Top 10 Cleanroom Design Mistakes and How to Avoid Them!

Incorrect Air Conditioning

One of the most common mistakes in cleanroom design is incorrect air conditioning. Cleanrooms generate a lot of heat, so they need a dedicated air conditioning system. If you don’t plan for the heat from equipment, lights, and people, the cleanroom will get too hot and uncomfortable.

To avoid this, make sure to include all heat sources when sizing the air conditioning system. This includes the heat from process equipment, exhaust, lighting, HEPA fan filter units, and personnel. Cleanrooms with higher occupancy and more equipment need more air changes to keep the air quality high.

For the best results, consider working with a local AC contractor to connect the cleanroom’s recirculation system to a central air unit that meets cooling needs and local codes. Also, install exhaust ducts and ventilation fans to vent heat outside the facility. This will help keep the cleanroom cool and efficient.

Small Gown Rooms

A common mistake in cleanroom design is having a gown room that’s too small. Everyone entering and exiting the cleanroom uses the gown room to put on and take off cleanroom garments. If the gown room is not big enough, people will have to wait in line, wasting time and causing frustration.

To avoid this, make sure your gown room is spacious enough to handle the flow of personnel. Here are some tips:

• Plan for the maximum number of people who will use the gown room at the same time.
• Ensure there is enough space for people to move around without bumping into each other.
• Store PPE in designated areas within the cleanroom and avoid touching or adjusting it unnecessarily.

A well-designed gown room can improve efficiency and keep workers happy. Don’t underestimate its importance in your cleanroom design.

Insufficient Large Doors

When designing a cleanroom, one common mistake is not having large enough doors to bring in equipment. Most cleanrooms hold large pieces of equipment that must be brought inside. If the doors are too small, it can be a big problem. While modular cleanrooms allow panels to be removed to create temporary openings, it takes a couple of hours to remove the panels. This can slow down your work and make things harder than they need to be.

To avoid this issue, make sure to know the size of the equipment that will be going into the cleanroom. Design doors that are large enough to bring them in easily. Here are some tips to consider:

• Measure the largest piece of equipment that will need to go through the door.
• Add extra space to the door size to account for any future equipment that might be even larger.
• Consider using sliding doors instead of hinged ones to save space and avoid issues with negative pressure gradients.

Proper planning for door size can save you a lot of trouble and keep your cleanroom running smoothly.

Remember, having the right door size is crucial for maintaining cleanroom standards and avoiding unnecessary delays.

Lack of Windows

Cleanroom windows are essential for several reasons. They allow management to easily oversee worker activity without needing to enter the cleanroom, which can save time and reduce contamination risks. Additionally, windows can help alleviate the feeling of being trapped, which is common when working in a cleanroom all day. This can improve worker morale and productivity.

Moreover, windows can be a great tool for giving tours of the cleanroom. Visitors can see the operations without having to put on special clothing, making the process more efficient and less disruptive.

Adding floor-to-ceiling windows can also give the cleanroom a high-tech look, which can be beneficial for marketing and branding purposes.

When planning your cleanroom, it’s important to consider the number, size, and location of windows. This will ensure that you get the most benefit from them.

Forgetting Material Pass-Throughs

Forgetting to include material pass-throughs in your cleanroom design can lead to significant issues. Planning how you will bring material into the cleanroom is an important part of most cleanroom designs. Without proper pass-throughs, you might end up using your gown room for material transfer, which is not ideal. Gown rooms are not designed for efficient material transfer and can introduce more contamination where cleanroom garments are stored.

Material pass-throughs come in various sizes and designs depending on their intended use. They can be actively ventilated or purely passive. It’s crucial to integrate them into cleanroom walls so they are flush with the clean side for better clean ability.

A common solution to machinery contamination in a cleanroom is to build a cleanroom within a cleanroom using partitions or curtains, to isolate the machine.

When planning your cleanroom, consider the size and volume of material that will be brought in and out. This will help you choose the right type of pass-through for your needs.

Low Ceilings

One of the most common mistakes in cleanroom design is having low ceilings. It’s crucial to consider all the equipment that will be used in the cleanroom. Many machines, like mixing machines, need extra space above them for top-mounted motors or raised platforms. Some semiconductor equipment also requires additional clearance due to their bell jar design, which lifts upward for operation.

Increasing the ceiling height of a cleanroom after it’s built is both complicated and expensive. Therefore, it’s essential to choose the right height from the start. A taller cleanroom might not be significantly more costly but can be critical when you purchase new equipment in the future.

