Hardwall Cleanroom

A Hardwall cleanroom is an enclosed zone where airborne particulates and pollutants are maintained at specific levels. 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. We build Hardwall Modular Cleanrooms that are compliant to the international organisation for standardisation (ISO) 14644-1: 2015.

The ISO 14644-1:2015 standard of Hardwall Modular Cleanrooms are classified into different categories, from class 1 to 9. The classification of each Cleanroom changes dependent on size and prevalence of the air particulates in the cleanroom. Cleanrooms that fall in Class 1 (which is the greatest in the classification) are tested for the smallest air pollutant size and lowest frequency while Class 9 cleanrooms are tested for a larger air particulate size range and higher frequency.

Particle counters are employed as the test method for classifying Hardwall Modular Cleanrooms. This method measures the size and quantity of particles using the Particles Per Cubic Metre (PPCMM) unit. The Particles Per Cubic Metre of an (ISO) 14644-1: 2015 Class 9 Modular Cleanroom corresponds to normal atmospheric air with contaminants >5 microns not allowed into the environment.

With Class 1 Cleanrooms, the removal of much smaller air contaminants of sizes >0.1 and >0.2 microns are accounted for, which makes the enclosed air space cleaner than other classes. The following is an example of this standard of testing.

Class 7 Hardwall Modular Cleanrooms go through valuations that check for an air particulate size of >0.5 microns and a particulate count that shouldn’t exceed 352,000. The Hardwall Cleanroom will have to be modified and re-evaluated if it goes over the required particle count and size to qualify for the classification.

Production in a contamination-free environment

The use of HEPA/ULPA filtering technology is employed to achieve the level of clean air quality in Hardwall Modular Cleanrooms. The use of these filters have passed scientific evaluation and are proven to keep out certain amounts and sizes of air particulates from a cleanroom. Non-filtered air passes through Filter Fan Units (FFUs) creating a positive pressure area inside the cleanroom. This positive pressure helps maintain the controlled level of clean air by preventing contaminated air from entering back into the cleanroom through perforated openings.

The type of Hardwall Cleanroom aforementioned assures that only air that has passed through the filtration unit enters the internal area allowing for contamination-free production.

Modular Cleanroom Benefits

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

With a Hardwall 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. Thus decreasing the number of potential contaminants that would otherwise infiltrate the Hardwall Cleanroom and disrupt production. Hardwall Cleanroom operators must undergo training in the reduction of contamination to prevent the introduction of microbial/foreign materials in to the production area.

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

Pharmaceuticals sector and TCA

TCA is committed to installing world-class Hardwall Modular Cleanrooms for the Hardwall industry, leveraging our talented engineers and over thirty years of expertise. Our Hardwall Modular Cleanrooms have a long track record of possessing outstanding build-quality, reliability, and durability. At TCA, every project installation process, from design to validation, is controlled by our managers to ensure the best results. 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.

From Engineering Grade aluminium and Ultra quiet high-efficiency Fan Filter Units to system monitoring and ultra-bright LED panelling, TCA finds fulfilment in offering the best and latest technology to help see your production grow. You can be assured and have peace of mind in our solutions as you’ll receive a five-year warranty.

Industry requirements

The use of a Cleanroom is crucial for any industry that requires their processes to have a reduced particulate occurrence to avoid the microbial spoiling and/or contamination of goods.

The need for a controlled air space makes the Cleanroom all the more essential as it mitigates the reduction of particulates through air filtration. Cleanrooms are used in industries such as food production, research, medical devices, electronics, production, Science and Technology, semiconductors and more.

At TCA, we are here to make sure you invest in the most suitable design for your application purposes. We can provide guidance concerning ideal Hardwall Cleanroom standards for you if you’re unsure about anything.

We only provide Hardwall Modular Cleanrooms that meet the ISO 14644-1: 2015 standard. These Cleanrooms range between ISO 1 and 9 classifications. Cleanrooms are put into different class according to the number and size of contaminants in the clean air area. To be categorised in the greatest classification (ISO 1), a Cleanroom will be tested for the smallest air pollutant size while Class 9 cleanrooms are tested for larger air particulate sizes and higher quantities.

The Cleanroom validation test method in which these Cleanrooms are classified is by use of particle counters, measuring the Particles Per Cubic Metre (PPCM). The use of particle counters accounts for the number and size of air particulates. ISO 1 rated cleanrooms are evaluated for the extraction of small air particulates >0.1 microns and >0.2 microns whereas an ISO 9 cleanroom, which has a similar PPCM to suburban air, will be tested for the removal of larger air contaminants >5 microns.

Containment solutions

Containment solutions are important in situations where dangerous air particulates that emanate from the production process need to be prevented from contaminating the outside air. Hardwall Modular Cleanrooms can be made to keep production safe by introducing contamination-free air into the work space and contain hazardous materials that come about during production through the use of ULPA, HEPA, or Carbon filters. 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.

Each containment solution we provide is unique as not two hazardous materials are the same and vary on quantities dependent on the use. This implies that every customer may require a different containment solution for their needs. We’ll cooperate with you to figure out the right containment plan for you.

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