What is Modular Cleanroom & Benefits?

What is Modular Cleanroom & Benefits?

Definition of Modular Cleanroom:

  Cleanroom is a controlled environment where the concentration of airborne particles is regulated. The primary function is to manage indoor contamination by eliminating pollutants such as dust particles from the air while also controlling temperature, humidity, pressure, and noise levels to meet specific cleanliness standards.
  Modular cleanroom, also known as assembled cleanroom, is a type of clean space created by dividing the main framework, doors, windows, and purification equipment into various modules. These modules are then customized, manufactured, and swiftly transported to the site for assembly according to the client's needs. As a specialized workspace with high cleanliness and stringent environmental control, modular cleanrooms are increasingly utilized in the pharmaceutical, biotechnology, and electronics manufacturing fields. With advancements in technology, the trend towards intelligent modular cleanrooms is becoming more prominent, which are not only enhance production efficiency but also improve product quality and ensure the health and safety of the operators.

Composition of Modular Cleanroom:
Modular cleanroom, as an assembled cleanroom, is a controlled environment of high cleanliness composed of a series of standard modules, which are typically divided into the following categories:
1. Structural Modules: Including wall, ceiling, floor, door, window, and configured air shower equipment.
â–ºWall and ceiling require smooth, flat surfaces that are durable, resistant to wear and impact, anti-static, insulating, sound-absorbing, and easy to clean. Common materials include stainless steel panels, painted steel panels, and tempered glass.
â–ºFloor must be wear-resistant, impact-resistant, fire-resistant, corrosion-resistant, seamless, anti-static, easy to clean, slip-resistant, dust-free, and free from harmful gas emissions. Common materials include epoxy resin and PVC flooring.
â–ºDoor and window are designed for airtightness, with non-opening observation windows and transfer equipment like pass box or goods air shower for material transfer. Personnel typically accesses through air shower rather than cleanroom door.
2. Ventilation and Air Conditioning Modules: Modular cleanrooms typically use Fan Filter Unit (FFU) with dual filtration systems (Initial and HEPA or ULPA filters) due to their small size. Temperature and humidity are generally controlled by small ceiling-mounted central AC units.
3. Electrical Modules: Including lighting, socket, intelligent control, and fire alarm, etc. Cleanroom lighting usually uses fluorescent lighting for high efficiency, long lifespan, and soft light, with a focus on airtightness and ease of cleaning. Ceiling-mounted lights are used in environments with lower cleanliness requirements, while teardrop lights are used in higher cleanliness areas. Special lighting such as yellow lights or UV lights can be installed for specific processes. Sensors for smoke, air velocity, particulate matter, differential pressure, temperature, and humidity may also be installed for intelligent control.
4. Piping Modules: Cleanroom is equipped with ducts, water supply pipes, and drainage pipes as required by the specific process.
Modular cleanroom aims to provide a highly controlled environment with high cleanliness. The design and configuration of these system modules vary according to the specific needs and specifications of the cleanroom to ensure the appropriate level of cleanliness and working conditions.

What is modular cleanroom design?
Modular cleanroom design is a building style in which smaller and self-contained units can be created individually then combined in various ways to create a whole bigger system. In terms of building and architecture, modular design incorporates universal components that are manufactured in a factory, then assembled on-site into the desired configuration, and can be expanded easily in future.

Advantages of Modular Cleanroom:

1. Modular cleanroom is a specially designed clean space with many significant advantages, mainly including the following aspects:
â–ºHigh Efficiency Cleanliness:
Modular cleanrooms utilize advanced air purification technology to precisely control indoor temperature, humidity, pressure, lighting, and other environmental parameters, ensuring that the indoor environment meets required cleanliness standards, providing strong support for industries with high-precision requirements such as scientific research, medical, and production.‌‌
â–ºFast Installation:
Modular cleanroom uses prefabricated modules, with most components pre-manufactured in the factory. These components are then transported to the site for quick and easy assembly, significantly reducing construction time and saving valuable time and costs.‌‌
â–ºFlexible Layout:
The layout design of modular cleanroom considers factors such as personnel flow, logistics direction, and equipment placement to minimize the risk of cross-contamination. This design ensures that the cleanroom meets production or research needs while complying with cleanliness requirements.‌‌
â–ºEnergy Efficiency and Environmental Friendliness:
By employing advanced energy-saving technologies, modular cleanroom effectively reduces energy consumption. Additionally, the use of environmentally friendly materials ensures the cleanroom is both aesthetically pleasing and environmentally conscious.
â–ºIntelligent Control:
The intelligent aspect of modular cleanroom is reflected in environmental monitoring and control. With intelligent sensors and monitoring systems, cleanroom can continuously monitor key parameters such as airborne particles, humidity, and temperature, promptly detecting and addressing any abnormalities to ensure the environment meets the required standards.
â–ºEase of Maintenance:
The structural design of modular cleanroom makes daily cleaning and maintenance simple and convenient, facilitating smooth daily operations.

