Quality advantage through cleanroom technology

The 150 sqm large CleanMediCell® cleanroom of ISO cleanroom class 7 offers docking options for 12 injection molding machines.

The injection molding machines are docked to the cleanroom. Material transport into the cleanroom is fully automated.

Complex cleanroom manufacturing: injection blow molding machine, automation system, and inspection rotary table, each with its own laminar flow enclosure. Fully automated transfer into the cleanroom via encapsulated conveyor belts.

The packaging industry is under strong international price pressure. Efficient processes and optimized workflows improve quality and reduce manufacturing costs. Automation and the use of cleanroom technology are the solutions for competitive plastics processing.

To produce sustainably competitive products, one must deliver exceptional quality and be well-organized. Kunststoff-Packungen AG in Kreuzlingen has been relying on ensuring quality standards through the use of cleanroom technology for several years. The Swiss packaging specialists have now further expanded their leading position with the installation of a new cleanroom product line that integrates up to 13 processing machines. Controlled hygienic production under cleanroom conditions is a prerequisite for supplying customers in the pharmaceutical industry and thus secures important markets in packaging technology. By reducing particles in the process environment, residual particle contamination and residual microbial load on the packaging parts can be significantly decreased. The expansion of the cleanroom facilities leads to a substantial increase in process safety, as explained by Marcel Fetzer, Head of Technology:

“The quality of the plastic parts has increased significantly with the use of cleanroom technology. Scrap rates could be reduced, and at the same time, higher production volumes can be achieved. Especially in the sensitive areas of the pharmaceutical industry, we must supply our customers with flawless quality. We are very confident that with the commissioning of the new system, we can further improve the high standards.”

Injection molding and blow molding are highly complex processes involving precise technical procedures that must be perfectly coordinated. When production is carried out under cleanroom conditions, the technical coordination requirements increase even further. Therefore, Kunststoff-Packungen AG is again relying on the expertise of the cleanroom specialist SCHILLING ENGINEERING for its new investment. In close collaboration between both teams, a state-of-the-art production line has been created that guarantees efficient processes.

In the newly established cleanroom system, up to 12 injection molding machines and one injection blow molding machine are docked in a satellite configuration along the outer edges of the 150 m² cleanroom of the CleanMediCell® series. Each machine is equipped with its own laminar flow enclosure, which significantly reduces particle emission. The produced packaging parts are automatically fed into the cleanroom via sealed conveyor belts, where final inspection and bag packaging are carried out by trained staff. An additional material transfer point—with active rinsing—ensures flexible workflows and added safety. All material and personnel lock systems are connected with a locking mechanism that automatically locks doors when another door in the lock system is opened.

The cleanroom system is based on the principle of turbulent mixing air and meets the requirements of ISO 7 cleanroom class. Only very quiet U15 ULPA high-performance filter fan modules are used. A fully integrated recirculation and exhaust air system within the cleanroom walls ensures precise cleanroom ventilation and low energy and maintenance costs. The wall elements are connected with a silicone-free GMP sealing clip system and can be dismantled for machine entry and exit.

A technical innovation for controlling and monitoring the cleanroom provides additional safety and efficiency. The innovative control system Control CR Control® establishes connections to the sensors measuring pressure, humidity, and temperature, as well as to filter modules, climate cabinets, door and lighting functions, and other components. All critical functions are monitored and recorded, and they are clearly displayed on a central touchscreen, from which they can be individually operated and adjusted.

The CleanMediCell® cleanroom system was offered by SCHILLING ENGINEERING as a complete solution, adapted to the specific production requirements, and handed over ready for operation. The forward-looking solution ensures, with innovative technology and efficient workflows, the high quality standards of Kunststoff-Packungen AG.