Interdisciplinary diversity shines at the Fraunhofer Cleanliness Technology Award "CLEAN! 2013"

Clean2013-NELIOR / AAF-Air Technology GmbH

Clean2013-NELIOR-Robustness / AAF-Air Technology GmbH

mosaix_stitchedimage_particleanalyzer_1 / Carl Zeiss Microscopy GmbH

unknown_metallicparticle_particleanalyzer_2 / Carl Zeiss Microscopy GmbH

corrmic_particle_unknown / Carl Zeiss Microscopy GmbH

MAS-100 ISO NT Continuous without Petri dish / MBV AG

MAS-100 Iso NT CM Flat / MBV AG

MAS-100 ISO NT CM with table and Petri dish / MBV AG

On the 2nd day of the Cleanroom Lounge, the moment had arrived: the three winners were awarded for their contributions with the Fraunhofer Cleanliness Technology Award »CLEAN! 2013«. The 1st prize went to »MEGAcel with NELIOR Filtration Technology« by AAF-Lufttechnik GmbH. Its air filter medium based on a PTFE membrane is extremely robust, almost free of outgassing, and also very energy-efficient. The runner-up is the »Correlative Particle Analyzer CAPA« by Carl Zeiss Microscopy GmbH. CAPA revolutionizes cleanliness technology with its bridge between scanning electron microscopy and light microscopy. The 3rd prize was awarded to the innovative method for continuous measurement of biological air contamination in isolators and RABS systems. The procedure was developed by the Swiss MBV AG with the MAS-100 Iso NT®.

1st Prize: AAF-Lufttechnik GmbH – MEGAcel with NELIOR Filtration Technology

Classified air cleanliness is a fundamental prerequisite for producing high-quality products under clean conditions. The filters mandatory in every cleanroom play an important role in the quality of the supplied air. When using air filters with conventional filter fibers with a diameter of about 1.0 µm, air molecules collide with the fiber surface, preventing unobstructed and thus optimal airflow (Slip-Flow Effect). Air molecules tend to settle on the fiber, so air can only be pushed through the filter medium at higher speeds.

The ePTFE membrane filters have significantly smaller fiber diameters. Due to the finer diameter of about 20 to 200 nanometers, they allow air molecules to pass more easily through the air medium. Particles that are retained pass the fiber surface at much closer distances and can thus be more easily captured, significantly increasing the particle separation efficiency by a factor of 2.

Because of the smaller fiber diameter, the operating pressure can be reduced by about 50 percent, which decreases noise levels and allows for a more compact filter design. Another aspect that impressed the jury relates to sustainability and environmental compatibility: the filter medium of AAF-Lufttechnik GmbH consumes up to 50 percent less energy.

Arnold Brunner from Hochschule Luzern states: »The American Air Filter Company AAF has made a significant, innovative step into the future of cleanroom technology with the filter medium Helior™ in the field of HEPA and ULPA filters. The air filtration performance, defined in the standard EN 1822 »Particulate Filters«, is further improved by shifting the MPPS (Most Penetrating Particle Size) into the < 0.1µm range. Above all, the new filters of the MEGAcel series impress with their very high mechanical durability and the halved pressure drop compared to traditional HEPA filters.«

2nd Prize: Carl Zeiss Microscopy GmbH – Correlative Particle Analyzer (CAPA)

Fast classification and characterization of particles according to ISO 16232 – with the »Correlative Particle Analyzer«, Carl Zeiss Microscopy GmbH establishes a previously unavailable connection between scanning electron microscopy and light microscopy: an innovative combination of hardware and software interfaces enables particles detected with the light microscope to be automatically, quickly, and precisely located in the scanning electron microscope. For example, image information from light microscopy can be quickly and automatically combined with element information from energy-dispersive X-ray analysis without unnecessary analysis effort. This combination opens new, time-saving possibilities especially for industrial quality assurance processes such as determining component cleanliness in the automotive sector (»Technical Cleanliness«).

»What’s elegant about the zoom lens on my camera is not only that it operates continuously, but also that I can change the focal length without losing sight of my subject and having to search for it again. With Zeiss’s »Correlative Particle Analyzer«, this is even possible when I need to change the lens. Viewed through the light microscope, switched to SEM, and found again without searching – all the information I gathered across various channels flows together automatically«, summarizes juror Thomas Wollstein, VDI. »This opens up new possibilities for quality assurance regarding cleanliness and purity.«

3rd Prize: MBV AG – MAS-100 Iso NT® Continuous Measurement

Biological air contamination in an isolator or RABS (restricted access barrier system) is today typically measured using a combination of active samplers and air plates.

The sensitivity of active samplers is good, but the measurement duration is limited to a few minutes. Air plates can be used over hours but are less sensitive. Additionally, sensitivity depends on particle size. Based on the proven platform of MAS-100 Iso NT®, MBV AG introduced a new device that combines the advantages of both measurement methods.

Dr. Lothar Gail from GMP Cleanroom Technology explains: »For determining airborne germs, good detection sensitivity and long measurement times are desired – requirements that are not easily compatible. The new system presented by MBV as MAS-100 ISO NT CM combines the sensitivity of active samplers with a measurement time extended up to 4 hours. The flow rate is reduced to either 4 or 8 l/min, while the collected air volume is increased up to 2000 liters. This allows measurement times that provide important advantages for monitoring pharmaceutical sterilization processes.«

This is enabled by an innovative head design, in which the agar plate rotates once during measurement. This increases the utilization of the agar surface and reduces drying, as a larger surface is overgrown. Additionally, the rotation allows for a temporal analysis of the colonies found: a colony at the 3 o'clock position was detected after a quarter of the total measurement time.

»It was exciting to observe the response to the inaugural awarding of this prize. We were very pleased with the multitude of high-quality applications and would like to thank all applicants. The diversity of applications was particularly impressive, spanning disciplines in cleanliness technology and ranging from small enterprises to large industries. We are already looking forward to the 2014 call for entries at the end of the year«, says jury chair Dr. Udo Gommel.

In addition to initiator Dr. Udo Gommel, Fraunhofer IPA, the expert jury includes Dipl.-Phys. Thomas Wollstein, VDI e. V., Dr. Lothar Gail, GMP Cleanroom Technology, Dr. Gerhard Kminek, European Space Agency, and Dipl.-Ing. Arnold Brunner, Hochschule Luzern.