Brewery Cleanrooms

A Brewerys cleanroom is a regulated environment that maintains a strictly low level of aerosol particles, airborne microbes, and chemical vapours. The cleanroom is used to filter polluted air as per the requirements of certain industries such as pharmaceuticals, E-liquids, healthcare facilities, as well as science and technology.

There are many types of contaminants that can harm the processes of research and production. Some of these include fibrous materials, aerosol particles, microorganisms, and chemical vapours among many others. Our Brewerys Modular Cleanrooms are developed to meet the required standard of the international organisation for standardisation (ISO) 14644-1: 2015.

Brewerys Modular Cleanrooms that fall within the standard of the ISO 14644-1:2015 are differentiated by classifications of class 1-9. Cleanrooms can vary between different classifications when the size and level of air particulates change. A Cleanroom with the greatest classification (class 1) will be tested for the smallest particulate sizes and lowest frequency whereas the minimum classification of Cleanroom (Class 9) will have a much higher frequency and larger sized range of air particulates entering the clean air space.

The test method in which these Brewerys Modular Cleanrooms are classified is by use of particle counters, which measures the Particles Per Cubic Metre (PPCMM) by size and quantity. For ISO Class 9 Cleanrooms, the removal of air pollutants of sizes >5 microns are analysed for in an environment that is typically equivalent to the air of suburbs.

Smaller air particulates of sizes >0.2 and >0.1 microns are focused on with Class 1 Cleanrooms, which results in a much cleaner environment. An example of this testing requirement is as follows.

A Modular Cleanroom that falls in Class 7 will be tested for the presence of an air particulate size of >0.5 microns where the highest particle count should be capped at 352,000. The Brewerys Cleanroom will have to be modified and re-evaluated if it goes over the required particle count and size to qualify for the classification.

Contamination-free manufacturing

Brewerys Modular Cleanrooms achieve the clean air quality by use of air filtration HEPA/ULPA technology. These technologies have undergone research evaluations to prove that they effectively reduce the quantity and size of air contaminants entering a cleanroom. Non-filtered air passes through Filter Fan Units (FFUs) creating a positive pressure area inside the cleanroom. It is this positive pressure that sustains the clean air conditions preventing the backflow of contaminated air into the Clean air space through exhaust openings.

The type of Brewerys Cleanroom mentioned earlier sees to contamination-free production because only air that goes through the filtration unit is allowed to enter the internal area.

Modular Cleanroom Benefits

  • Modular Construction
  • Quick Assembly Time
  • Versatility
  • Reconfiguration
  • Airflow Control
  • Inexpensive Modifications

With a Brewerys Cleanroom solution, there’s a low likelihood of product contamination and this is the first stage of securing a pollution-free production area. Putting clean air policies in place that will ensure particulates are not brought in by personnel working in the cleanroom is the next step in developing a clean production environment. One way to achieve this involves utilizing Cleanroom PPE such as overshoes, hair nets and gowning. Fibres and other potential pollutants entering the cleanroom will be further reduced as a result, allowing production and research to go on without interference. Those operating in the Brewerys Cleanroom must undergo contamination reduction trainings to avoid the introduction of pollutants in the clean air space.

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
  • Validation

TCA and Pharmaceuticals industry

At TCA, we leverage our experience that has spanned over three decades, as well as our talented engineers to deliver the best Brewerys Modular Cleanrooms available. Our products are built with high quality and are designed to be reliable and durable. Our project managers supervise the planning, construction, and validation of our products from start to finish to ensure our customers are satisfied. We control the design process and installation allowing us to be one of the most competitive Cleanroom solutions around, boasting our high quality and approachable service.

With the sophisticated systems that we provide, including Ultra-bright LED panelling, Engineering Grade aluminium and silent high-efficiency Fan Filter Units, your productivity will be enhanced. You can be assured and have peace of mind in our solutions as you’ll receive a five-year warranty.

Industry requirements

Cleanrooms are a critical part of the research and production processes in certain industries to ensure contamination-free production.

A Cleanroom is essential for a controlled air space reducing the incidence of particulate contamination via air filtration. Food production, semiconductor production, science and technology, medical devices manufacturing, as well as electronics production are some of the industries where Cleanrooms are used.