Remember, cleanrooms are tall. Typically, there is a 2-foot high plenum above the cleanroom ceiling that holds HEPA fan filter units, lights, electrical cabling, and sprinkler pipes. This means that for a cleanroom with a 10-foot internal ceiling, the top of the deck will be more than 12 feet high.

To avoid this mistake, always plan for the future and ensure your cleanroom has adequate ceiling height from the beginning.

Undersized Cleanroom

One of the most common mistakes in cleanroom design is creating a space that is too small. Designing your cleanroom to fit only your current equipment can lead to problems down the road. You might need to add more equipment, rearrange existing setups, or introduce new processes. Planning for a cleanroom that is 10-20% larger than your current needs can help you avoid these issues and delay the need for expansion.

• Future-proof your cleanroom by considering potential growth.
• Avoid the hassle of frequent expansions by planning ahead.
• Ensure flexibility for new processes and equipment.

A cleanroom that is too small can quickly become crowded and inefficient, hampering productivity and cleanliness.

Incorrect Cleanroom Grade

Choosing the wrong cleanroom grade can lead to serious problems. It’s crucial to match the cleanroom grade to the processes it will support. If the grade is too high, you might overspend on unnecessary features. If it’s too low, the cleanroom won’t meet the required standards for future processes.

To avoid this mistake, follow these steps:

1. Consult with all stakeholders to understand the specific needs.
2. Research the industry standards for your processes.
3. Plan for potential future uses of the cleanroom.

Always ensure the cleanroom grade is neither over-specified nor under-specified. This balance is key to a functional and cost-effective cleanroom.

Protrusions into the Cleanroom

Protrusions into the cleanroom can disrupt the smooth surfaces that are essential for maintaining cleanliness. Eliminate as many as you can to ensure a more effective cleanroom environment. Common offenders include:

• Lights
• Smoke detectors (they won’t work anyway, get rid of them)
• Power points

These items can create areas where dust and other contaminants can gather, making it harder to keep the cleanroom sterile. By removing these protrusions, you can maintain a higher level of cleanliness and compliance.

Poor Planning for Future Expansion

When designing a cleanroom, it’s crucial to think ahead. Failing to plan for future growth can lead to costly modifications and disruptions. Here are some key points to consider:

• Design your cleanroom 10-20% larger than your current needs. This extra space can accommodate new equipment or processes without immediate expansion.
• Ensure that installations are cleanroom-compliant from the start. Non-compliant installations may need to be dismantled and reinstalled, leading to additional costs and delays.
• Coordinate with all stakeholders early in the process to avoid rework and rescheduling.

Planning is everything. Avoiding mistakes in cleanroom construction can save time and money in the long run.

Conclusion

Designing a cleanroom is a complex task, but avoiding common mistakes can make the process smoother and more successful. By paying attention to details like proper air conditioning, adequate space, and the right materials, you can create a cleanroom that meets your needs now and in the future. Remember, planning ahead and consulting with experts can save you time and money in the long run. Keep these tips in mind, and you’ll be well on your way to a cleanroom that works perfectly for you.

Frequently Asked Questions

What is the importance of correct air conditioning in a cleanroom?
Proper air conditioning in a cleanroom is crucial because it helps maintain the required temperature and humidity levels. This ensures that the environment remains stable and reduces the chances of contamination.

Why should gown rooms be spacious?
Gown rooms need to be spacious to allow staff to comfortably change into cleanroom attire without bumping into each other. This prevents contamination and makes the process more efficient.

Why are large doors necessary in a cleanroom?
Large doors are essential for moving equipment and materials in and out of the cleanroom easily. Without them, you might struggle to bring in new machinery or remove old equipment, disrupting operations.

How does having windows in a cleanroom help?
Windows in a cleanroom allow for natural light, which can improve the morale and productivity of the staff. They also enable supervisors to monitor activities inside without entering and risking contamination.

What are material transfer hatches and why are they important?
Material transfer hatches are small compartments that allow materials to be transferred in and out of the cleanroom without opening the main door. This minimises the risk of contamination and maintains the cleanroom’s integrity.

Why should you plan for future expansion when designing a cleanroom?
Planning for future expansion is important because your needs may grow over time. Designing a cleanroom with extra space can save you time and money in the long run, as you won’t need to reconstruct or expand the facility later.