Previously produced through industry-specific total integration – a new approach for cleanroom projects

The integration processes in machinery and plant projects for cleanroom technology have stagnated for decades. Although the requirements for cleanliness and efficiency have significantly increased, many workflows still follow traditional patterns – with considerable disadvantages for product quality, process safety, and project timelines. Hanselmann GmbH has taken this situation as an opportunity to fundamentally question established workflows and optimize them with a modular overall concept.

Goal and Benefits

The aim was to develop a consistently clean, safe, and time-saving integration technology for machinery and plant construction projects that meets the specific requirements of cleanroom-critical industries such as pharmaceuticals, microelectronics, or aerospace. The result: a combination of temporary cleanroom systems, lint-free packaging technology, and standardized transport concepts – with measurable time savings for production start-up.

Initial Situation

Typically, machines are manufactured in conventional production environments, packed in wooden packaging, and often unpacked outdoors – even if their use later takes place in a cleanroom. This approach is problematic not only in terms of particle contamination but also prone to transport damage and time-consuming rework. The consequence: project delays and additional validation efforts.

Solution Approach: Holistic Cleanliness from the Start

Hanselmann GmbH addresses these challenges with a three-part integration approach:

1. Temporary Cleanrooms:
Cleanroom systems are installed directly at the machine manufacturer on a rental basis. These create ISO-compliant conditions (Class 8 to 5) during manufacturing and enable cleanroom-compatible pre-production.

2. Holistic Lean Processing System (HLPS):
The HLPS allows machines to be built on a "baseplate" that remains part of the system throughout the entire supply chain. A traditional wooden packaging is deliberately avoided – instead, a special film protects against weather and contamination. This drastically reduces particle ingress and allows targeted control of environmental influences.

3. Standardized Transport and Handling Processes:
With the modular "Lift-and-Roll" system, machines can be moved safely – even in hard-to-reach areas such as upper floors. All moves are tested, standardized, and adaptable to customer-specific conditions. Additionally, the Hanselmann team onsite ensures compliance with all cleanliness and GMP requirements.

Results and Practical Example

The application of this methodology has shown that integration times can be significantly shortened – by several weeks to months depending on the project. At the same time, the risk of technical damage and contamination sources is greatly reduced. Early use of cleanliness solutions also makes validation processes more efficient and predictable.

Conclusion

The traditional integration approach often no longer meets today's cleanroom requirements. With a holistic, clean, and standardized procedure, Hanselmann GmbH successfully contributes to shortening the time-to-production – taking into account all technical and logistical framework conditions.