. To fail, to iterate, to keep going until they find a solution that works for a particular therapeutic area or market. All without burning a hole in the budget.
Portable cleanrooms are a stepping stone towards the future. Not only are they witnessing great advances in their manufacturing, but their flexibility allows users to continuously keep up with new manufacturing technologies, new product lines, and new markets.
Today, portable cleanrooms are no longer optional. Reach out to our team of experts today to get yours.