Implementing Cleanroom Class 7 in existing facilities

The requirements for cleanrooms in medical technology, aerospace, semiconductor industry, and other highly sensitive sectors are continuously increasing. However, not every company has the possibility to construct new buildings or extensively retrofit existing spaces. Additionally, repurposing existing space is more sustainable and economical. This is where sphairlab GmbH comes in: with an innovative cleanroom concept that can be installed in existing buildings in the shortest possible time, the company demonstrates how flexibility, cost-effectiveness, and technical precision can be combined.

Recently, a class 7 cleanroom according to ISO 14644-1 was established in Bergisch Gladbach, embodying these principles. Two rooms previously used as offices were converted into a roughly 30-square-meter cleanroom with an anteroom. The particular challenge was to optimize the limited space and low ceiling height. Thanks to sphairlab's textile cleanroom tent, the available space was utilized efficiently without requiring structural modifications to the building.

The walls and ceiling of the cleanroom consist of special textiles and transparent films, which are not only lightweight and flexible but also allow natural light to enter the space. This creates a pleasant working atmosphere and also enables external viewing without visitors or colleagues needing to enter or sneak into the cleanroom. The technical core of the cleanroom is a ventilation system with HEPA filtration, positioned outside the room, which supplies filtered air through a textile source outlet into the cleanroom. This design ensures a uniform displacement airflow, avoiding drafts and guaranteeing compliance with ISO 14644-1 class 7 cleanroom standards.

Another feature of the cleanroom is the emergency exit, implemented via a zipper in the cleanroom wall. This solution emphasizes the system's flexibility and demonstrates that even textile cleanrooms can meet relevant safety standards. The construction and manufacturing of the cleanroom were carried out in close collaboration with regional partners from the Aachen city region and North Rhine-Westphalia. Within a few days, the cleanroom was ready for use, allowing the customer, Prothea Technologies GmbH, to quickly utilize the new space for medical technology production.

A key advantage of the sphairlab concept is its cost-effectiveness. Traditional cleanrooms often require significant investments in new construction or the renovation of existing buildings. In contrast, the textile cleanroom tent enables retrofitting in already existing rooms without the need for extensive construction work. Additionally, the system is modular, allowing the cleanroom to be expanded or relocated as needed. This flexibility is especially beneficial for growing companies or changing requirements.

Fabian Klarner, Managing Director and VP Engineering of Prothea Technologies GmbH, summarizes the benefits of the new cleanroom: “Thanks to the sphairlab cleanroom tent, we were able to create a cleanroom from two nearly vacant offices with minimal invasiveness. Every millimeter of our space was utilized efficiently. We are particularly excited about the flexibility to easily move or expand the cleanroom later.” This project demonstrates that cleanrooms do not necessarily have to be expensive or inflexible. With innovative solutions like sphairlab's textile cleanroom tent, high-quality, certified cleanrooms can be created in existing buildings — quickly, economically, and future-proof.

The example in Bergisch Gladbach shows how modern cleanroom technology can be tailored to the needs of companies that wish to avoid extensive renovations or new constructions. The combination of textile materials and modular construction makes sphairlab's cleanroom an attractive solution for a variety of industries. Whether in medical technology, special machinery construction, or the semiconductor industry — the concept offers the possibility to establish cleanrooms where space or cost constraints previously made it impossible.

For companies facing the challenge of creating cleanroom conditions within existing buildings, the sphairlab system provides a convincing alternative to conventional solutions. It demonstrates that innovation and cost-efficiency can go hand in hand to meet the growing demands for cleanrooms.