Cleanrooms are highly controlled environments where the air quality is monitored to ensure the stringent standards of cleanliness required for the manufacture of pharmaceutical, electronic and healthcare goods are met. These stringent standards require high fresh air rates, extensive filtering, temperature, and humidity control.
Cleanrooms are designed to different class specifications depending on the sensitivity levels of the production process. The higher the class in cleanroom the more stringent the demands on air quality become and therefore the need for improved air filtration increases.
To ensure that a cleanroom is capable of reaching the required cleanliness levels, it is important that the air supplied into the cleanroom is filtered using filters that conform to and are certified by the standards governing high efficiency air filters. These standards not only set out the efficiency standards that are demanded from these air filters but they also set out the testing methods required to classify these filters into their categories.
Your cleanroom filtration system is an integral part of your cleanroom, regardless of whether it is a softwall, hardwall,modular, monobloc or rigid wall cleanroom. The filtration system is essentially what keeps your cleanroom clean.
At Total Clean Air, our goal is to assist our clients in protecting their critical environments through innovative cleanroom designs. One of the components we use to accomplish this is pneumatic filters. We install and maintain pneumatic filters of different types so as to ensure that your secure environment meets the high standards required of a cleanroom.
Modular Cleanroom Benefits
- Modular Construction
- Quick Assembly Time
- Airflow Control
- Inexpensive Modifications
Pneumatic filters are instruments that contribute to maintaining the integrity of cleanroom environments by extracting contaminants from the compressed air stream but, still allowing air to pass through. Cleanrooms typically make use of different levels of filtration. These are utilised in a filter-regulator-lubricator form factor with the various filter housings interlinked.
At Total Clean Air, we offer different types of filters in sizes that will fit your cleanroom needs. HEPA and ULPA filters are the names given to the different groups of high efficiency filters. They are used to constantly recirculate the air inside a cleanroom, with external air which is introduced into the room also going through a filtering process to remove dust.
The average commercial pneumatic filter is capable of extracting particles from the air that are as tiny as 5 micrometres. This process of filtering maintains the pneumatic devices and protects them from damage which typical contaminants cause. Dirt particles, lubricant particles ejected by the compressor, aerosols or small water droplets are just some of the contaminants extracted from the air by a primary filter.
Secondary filters can extract contaminants as small as 50 nanometres in size from the air stream. These contaminants or particles include odours, vapour, fumes, mist, oil and moisture as well as tiny particles. Secondary filters can be supported by membrane air dryers. Membrane air dryers are “point-of-use” air drying devices which are used to depress the pressure dew point. This is accomplished by removing water vapour selectively from the compressed air stream. This occurs as the compressed air stream flows through the hollows inside narrow membrane fibres.
However, membrane air dryers can be easily damaged when they come into contact with water, oil, or similar liquid droplets. They therefore need to be protected with a top quality coalescing air filter installed within or immediately upstream from the membrane air dryer housing.
The applications of air filtration devices are diverse and can be used in many cleanroom environments, including specialised scientific research, food processing, and industrial production such as manufacturing of pharmaceuticals or microprocessors.
Cleanroom Design, Build & Validation
- Budgeting and planning
- Engineering, design & layout
- Airflow and filtration design
- Construction and Installation
- Full Certification of our product
- Industry-specific equipment installation
HEPA and ULPA Filters
HEPA (high-efficiency particulate air) filters are the most popular option in terms of filter choices. They filter out 99.99% of particles 0.3µm or larger. When maintained properly and in the right environment, these filters can last for 7 years or more before they have to be replaced.
Since every factor in your cleanroom can affect filters differently, it is hard to give a specific time frame for HEPA filter replacement. The temperature, humidity, and air pressure levels all factor into your HEPA filter’s lifetime. So, it is important that you have your filter leak tested at least once every two years. If significant leaks are found, sometimes they can be repaired, and sometimes, you may have to replace the filter altogether.
Ultra- low particulate air filters function in a similar fashion to HEPA filters, but are even more efficient. Specifically, ULPA filters are rated to remove 99.999% of all contaminants larger than 0.12µm in diameter. Since ULPA filters function similarly to HEPA filters, the maintenance and replacement processes are similar. The difference is that ULPA filters are more expensive than HEPA filters, making your maintenance plan more important.
At Total Clean Air, we install, manage and repair HEPA and ULPA filters of standard quality. We run tests to ensure the filters are working efficiently, and if during the test, the filter is found to be below specified efficiency standards, Total Clean Air engineers will to replace the filter media onsite.
