Modular cleaning system and cleanroom for the highest high purity requirements

The overall process is crucial. Through seamless integration of cleaning and cleanroom processes, the individual steps are perfectly coordinated. The highest purity and maximum safety are achieved by selecting the optimal cleaning technology and continuously monitoring the cleanliness of the production environment. (Photos: LPW and Weiss Klimatechnik)

The air conditioning of Weiss Klimatechnik's cleanroom ensures stable conditions and saves energy. The filter systems used, as well as the thermal and hygienic treatment, achieve ISO Class 6 or 5. (Photos: LPW and Weiss Klimatechnik)

Cleanrooms create the environmental conditions necessary for subsequent processes (assembly, packaging, etc.) after parts cleaning. The cleaning technology must be closely coordinated and adapted to these conditions. (Photos: LPW and Weiss Klimatechnik)

The PowerJet Compact CNp system (from left to right: Clean module, Clean AM, and Pure) is standardly equipped with a treatment chamber embedded in the two feed tanks for goods up to a batch size of 600 x 400 x 300 mm for weights up to 150 kg. The recirculation system features an integrated full-flow filtration with a filter area of over 4 m² and filter units up to 0.5 µm. (Photos: LPW and Weiss Klimatechnik)

Where the highest purity is required, precise and seamless processes are indispensable. In this regard, LPW Cleaning Systems GmbH and Weiss Climate Technology GmbH are sought-after partners. They offer comprehensive high-purity solutions for industries such as medical, semiconductor/high vacuum technology, aerospace, or pharmaceuticals. The collaboration of experts in cleaning systems and cleanrooms stands for tailored, efficient material flows with optimal product quality, traceable quality parameters, and flawless documentation. And for a better user understanding of the interfaces between pre-production, cleaning technology, and cleanroom. Because technical cleanliness is not a single operation.

LPW has established itself worldwide in recent years as a partner for customized solutions in the high purity segment. The cleaning systems are used in many high-tech fields and meet the highest cleanliness requirements. In early 2023, the specialists from Riederich designed a new cleanroom for their test and service center, which had to be re-equipped after a fire damage. This new installation was to build on the previous experience of the LPW team with cleanroom-assisted cleaning. The company chose Weiss Climate Technology, a long-standing network partner, as the implementer for this project.

The Hessian experts stand for:

– Energy-efficient air handling and filtration systems with suitable control and regulation technology
– Open communication, especially when it comes to critical interfaces to cleaning technology
– Flexible co-engineering in integrating the cleanroom into building monitoring (e.g., air particle measurement)

In addition, Weiss Climate Technology was able to complete and qualify the new cleanroom within just four months from order placement.

PowerJet Compact Concept

At the same time, LPW advanced the development of a standard cleaning system concept (PowerJet Compact series) for highly clean supply chains in various high-purity industries—and developed the idea of integrating Weiss Climate Technology cleanrooms as interfaces to the clean environments.

Key features of the Compact system:

– Supports the intention to gradually establish a clean production process, even while maintaining existing infrastructure and machinery
– High-quality intermediate cleaning (e.g., ASML Grade 4/2) up to final cleaning with cleanroom connection, validated monitoring, and suitable ultrapure water supply
– Investment in affordable partial steps.

The 3-stage PowerJet Compact series is now successfully on the market with three highly modern modules:

– Module "Clean": The powerful pre-cleaning system, already equipped with CNp, ultrasound, and vacuum infrared drying.
– Module "Clean AM": Ideal for the highest purity after additive manufacturing—for powder removal and metallic printed parts.
– The highest-quality module "Pure" was specifically designed for connection to gray or cleanrooms, with an outlet for an on-site ultra-pure water supply or connected to the LPW-UPW module as a supply and recirculation system. It has repeatedly proven its performance in various high-clean process chains—most recently in the supply chain of high vacuum technology for ASML/Grade 1 requirements.

Particularly the Pure module was the focus during coordination meetings with Weiss Climate Technology. Because high-purity process chains depend on coordinated steps. The transition from pre-processes (manufacturing, handling, pre-assembly, possibly pre-cleaning) to cleaning technology and subsequently into the clean environment presents challenges in individual operations, especially at the interfaces between operations.

Besides the quality and process requirements for cleaning/rinsing and drying processes, this high-end module is prepared for the use of ultra-clean media and, thanks to its extensive sensor technology, for integration into high-performance monitoring systems. Media flows are monitored according to requirements. Furthermore, integration into an online service, remote maintenance systems, a cloud-based LPW dashboard, and ongoing batch-related process data validation and analysis are possible. If needed, a high-performance LPW pure water unit can also be integrated into the system, which can serve as a pure water supply or as an additional loop with tempered pure water in the process. PowerJet Compact Pure also features an "interface" (front access to the treatment chamber) for direct integration into the cleanroom wall. All maintenance accesses remain outside the cleanroom, allowing unrestricted operation without unnecessary cross-contamination influences.

Modular System and Cleanroom: An Unbeatable Duo

First things first: a cleanroom is not a "cleaning room," but a controlled environment that reduces particle contamination to a defined minimum. The purity largely depends on what is introduced and how the process is designed. If contaminated parts or unsuitable packaging enter the cleanroom, the contaminants remain and can even jeopardize ongoing processes. Therefore, a cleanroom guarantees controlled conditions but is not a substitute for clean processes. The "production" of technical cleanliness begins long before. Through appropriate pre-cleaning, proper handling, and trained personnel. Correct clothing, material sluices, clear procedures, and behavioral rules ensure that the cleanroom environment can fulfill its function. Process discipline is crucial. Regarding this, Weiss Climate Technology and LPW provide a clear guideline: processing and cleaning systems are located outside the cleanroom. Integrated material and personnel sluices ensure minimal particle entry. Technically clean products are transferred from the system into the cleanroom without contamination. Control, monitoring, and packaging take place inside the cleanroom.

The Weiss Climate Technology cleanroom module and the LPW modular system are perfectly coordinated in tandem and offer six key advantages in practice:

– The modular design of the cleaning & cleanroom system allows for customized solutions with minimal effort and very cost-effective planning and construction in the shortest time.
– Compact ventilation units, manufactured by Weiss Climate Technology at the Reiskirchen plant, ensure maximum energy efficiency and system safety, reducing the need for technical space.
– The layout of the cleanroom is optimized for user-friendliness and short distances.
– Front-side integration of the systems reduces heat generation inside the cleanroom, leading to lower power consumption and long-term economic efficiency.
– Comprehensive monitoring of particles, temperature, humidity, and cleaning parameters ensures maximum traceability.
– Planning and implementation from a single source, with expertise and proven technology made in Germany.

Technical Cleanliness Requires Holistic Approach

Thinking in individual operations, whether in cleaning technology or cleanroom, does not meet the new and significantly increased demands of high-tech industries for overall process quality under the aspect of technical cleanliness. Coordinating all subprocesses, especially interfaces, makes the required level of quality possible and economically efficient. Of course, not every supplier is able or willing in the first step to completely overhaul their existing processes for these new tasks. The development toward this is an entrepreneurial process involving investments in suitable partial steps. Economically tailored to the growing demand and revenue in these business areas. Modules for cleaning, water supply, and gray/cleanroom environments enable this. When suppliers of these building blocks coordinate and build on their own expertise in clean production processes over years, they are also capable of accompanying this transformation with application specialists and tailored training programs.