Clean Room HVAC Design

clean-room-design-service-by-iceberg,, india

A clean room is a space whose environment can be highly controlled. Clean Rooms designed by ICEBERG HVACR decrease contamination from microbes, dust, airborne organisms, vaporized particles, and chemical vapors. These tiny particles can have heavy effects on processes, research outcomes, and products. Clean rooms can maintain control of air circulation, particle levels, humidity, and temperature. They have become an important part of various industries. Industries such as pharmaceuticals, electronics, biotechnology, aerospace, food and beverage, research, and development cannot function without clean rooms. ISO 14644, FDA, and cGMP are the regulatory standards for clean room design.

We are a leading Clean Room Consultant firm based in Pune, India, with a portfolio of over 3000 projects. We’re known for successfully implementing large-scale HVAC systems in important industrial sectors like Pharmaceuticals, Hospitals, Hospitality, Malls, and IT Buildings. About 30% of our revenue comes from ‘Design & Build’ projects, where we’ve integrated advanced energy-efficient HVAC techniques. This success has led to nearly half of our revenue coming from repeat business from satisfied clients. We’ve earned trust with multiple repeat contracts from clients like Cipla, Sahyadri Hospital, Rubicon, and Bharat Serum.

Custom Clean Room Solutions

ICEBERG HVACR offers Clean Room designs according to the client’s needs, making sure the performance is fitting and the finest. Strict design standards are lodged, and pharmaceutical clean rooms have elements like laminar flow hoods and specific air filtration, guaranteeing compliance with Good Manufacturing Practice (GMP) regulations. For the electronic industry, we design Clean Rooms solutions to prevent particle contamination, improving the production of high-quality accessories. Our biotechnology clean room design mainly focuses on sterile conditions and maintaining temperature and humidity.

Define Requirements

The main purpose of a clean room is to provide regulated surroundings. ISO 14644 sets cleanroom standards, detailing permissible particle counts. It guides HVAC design for controlled environments, focusing on continuous monitoring and validation to ensure adherence to cleanliness criteria. Microbes, dust, airborne organisms, vaporized particles, and chemical vapors are controlled which can be extremely harmful to product integrity and process.

The location of the cleanrooms is the most important for its productivity. While designing the Clean Room, we first check if the building is tough enough to harbor the specific requirements of a cleanroom, such as airflow, vibration control, flooring and wall finishes, temperature humidity, etc. easy access for transporting the equipment and elements into the clean room is vital to decrease the risks of contamination.  We leverage smart energy models in the Clean Rooms designs that do the job using less energy, which means lower utility bills.

Effective environmental controls help maintain the perfect conditions inside a controlled space. Accuracy in regulating temperature, pressure, and humidity is crucial to meeting specific requirements. Control of these factors is very important as they may lead to serious issues such as moisture and the invasion of contaminants. These controls create the rigid conditions necessary for the processes to be conducted in the cleanrooms.

In making the architectural design for a cleanroom, pay attention to materials and layout. Ceilings, doors, floors, and walls are made of materials that produce a minimalistic number of particles. The layout is designed for cleaning, non-porous surfaces that are smooth to practice rigorous hygiene protocols. The doors are mapped out for airtight sealing to prevent pollutants from entering.

Creating effective and successful HVAC systems is key to the design of a cleanroom, as it helps maintain cleanliness and air flow within a controlled environment. Using filters like HEPA ensures the removal of particulate matter, microbes, and contaminants. The system provides a consistent and controlled airflow, which prevents the buildup of airborne particles, which can be highly dangerous for the products or processes in the cleanroom.

Clean Room Design Process

  • Determining air handling unit (AHU) capacity and configuration: single-pass vs. recirculation, chilled water vs. direct expansion
  • Designing ductwork for minimal pressure drop and contamination control: material selection, sizing, velocity control
  • Filter bank design: number and arrangement of HEPA/ULPA filters, pre-filters, bypass considerations
  • Fan selection and sizing: noise control, static pressure requirements, redundancy options
  • Humidification and dehumidification system design: equipment selection, control strategies, integration with HVAC system.
  • Designing diffuser systems for laminar flow: selection, placement, airflow velocity control.
  • Displacement ventilation design: air supply and return strategies, underfloor plenum design.
  • Downdraft booth design: airflow characteristics, personnel protection, containment efficiency.
  • Airflow modeling and computational fluid dynamics (CFD) analysis: predicting airflow patterns, optimizing design.
  • Pressure cascade calculations: determining pressure differentials between zones based on classification.
  • Airlock design: number, types (e.g., double door, purge), interlocking systems.
  • Doorway protection design: air curtains, jet nozzles, pressure equalization strategies.
  • Selecting and configuring building automation system (BAS) for HVAC control: setpoints, alarms, data logging
  • Integrating control systems with monitoring equipment: airflow, pressure, temperature, humidity sensors
  • Coordinating HVAC design with cleanroom envelope, walls, ceilings: minimizing penetrations, material compatibility.
  • Designing for ease of access to filters, diffusers, and other equipment for maintenance.
  • Considering noise control measures in HVAC equipment selection and placement.
  • Developing test plans for airflow, pressure, filter integrity, and microbial monitoring
  • Selecting appropriate testing methods and equipment based on cleanroom classification and standards
  • Evaluating test results and implementing corrective actions if necessary

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