Ensure production efficiency in the cleanroom

nora systems Biotest AG Dreieich, Dirk Wilhelmy

nora systems Biotest AG Dreieich, Dirk Wilhelmy

nora systems Kisico Oestrich Winkel, Markus Bachmann

nora systems Kisico Oestrich Winkel, Markus Bachmann

nora systems Ries Pharmacy Nördlingen, Oliver Heinemann

In increasing numbers of industries, production is taking place in cleanrooms – not only in the pharmaceutical and cosmetics sectors but also in electronics or the automotive industry. Because the removal of damaging particles and microorganisms from the air results in significantly higher quality and safety for products and processes. To maintain the unrestricted functionality of machines and systems, regular maintenance is essential. However, shutting down production for maintenance measures, a so-called shutdown, costs companies time and money: frequent and prolonged maintenance work should therefore be avoided as much as possible. This is especially true for extensive renovations, such as those sometimes required for floors. High demands are placed on flooring in cleanrooms and GMP areas. The materials used must emit only very low levels of emissions and be easy to clean. Depending on the substances and components worked with in the cleanroom, low emissions and electrostatic discharge capability (ESD suitability) may also be required. The choice of cleanroom floors is primarily determined by the EG-GMP guideline or the classification according to ISO 14644. If the cleanroom floors no longer meet these standards or do not comply with the required ESD norms, they must be replaced or renovated. Damage to the floor covering or substrate can disrupt workflows and also pose risks to humans and the environment, for example if substances escape through a damaged coating. Especially during renovations, quick-installation systems, such as those offered by rubber flooring manufacturer nora systems, provide a good opportunity to keep downtime as low as possible. nora flooring systems are used in many cleanrooms worldwide. They have been tested by independent testing institutes, such as the Fraunhofer Institute for Production Technology and Automation, and certified as suitable up to ISO Class 3 or GMP Class A.

Immediate usability after installation

How often cleanrooms should be maintained depends on the process and the particle cleanliness class of the air. The two guidelines ISO 14644 and VDI 2083-9.1 provide orientation for the intervals between inspections. The goal of these measures is to ensure a specified product quality, in accordance with GMP guidelines. For cleanrooms of ISO classes 1 to 5, a semi-annual check is recommended, while cleanrooms of ISO classes 6 to 9 should be inspected once a year. These production downtimes naturally generate high costs and should therefore be kept as minimal as possible. Floor quick-installation systems offer a practical solution to minimize shutdown times. With nora's nTx technology, rubber floors can be installed directly on existing coatings or substrates, such as coatings or pharmaceutical terrazzo. In nora nTx, the coverings are already equipped with an adhesive backing from the factory. After removing the protective film, the floor can be installed cleanly and securely with a few simple steps and is immediately walkable. The cleanrooms can be brought back into operation more quickly, eliminating drying times.

Minimizing sources of error

"With conventional wet installation, it usually takes at least 72 hours before the floor is usable," explains Frank Bähr, nora market segment manager for industry. "With nora nTx, drying and waiting times are completely eliminated." Due to the adhesive backing applied at the factory, no curing time for the adhesive needs to be considered, so the surface can be used immediately again. Another advantage of using the quick-installation system is the flawless installation result. Errors such as using too much or too little adhesive or installing the coverings too early or too late into the adhesive bed are excluded with nora nTx thanks to the self-adhesive backing. Additionally, the modular installation allows for easy reconfiguration of areas to adapt to changing process conditions, such as those resulting from changes in production. nora nTx floors are easy to clean and resistant to acids, alkalis, solvents, and disinfectants.

Conductive dry adhesive tape – for more surface in less time

A useful addition to the nora nTx quick-installation system is nora dryfix ed, an innovation for fast installation of rubber coverings in areas with ESD requirements. It complements the nora system offering. The conductive dry adhesive tape from the roll allows for rapid installation of electrostatically dissipative (ed) and electrostatically conductive (ec) nora flooring. "Here too, the installer benefits from more surface coverage in less time compared to traditional wet installation by eliminating steps and drying times," emphasizes Bähr. The product also withstands extreme dynamic pressure loads, such as rolling heavy equipment. Customers receive a ten-year warranty on the electrostatic properties.