Recent Projects
How Airkey Built an ISO 6 Modular Cleanroom for Neutron Generator Manufacturing
2026-07-06
This project was delivered for a sterile laboratory in Arizona, USA. The cleanroom adopts Airkey's Wave Series modular cleanroom solution (FSP-I8N-A22(7.3×3×2.7)-F), with a total area of 21 square meters and an internal height of 2.4 meters. The project serves the medical industry and was specifically designed to meet the strict environmental requirements of peptide synthesis and laboratory operations.
The client, Nexus Synth, is a leading peptide manufacturer based in the United States. The company specializes in supplying high-purity research peptides, custom peptide synthesis services, and proprietary peptide blends for laboratories and B2B partners. Due to the highly sensitive nature of peptide production, the client required a clean and controlled environment that could ensure product purity while supporting flexible manufacturing processes.
Peptide synthesis involves strict control of physical, biological, and chemical contamination risks. The modular cleanroom was designed to improve both product purity and production efficiency throughout the manufacturing process.
During raw material preparation and weighing, a negative pressure dispensing booth is used to prevent the spread of highly reactive or toxic dust particles, ensuring operator safety and environmental control.
For solid-phase and liquid-phase synthesis, the cleanroom provides a modular reaction tank cluster that allows rapid switching between different peptide synthesis processes. This flexible configuration helps improve production efficiency while supporting multiple product requirements.
In cyclopeptide production, the cleanroom creates an anaerobic environment where oxygen concentration can be controlled below 1 ppm. The system also incorporates explosion-proof features to ensure operational safety during sensitive chemical reactions.
For pyrolysis and cyclization processes, sealed reactors are utilized to minimize exposure to hazardous chemicals and reduce the risk of cross-contamination. The enclosed design also supports safer waste discharge and handling procedures.
During purification and concentration stages, a skid-mounted purification module is integrated with HPLC systems to improve purification efficiency and streamline process flow.
The freeze-drying area is designed to provide a clean environment that can be seamlessly connected to freeze dryers, ensuring product integrity throughout the drying process.
For formulation, filling, and packaging operations, positive pressure differentials such as +10 Pa are maintained to support aseptic filling conditions and protect final products from contamination.
The cleanroom adopts an aluminum alloy profile frame combined with PVC anti-static transparent soft curtains. Both the frame and curtain materials undergo anti-static treatment, providing controlled surface resistivity that effectively prevents powdered peptide products from adhering to surfaces due to electrostatic attraction. This design helps maintain cleanliness while improving operational convenience.
The cleanroom is equipped with stainless steel adjustable leveling feet at the base of the structure. These leveling feet compensate for uneven floor surfaces and ensure the entire cleanroom remains level after installation.
The support system also enables relocation and reuse of the cleanroom, making it suitable for future production line modifications or facility layout changes. Once the final position is determined, the leveling feet can be locked to provide stable and reliable operation.
To facilitate the movement of large production equipment, the cleanroom incorporates a specially designed large-format equipment access door. The door utilizes a quick-release pin connection structure that allows operators to remove and reinstall panels without specialized tools.
EPDM sealing gaskets are installed around the door frame to maintain airtight performance, while the enlarged opening dimensions provide sufficient clearance for equipment transportation and installation.
All cleanroom components are prefabricated and pre-assembled in the factory before shipment. This modular construction approach significantly reduces installation time on site while ensuring structural consistency and quality control.
The prefabricated design also improves construction efficiency and minimizes disruption to client operations during installation.
Before shipment, all equipment is pre-installed, labeled, and tested in the factory. After on-site assembly, the cleanroom undergoes comprehensive testing for cleanliness levels, illuminance, and airflow velocity.
All performance tests were successfully passed on the first attempt, demonstrating the reliability of the modular cleanroom system and its ability to meet the client's operational requirements.
This USA sterile laboratory project demonstrates how a modular cleanroom can provide a flexible, efficient, and compliant solution for peptide synthesis applications. Through its anti-static enclosure system, modular process integration, quick-installation design, and validated performance, the cleanroom successfully supports high-purity peptide production while allowing future scalability and operational flexibility.
The project highlights the advantages of modular cleanroom technology for modern pharmaceutical and biotechnology facilities that require rapid deployment, strict contamination control, and long-term adaptability.
