Designing a manufacturing cleanroom is a critical step in ensuring the company’s output consistently meets targets without major quality issues. Being thoughtful about the room’s design can reduce problems like static and particulate matter contamination that could otherwise harm products.
Set minimum standards
In industries such as food production and pharmaceuticals, cleanrooms must meet certain regulatory requirements regarding particle sizes and counts, as well as how often the area gets tested for those contaminants. However, in sectors like electronics manufacturing, it’s more common to set internal standards based on the leadership’s desire for improved quality control.
Once you’ve decided on the parameters for the cleanroom’s environment, it’ll be easier to plan specifics such as which filtration systems will give those outcomes. For example, different ISO cleanroom ratings require a varying number of air changes per hour.
An air change is when the room’s total air volume gets removed and replaced. The standards you set for the cleanroom will also dictate aspects like the amount of coverage provided by ceiling filters.
As the number of air changes per hour rises, the room’s particle count will go down. However, more frequent air changes will also increase initial project costs and expenses associated with running the facility. These are important considerations that are best ironed out in the project’s early stages.
Create a floor plan
Drawing a floor plan of the manufacturing cleanroom will give all involved parties a visual aid that ensures everyone is on the same page and understands the specifics needed to make the project successful.
Start by defining the length, width, and height of the various required spaces within the cleanroom. Then, note the window details, such as the distance between them, what shape they’ll be, their size, and whether they’ll be flush-mounted or semi-flush with a gasket design. Although the former style is usually more expensive, some people prefer it for its sleeker appearance.
Make sure the floor plan contains details about the doors, including the airlock systems, which prevent the air from two separate spaces of different cleanliness levels from mixing. Choose corrosion-resistant materials with stainless-steel side frames and shrouds. That approach means the doors will tolerate frequent cleaning and resist microbial and fungal growth. Look for options without exposed coils and fasteners when possible. Those are more difficult to clean and could harbor bacteria.
Don’t overlook things like pass-through necessities for material handling and the locations of things like sinks. These items discussed here do not comprise a comprehensive floor plan but should get you thinking about what to include.
Plan mitigation measures for contamination sources
Designing an effective manufacturing cleanroom means understanding how contamination happens. Only then can people who are part of the design team take the right measures to minimize those sources.
Surfaces and cleaning methods
Being thoughtful about the materials of all surfaces, including flooring, will help you have productive discussions about what cleaning methods are best. One option is to use an electrostatic sprayer. These encourage particle adherence with electrostatic electricity, which ionizes airflow and allows particulate matter to get pulled to the surface for easier cleaning.
Employee-related safeguards
Workers are among the biggest contamination sources. However, you can lessen their effects by including a gowning area in your manufacturing cleanroom. Leave enough room outside of that area for employee lockers to store things like watches and jewelry. When planning the hand-washing area, include enough wall space to accommodate electric dryers with HEPA filters.
Furniture
The furniture can also be a significant contamination source, especially due to particle shedding or materials that are inappropriate for cleanroom use. Evaluate furniture options only after creating the standard operating procedures for cleaning and sterilization in the facility. That way, you can make sure the chosen furniture will tolerate those techniques.
Although 304-grade stainless steel was once a popular choice, 316-grade stainless is becoming more frequently selected. That’s because 304-grade steel can degrade due to chloride corrosion.
Static electricity
If the manufacturing cleanroom is to produce items sensitive to static electricity, ensure the design cuts that risk. One option is to install either dissipative or conductive anti-static flooring, which you’ll find in varying resistance levels. Similarly, anti-static wall panels can both control discharge and minimize particle shedding, depending on the type chosen.
You may even want to include room for an air shower in your cleanroom’s design. Air showers utilize high-pressure, filtered air to remove dust and other contaminants. If the air shower includes an ionizer, it can be an effective option for reducing, though not eliminating, static electricity.
Design with a long-term viewpoint
Throughout all phases of designing a manufacturing cleanroom, explore what you could do so the facility meets your immediate needs, as well as future requirements. Having that mindset is of exceptionally high importance if you’re part of a factory aiming to bring more semiconductor manufacturing to the United States.
Some statistics indicate it could cost up to 50% more to construct and operate a semiconductor fabrication facility in the United States versus China. Granted, a cleanroom is only one aspect of such a factory. But if it’s one in your sphere of influence, that’s all the motivation you need to do everything in your power to make the cleanroom an effective part of a profitable and productive facility.
Do you anticipate hiring a substantial number of new employees within the next several years to cope with growth? If so, that may be enough justification to make the cleanroom larger than you need now so it’s ready for more workers later.
Thinking about longevity also means exploring how you might pay more for extra-durable, cleanroom-appropriate floors and furniture. That investment could pay off in the long run.
Understand the value of professional input
Perhaps you’ve spent years engineering semiconductors and other electronic components but have not had direct experience designing cleanrooms. Alternatively, maybe you have built a cleanroom in the past but want to ensure all the bases are covered. These are instances when it could be wise to consult with someone who specializes in cleanroom design.
Use their recommendations along with this guide and make sure to thoroughly discuss any specific requirements of your company. Doing so will increase the likelihood that you and other stakeholders will be happy with the results and should reduce the chances of costly mistakes or oversights.
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