Cleanroom Cost-Cutting Techniques You Need To Know

Cleanrooms are an essential part of the manufacturing process for many types of medical equipment. They’re also a good option for manufacturing other kinds of products, but they’re particularly valuable in the medical industry because they help to ensure that products are made with the highest quality possible.

Cleanrooms are designed to keep out contaminants and pollutants, which can cause problems with the product’s quality. By using cleanrooms, manufacturers can be confident that their products will be safe for patients. 

Your budget doesn’t have to be ruined by rising energy prices. Energy-related costs can be managed by choosing realistic equipment and designing cleanrooms appropriately.  These seven cost-effective strategies listed below will assist you in maintaining your cleanroom performance and production without going over budget.

Assessing The Size Of Cleanrooms

Starting with the choice between brick-and-mortar and modular construction. Building permissions are typically unnecessary when using a modular room, and if your company relocates, the room may be taken apart and rebuilt at the new location. You should also take your cleanroom’s size into account. 

Create the floor plan and ceiling height to suit your unique requirements. Keep in mind the regulated atmosphere of the future that you have imagined. Larger areas initially cost more to build and maintain, but if your facility intends to grow in the future, a bigger cleanroom means you’ll be ready to operate when workflow increases—no waiting for extra parts to be delivered and installed.

If you want to go with a tried and tested choice, simply pick ISO 7 cleanrooms. Modular ISO 7 hardwall and softwall cleanrooms protect your project from particles in a big way. They need a lot of air changes and only let a certain number of particles be in the air at once in a room. ISO 7 cleanrooms are recommended for tasks that need to keep the number of particles in space to a moderate level. 

ISO 7 clean rooms meet all ISO 14644-1 standard, which assess how many particles can be in a room and how many times the air can be changed per hour. Also, ISO 7 cleanroom systems come with either hard or soft walls, which can be changed to meet your exact needs.

Selecting The Air-Conditioning Methods

Your regulated space’s quality is at risk, and choosing the incorrect air conditioner adds needless expense. Depending on the use, room and equipment size/type, and the number of employees, your existing HVAC (high-volume air conditioning) system might be the most cost-effective way to cool down your cleanroom. 

Nonetheless, the cleanroom will increase the HVAC system’s thermal needs, so you must ensure it can handle the entire energy load. Additionally, if the central system fails, some crucial applications could need a specialized system to maintain cleanroom temperature consistency. While a specialized AC module may provide a workaround for a facility without needing an air conditioning system or an overworked HVAC unit, it is not always the ideal option. 

Pass-Through Chambers To Save Some Cash

Carefully placing a pass-through or talk-through chamber can save up a lot of time and money. Transferring materials or supplies requires fewer people to dress. The gowning procedure involves materials and can take some time. Access doors offer efficient access for personnel to enter or leave a vital area, but they also create the potential for pressure differential swings between zones. 

This problem is resolved by a pass-through chamber’s comparatively modest air volume, which effectively maintains steady pressure and minimizes contamination from increased foot traffic. Getting rid of long pressure recovery times helps keep energy expenses in check.

Efficient Fan/Filter Units (FFU Filter)

The cost of changing an FFU filter includes the cost of cleaning, testing, certifying, and raising the ISO level of your controlled environment, among other expenses. Revenue is lost for each hour of downtime. 

Contamination is avoided using room-side replaceable (RSR) fan/filter systems because the filter may be changed inside the cleanroom without breaching the ceiling barrier. The RSR does away with the requirement for extended shutdowns while changing filters.

Dust-spot ratings for air filters should be between 35% and 80%, or they should have a Minimum Efficiency Rating Value (MERV) between 8 and 13. The better the defense for both the hardware and the people inside, the higher the rating. A 30% rise in static pressure along a coil is thought to cost $200 for every 10,000 CFM of airflow (at 7 cents per KWH). 

Electrically commutated (EC) fan/filter units with effective DC motors are frequently needed to handle this, especially in facilities subject to low energy-use restrictions. Despite having a higher initial cost, these units quickly pay for themselves through reduced energy use and utility costs.

Could A Pre-Filter Be Useful?

Absolutely! Pre-filters can be cleaned and reused and are less expensive than HEPA or ULPA filters. The effectiveness of some pre-filters in removing lint dust from airflow has been rated at up to 80%, reducing the particle impact on your higher FFU filter. A HEPA or ULPA filter will last longer if there are fewer particles.

Inexpensive Lighting Options

Reduced heat production from energy-efficient LED (light-emitting diode) panels lowers cooling expenses. Although the bulbs last 5 to 8 times longer, they provide lumens comparable to fluorescent lights. 

LED strips are attached directly to the ceiling grid between FFUs in rooms with complete or almost complete FFU coverage to prevent laminar flow obstruction.

Installing Energysaver FFU Systems

Fan speed management is made simple using EnergySaver FFU control systems and a power distribution module (PDM). Individual FFU speed adjustments no longer require scaling a ladder! By removing ceiling breaches, the EnergySaver enables per-zone remote fine-tuning of flow volume, air change rate, and internal pressure. 

When the room is empty, night setback mode maintains the integrity of your cleanroom by running the fan at a lower speed, which uses less energy and emits less heat.

Cleanrooms are so prevalent across many industries that the size of the global cleanroom technology market was estimated at USD 4.0 billion in 2020, and it is anticipated to increase at a CAGR of 5.4% from 2021 to 2028.  

When so much money is going into an industry, it is important to think wisely. To save, you must first spend; although some of these high-tech features may initially be more expensive, their energy efficiency and minimal maintenance needs result in significant long-term savings.

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