With TCA delivering your Cleanrooms, rest assured you’ll be getting what meets the highest standards for your needs. Further guidance can be provided if you need assistance with choosing the right standard of Brewerys Cleanroom for your industry.

Our Brewerys Modular Cleanrooms are constructed to meet the standards of the ISO 14644-1: 2015. These Cleanrooms range between ISO 1 and 9 classifications. The size and quantity of air particulates in a Cleanroom will determine the class it belongs to. ISO 1 Cleanrooms, which are the highest classification, are valued based on having the least number and sizes of particulates while the lowest class (ISO 9), will be evaluated based on the larger quantities and a higher presence of air particulates in the enclosed space.

Particle counters are used to determine the classification of Brewerys Modular Cleanrooms by assessing their Particles Per Cubic Metre (PPCM). Each Particle counter measures airborne particulates by size and also quantity. More cleaner air environments are realised with ISO 1 cleanrooms because they focus on the removal of the smallest air particulate sizes >0.1 microns and >0.2 microns while ISO 9 Brewerys Modular Cleanrooms are only dedicated to the elimination of larger air particulates >5 microns.

Containment solutions

When certain unhealthy substances are to be prevented from making it into the external atmosphere from the cleanroom, containment solutions are required. These solutions can be put in place to enable the Brewerys Modular Cleanrooms protect the external environment from harmful materials by extracting and containing internally generated substances through the use of HEPA, ULPA, or Carbon filters whilst protecting the production area by introducing only filtered air. With our help at TCA, you can have containment solutions installed in your modular cleanroom that will see to the prevention of hazardous substances entering the outside air, keeping you out of the crosshairs of regulators.

Containment solutions can differ due to the fact that hazardous materials are different from each other based on quantity and use of each cleanroom. This indicates that containment level can vary from customer to customer. We will always work closely with you to provide a system that ideally suits your needs.

Airflow and Filtration

Our Cleanrooms are designed to be compliant to the specified ISO 14644-1:2015 grading. With this in mind, we take into consideration the level of air filtration required and the end function of the cleanroom. The level of air filtration required is determined by the air changes per hour (ACH), this determines how many Filter Fan Units are to be used in the cleanroom. What we also determine by the strategic positioning of the FFUs and exhausts is the flow of air around the cleanroom. This can mean the difference between a uni-directional (laminar flow) and a non-unidirectional (turbulent flow) airflow around a cleanroom, potentially leading to a contaminated product. With this in mind, we can greatly increase the number of ACH and control the air flow within the cleanroom.

Filtration of air is controlled by our ultra-quiet, high-efficiency filtration modules. These filtration modules automatically compensate for a build-up of dust and other materials that occur over time within a HEPA/ULPA filter increasing the fan speed to reach the set flow rate. This increases the life of the filter, reducing cost overtime for the end user.

Cleanrooms Customised to Your Needs

At TCA there is no such thing as a standard modular cleanroom. Each Cleanroom we design is made to fit your unique work conditions and is designed with your needs in mind. We make each modular Cleanroom to order and make you part of the design process.

With TCA you have the option of doing almost anything with a cleanroom design. This means that your Cleanroom can be many shapes and sizes fitting the most obscure of rooms and can have a range of finishes. We have yet to find a design that we could not accommodate.

Our customisable options mean that all components of the Cleanroom such as doors, windows, lighting, ceilings and filtrations can be altered to better suit your needs. You also have the option of installing furniture, air showers, pass through chambers, fire suppression, air-conditioning and much, much more. We pride ourselves in being able to meet design requests however unique in shape and size they may be.

phillip.godden
Phillip Godden

Phillip Godden is the Founder & Chief/Executive Officer at Total Clean Air.

Working Hours

  • Monday 08:00 - 19:30
  • Tuesday 08:00 - 19:30
  • Wednesday 08:00 - 19:30
  • Thursday 08:00 - 19:30
  • Friday 08:00 - 19:30
  • Saturday 08:00 - 19:30
  • Sunday 08:00 - 19:30