Modular Cleanroom Services
- Design & Build
- Free Site Survey
- Free Design Service
- Cleanroom Planning
- Construction and Installation
- CNC Engineered
- Training & Support
- Discounted Service Contracts
- Remedial Works
- Panel Repairs
- BMS Management
- Cleanroom Certification
- Differential Pressure Qualification
- Servicing Testing Validation
- Smoke Testing
- DOP Testing
DOP Testing to Keep Your Pneumatic Filter at Optimal Performance
When it comes to cleanroom environments, air cleanliness is typically measured by using a particle counter to take count of airborne particles. A smaller particle amount means cleaner air which in turn points to a higher class cleanroom. A pneumatic filter can help achieve this.
Filter integrity testing or Dispersed Oil Particulate (DOP) testing is a form of assessment that is used to verify the integrity and performance of an installed Ultra Low Penetration Air (ULPA) filter or a High Efficiency Particle Air (HEPA) filter. The testing involves constantly introducing particulates to the ULPA and/or HEPA filter and measuring the output.
During the test, oil is dispersed into the upstream flow of the filter media as an aerosol. The amount of particles occurring in the downstream flow will then be measured with the aid of a calibrated photometer.
ULPA filters are tested to 99.9995 percent on 0.12 micron efficiency while HEPA filters are tested to 99.99 percent on 0.3 micron efficacy. The whole filter face will be assessed during the DOP test to verify if there is a leak or other damage that could compromise the integrity of a cleanroom environment.
If a filter is not functioning optimally, there is the risk of a secure environment being breached, leading to contamination which disrupts critical processes and product quality. At Total Clean Air, our effective services will minimise your cleanroom downtime and ensure that you can resume operations within the shortest time possible.
The High Standards of Air Filtration We Use in Our Cleanrooms
Cleanrooms are required to be very sterile environments and require a high level of air quality. Particulate and molecular contamination control is crucial since the tiniest micron of dust or gas molecules can cause damage. At Total Clean Air, we offer a wide range of HEPA air filters and air filtration systems for a variety of contamination control applications and modular, hardwall and softwall cleanroom environments.
Our cleanroom specialists will create and design an air filtration system with premium HEPA filters and effective air filtration systems to ensure that your cleanroom operates with the most advanced equipment available. When using this system, particles and bacteria are charged due to ion flux inside an ionizing field where some of the bacteria are killed upon entry into the grid. The charged particles and bacteria are efficiently filtered up to 1000 times more effectively than conventional filters with the same pressure drop and flow rate. Bacteria caught on the filter are killed by a continuous dose of ionizing radiation.
This filter system is rated at 99.999999+% DOP, providing virtually particle free air in the cleanroom. In addition, this filter has enough power to allow for double HEPA filtration air recirculation. Contamination control depends on a reliable filter system. A malfunctioning filter can introduce contaminants into a controlled environment. Filters need to remove impurities from the process stream but avoid transferring impurities that could then be found a device or product’s surface. The filters themselves must be manufactured and packaged in a controlled environment.
Maintaining the integrity of a secure environment to ensure continued effective performance of a cleanroom will require validations to be performed at process-dependent intervals. This will prove the cleanroom environment is in compliance with ISO 14644-1:2015 which covers the classification of air cleanliness according to particle concentration.
- ISO 4-9
- ISO 14644
- Low Power Consumption
- Environmentally Friendly
- HEPA Filters
- Air Filtration
- Fan Filter Units
- Cleanroom Ceiling System
- Temperature Control
- Access Control
- Inter Lock Door Systems
- Air Showers
- Unidirectional Airflow
- Desiccator Cabinets
- Horizontal Flow Wall Modules
- Horizontal Laminar Flow Clean Benches
- Laminar flow cabinets
- Laminar Flow Canopy
Contact Us for Pneumatic Filter Installation or Maintenance
At Total Clean Air, your contamination control requirements are our priority. Our proven expertise, CTCB certified engineers and ISO classified controlled environments are available to protect your critical processes and add value to your operations. We install filters such as pneumatic filters to ensure air integrity.
Your cleanroom is necessary for the protection of your critical processes and environments. We can help ensure this by providing pneumatic filter installation and maintenance that guarantees filter integrity and efficiency. Our services are ISO 14001, ISO 9001 and OHSAS 18001 accredited.