Small cleanroom solutions for maximum efficiency and cost-effectiveness

The design of cleanrooms varies depending on the product, process, required cleanliness class, and existing spatial conditions. Whether as a single workstation with a laminar flow box, a partial enclosure, or a machine cabin – numerous cleanroom applications can be realized with item’s modular components.

Based on state-of-the-art filter technology and components specifically designed to meet the particular requirements, cleanrooms can be constructed up to ISO Class 2. For example, various wall and ceiling structures with easy-to-clean transitions are created using item’s specialized framing system.

One way to create smaller clean rooms within a cleanroom is to install a laminar flow box with a height-adjustable work table.

A filter fan unit draws in the air, filters it, and generates a turbulence-free airflow with clean air inside the laminar flow box and machine enclosure.

If larger production areas need to be protected from contamination, partial enclosures with multiple filter fan units are suitable. The interior can be designed to be cleanroom-compatible and customized using numerous item components from the modular system.

Numerous research, development, and manufacturing processes must take place in particle-free environments. Sometimes, additional areas with even lower particle concentrations are necessary within these cleanrooms to protect particularly sensitive products. How can these production environments be implemented as simply and cost-effectively as possible? Modular building block systems enable cleanroom solutions that can be optimally adapted to existing requirements.

For sensitive products in research and industry, protection from harmful environmental influences is essential. In so-called cleanrooms, the air is treated with special filters. Personnel must wear appropriate protective clothing and adhere to specific behavioral rules. For example, hurried and uncontrolled movements should be avoided to prevent unnecessary stirring up of particles. "It is important to create a cleanroom-conscious awareness," says Kevin Haas, Product Manager for the Pure Production sector. "This is a particular challenge in implementing projects in cleanrooms, in addition to technical aspects." A certain sensitivity among employees is required. They must understand that their behavior significantly contributes to the cleanliness of the room. In addition to correctly wearing protective clothing with gloves and masks, proper entry and exit procedures are also highly important. Between rooms of different cleanliness classes, enclosed areas are used where employees put on their protective clothing according to prescribed rules. These airlocks prevent airflow between the rooms when people enter or materials are transported. The primary goal is to prevent all particle emissions.

Solutions for cleanrooms of high ISO classes

Cleanroom technology plays an important role in numerous industries. The requirements vary depending on the product and process. There are no standard solutions. "In sensitive production environments, there are sometimes areas that need even higher levels of purity," says Kevin Haas. "Often, creating separate smaller cleanroom systems is a more cost-effective alternative to large cleanrooms. This essentially creates a cleanroom within a cleanroom." For example, partial processes of camera production take place in such cleanrooms. Cleaning lenses and inspecting assemblies are also performed under cleanroom conditions. Areas that meet higher ISO classes are required for these tasks. Wafer manufacturing for electronic components also occurs in cleanrooms with high air purity requirements. While ISO classes 7 or 8 are sufficient for most applications, in these specific production or assembly areas, ISO class 5 is often required. This allows up to 100,000 particles of 0.1 micrometers in size and only 823 particles of 1 micrometer in size.

Mini-environments instead of large cleanrooms

If consecutive work steps are to be performed under different cleanroom conditions, the approach has often been to adhere to the strictest requirement and thus integrate the entire production process into a higher ISO class cleanroom. However, this involves greater effort and costs. Cost-effective solutions like modular systems from item are more advantageous. Users benefit from significantly lower acquisition costs because they only need to equip smaller production areas with appropriate cleanroom technology instead of an entire room. These process enclosures can be flexibly designed in the required shape and size, with the appropriate equipment. Based on state-of-the-art filter technology and components specifically tailored to the particular requirements, cleanrooms can be designed up to ISO class 2. Whether as a single workstation with a laminar flow box, a partial enclosure, or a machine cabin – numerous cleanroom applications can be realized with item’s modular components. "For example, for quality control of lenses in camera production, workbenches within a cleanroom can be relatively easily converted into a higher ISO class cleanroom workstation," says Kevin Haas. "In contrast, larger, walk-in enclosures are needed for consecutive process steps that all need to be performed under cleanroom conditions." The right solution depends on many factors and is influenced by the process itself, the required cleanliness class, and the available spatial conditions.

Custom design thanks to numerous components from a modular system

One way to create smaller cleanrooms within a larger cleanroom is to install a laminar flow box with an adjustable worktable from item. The filter fan unit draws in air, filters it, and generates a turbulence-free flow of clean air inside the box. The purified air displaces the existing air and prevents contamination in the workspace. It is exhausted without turbulence through a perforated plate. "With these mini-environments, we achieve ISO class 5," explains Kevin Haas. "The interior of the box can be equipped with swivel arms for material and tool supply or other components from the item workstation system. It can be flexibly adapted to the respective requirements." The laminar flow box can also be used as a variable table extension. The hood with the filter fan unit can be used for all table sizes and only deployed when needed. To protect larger production areas from contamination, partial enclosures with multiple filter fan units are suitable. Here, purified air flows through filters in the ceiling into the work or production area. An overpressure is generated, preventing dirt and other particles from entering the room. The interior can be customized with numerous item components from the modular system to be cleanroom-compatible and individually designed. The parts are specifically designed for this purpose. For example, a dedicated framing system ensures sealed surfaces for the cleanroom-compatible construction of walls and ceilings. The smooth, closed surfaces of the aluminum profiles used for the individual structures also allow for optimal cleaning and prevent particle buildup. All cables are routed through integrated cable channels. "In cleanrooms, the outgassing of materials must be minimized as much as possible," emphasizes Kevin Haas. "Seals made of plastic are problematic in this context. We therefore only use materials with low outgassing and have this certified by the Fraunhofer Institute." To prevent contamination of components and processes by tiny, invisible particles, not only adapted employee behavior and appropriate protective clothing are necessary, but also suitable technical equipment. With its cleanroom solutions, item meets all requirements according to ISO 14644-1 and additionally offers ergonomic solutions that optimally support employees in their workflows. Workstations for cleanrooms can also be designed to be ESD-safe. Furthermore, customers benefit from an aesthetically pleasing, high-quality, and functional design. From the start of the project, item provides project planning, possibly in collaboration with item Plus partners, and supplies all components for the customized design of cleanrooms quickly and reliably.