Let’s be honest: Building a new cleanroom can seem like a daunting task. The process can at first seem expensive, complicated, and difficult to figure out. As a result, many businesses are now looking to get compliant in the most straightforward way possible. In this article, we’ll cover what modular cleanrooms are, how they compare to traditional cleanrooms, some of their design features, and more.
What Are Modular Cleanrooms?
A modular cleanroom is a controlled environment built with pre-made parts and assembled on location. They differ from traditional cleanrooms in that they are built in a factory beforehand, and are much more flexible. “Modular” simply means that the parts come in modules, or sections, that are then pieced together.
They can be installed inside an existing building, built along existing walls, or freestand as their own building. And of course, they can be designed to meet ISO and other industry standards, just like traditional cleanrooms.
Modular Cleanrooms vs. Traditional Cleanrooms
These days, many companies are choosing modular walls for their cleanrooms over traditional construction. But why? Aren’t traditional cleanrooms a more “permanent” solution? Not exactly, and the answer comes down to a few important advantages:
Lower Costs
Though most people building cleanrooms aren’t in a hurry, modular cleanrooms can be built faster, simply because the manufacturing process is more straightforward. Parts are built in sections within a factory. All this leads to lower overall costs, especially when working with a single manufacturer. When you have to deal with multiple contractors, it leads to price uncertainty, and this often causes companies to go over budget.
Flexibility
Another great part of modular cleanrooms, which could also be included as a cost advantage, is their reusability. They can be permanent, but they don’t have to be. In fact, they can be expanded, adjusted, or even relocated to a new location altogether. This would be downright impossible with traditional cleanrooms.
Simple Maintenance
Further, modular cleanrooms are built for easy maintenance. If a panel or ceiling tile gets damaged, it is easy to replace, and there’s no need to tear down walls. HVAC systems, filters, and lighting can also be serviced/replaced without shutting down the space. With traditional cleanrooms, if a wall is damaged, you may need to cut into the drywall, or even demolish walls.
Customization Options
Also, modular cleanrooms give you many more choices when it comes to customization. With modular, you can choose from different wall materials and finishes, ceiling types, flooring, lighting, doors, windows, and more; also, if you want to change your setup later, you can install new features as needed.
With traditional construction, changes to the design are more difficult and expensive once the building has been created. Retrofitting new features may mean tearing down sections of the wall, costing you more money and time.
Standards & Compliance
Finally, both modular and traditional cleanrooms can meet required ISO, GMP, FDA, and other standards. But modular cleanrooms do have one advantage here. Because parts are built in a controlled factory environment, it’s easier to maintain consistent quality, and this can help with compliance.
With traditional cleanrooms, much of the work is done on-site, which unfortunately introduces a degree of variability/uncertainty, and this can in turn increase the risk of delays during inspections or certification. Modular systems give you the same level of compliance, and often with a faster and more predictable approval process.
What Industries Use Modular Cleanrooms?
These days, modular cleanrooms are used in just about every place that traditional cleanrooms are. Here are some of their most common applications:
- Pharmaceutical manufacturing and packaging: Creating sterile environments is important for a lot of drug manufacturing, as well as compounding facilities. Modular cleanrooms help pharma companies and pharmacies build compliant spaces.
- Medical device production: Devices that are implanted or go near the body must stay clean, and modular cleanrooms are used in many parts of their manufacturing process.
- Aerospace and defense: Small particles can cause important aerospace and defense equipment malfunctions, so they are used to create low-particle spaces for many manufacturing stages.
- Semiconductor and electronics: Semiconductors and electronics in general require some of the strictest environments; modular cleanrooms can be used in some of the strictest applications, and they can also scale with production.
- Biotechnology: Labs and other production spaces in biotech use modular cleanrooms to meet strict regulations and standards.
- Food and beverage processing: Last but not least, modular cleanrooms help the food & beverage industry keep out viable particles that may affect consumers.
The Two Main Types of Modular Cleanrooms
Given the huge variety of customization choices for modular cleanrooms, it can seem like there are many different types. However, each application usually falls within one of two kinds.
Hardwall Modular Cleanrooms
Hardwall panels are rigid, and are usually what one imagines when they hear “modular cleanrooms.” They are a fully enclosed space, often in a post-and-panel system (but not always). They’re great for ISO 5 to ISO 8 environments, and for any application that may need a more permanent or strict space.
Softwall Modular Cleanrooms
Softwall cleanrooms, on the other hand, are just what they sound like. They typically have vinyl curtains that form the soft “walls” of the cleanroom, so to speak, and these are hung from a rigid metal frame. Softwall cleanrooms usually cost less and are easier to set up; they can also be put on casters for easy relocation. They’re usually not used for the strictest spaces, but they are great for ISO 7 or ISO 8 applications.
Design and Customization Options
Furthermore, modular cleanrooms can come in many different systems, with various finishes, materials, and other design features. In fact, this is one of the major benefits of modular: that they can be highly customized. Here are a few common design and customization options that can be added:
- HVAC and HEPA/ULPA filtration systems
- Pressure control
- Wall and ceiling materials
- Flooring and coatings
- Lighting and electrical
- Air showers
- Pass-through chambers
- Fire suppression systems
- Environmental monitoring systems
- Custom windows and doors
At Allied Modular, we’ll help you choose the right features for your process and budget.
The Bottom Line
Modular cleanrooms can give you the same compliance as traditional cleanrooms, but with lower costs, more customization choices, and more flexibility. If you need a clean space that can adapt with your business, modular is by far the best choice.
Interested in setting up modular cleanrooms at your facility? Reach out to the experts at Allied Modular for a quote on new spaces today:
FAQs About Modular Cleanrooms
1. How much do they cost?
Given the variability of sizes, requirements, and features, it’s hard to say with certainty how much a modular cleanroom will cost. Some manufacturers estimate that it can be anywhere from $100 to $1,000 per square foot, but of course a lot depends on how you customize it.
2. Are they reusable if our business moves to a new location?
Yes, they are reusable. If your business moves to a new location, your cleanroom can be disassembled and installed there. Obviously, this is a major advantage of modular spaces.
3. Can they integrate with existing HVAC or building systems?
Yes, they can be designed to either operate with independent HVAC systems or fit into your building’s existing systems, depending on what your space allows, what your cleanroom classification requires, etc.