2. Advantages Over Traditional Cleanroom:
â–ºFast Installation:
Compared to traditional construction methods, the installation efficiency of modular cleanroom is greatly improved, allowing for faster production use.‌
â–ºMobility:
Modular cleanrooms can be assembled, disassembled, and repositioned within a short time.
â–ºReconfigurability:
The layout of modular cleanrooms can be rearranged, expanded, modified, or upgraded based on changing cleanliness requirements.
â–ºCost Efficiency:
Modular cleanroom is designed and manufactured off-site, requiring only a fraction of the cost of permanent structures, with on-site installation taking minimal time.
â–ºMinimal Disruption:
Installation of modular cleanroom causes far less disruption to daily operations, allowing many users to maintain part or all of their processes during the setup period.
â–ºLow Pollution:
The use of pre-cut panels and prefabricated components reduces on-site pollution and noise, maintaining a clean working environment.‌
â–ºRecyclability:
Modular cleanrooms can be disassembled, moved, and reinstalled, making them considered as capital machinery for tax purposes.
â–ºCleanliness:
Modular cleanroom is a better choice for meeting ISO 6 classification cleanroom requirements. The materials used in these systems do not shed particles like drywall or metal fasteners, thus reducing contamination levels.
In conclusion, modular cleanroom brings revolutionary changes to cleanroom engineering through their unique design, high-quality materials, rapid construction cycles, high flexibility, and excellent cost-effectiveness.

Applications of Modular Cleanroom:

Modular cleanroom has a wide range of applications across various industries, primarily including electronics factories, food processing plants, laboratories, and more. Here are some detailed examples:‌

â–ºElectronics Factory: In electronics manufacturing, modular cleanroom creates high-level clean areas such as assembly lines and inspection tables. These areas have stringent cleanliness requirements, especially near equipment that may release dust particles or special gases during production. By using modular cleanrooms, critical processes are kept within clean zones, enhancing product quality. In the optoelectronics industry, fan filter system on production equipment tops improves air quality, providing a safe and comfortable production environment.‌

â–ºFood Processing Plant: During food production, especially in packaging, using Class 100 modular cleanroom ensures the produced food meets safety standards. The application of modular cleanroom in the food industry is increasingly widespread, meeting GMP food QS standards in China, and providing a safe and stable clean environment for food processing.‌

â–ºLaboratory: Laboratory research requires specific controls over temperature, humidity, illumination, and cleanliness. Modular cleanroom provides purified clean work areas, increasing the success rate of research projects by maintaining a controlled environment.

â–ºAerospace Industry: Cleanroom in aerospace is a highly controlled space designed to minimize dust, microorganisms, chemical gases, and other airborne pollutants. These spaces have strict requirements for temperature, noise, illumination, static electricity, and micro-vibration, ensuring that the manufacturing processes of aerospace components meet required cleanliness standards. The cleanroom design aims to optimize the working environment, ensuring product quality and safety.

â–ºBiomedical Industry: Biomedical cleanroom focuses on controlling airborne microorganisms, adhering to cleanroom classification standards with additional microbial control requirements, providing a relatively sterile environment by controlling microbial quantity and quality in the air, reducing infection risk, and ensuring the safety and effectiveness of medical procedures. They require strict control over temperature, humidity, pressure, and other parameters to maintain suitability and safety.

â–ºMedical Industry: Cleanrooms for medical experiments emphasize controlling air cleanliness, temperature, humidity, pressure, and noise. They exclude particulates, harmful air, and bacteria, while controlling temperature, cleanliness, pressure, airflow, noise, vibration, illumination, and static electricity within specific ranges, ensuring extremely low levels of particulates like dust, airborne biological entities, or vaporized particles, maintaining a pure and safe experimental environment, protecting the accuracy and reliability of experimental results.‌‌‌

Additionally, modular cleanroom is widely used in microelectronics, semiconductors, optoelectronics, precision machining, chemical industries, nuclear industries, printing, coating industries, genetic engineering, and more. These fields demand strict environmental control. And modular cleanroom, with the ease of operation, expandability, convenient construction, disassembly, low operating costs, and reusability, provides efficient and stable clean environments for these industries.

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