With innovation driving the micro manufacturing sector forward at a high speed, organisations are under pressure to ensure that their production facilities can cope with the fast growth and demand for mass production when a product is successfully launched on the market.
Over the years, modular cleanrooms have become the preferred way of achieving an ISO 14644-1 classified environment for many organisations within the micro manufacturing sector. From the small start up to blue-chip companies, the modular cleanrooms versatility is proving to be a hit and its popularity is showing no sign of slowing down.
Whilst high-investment, static, traditional build cleanrooms offer a solution to some; for others a more flexible, rapid response, modular cleanroom unit may offer a better solution and enable them to meet the requirements of individual contracts, production variations, building constraints, budgets and time restrictions, giving them a competitive advantage.
Below, modular cleanroom manufacturer, Connect 2 Cleanrooms, detail how the modular construction of their bespoke cleanrooms allowed two micro-manufacturing companies to make smart investments in their clean-air environments.
Quantum dot manufacturer, Nanoco, were able to maintain the investment made in their original cleanroom facilities, despite outgrowing them. Whereas German ophthalmic device manufacturer, MORCHER®, have made the move from traditional build to modular cleanroom; appreciating the flexibility offered by the modular approach.
Nanoco develop applications incorporating semiconductor nanoparticles, known in the industry as ‘quantum dots’. They have expanded from a university spin-out to a global company, partnering major R&D and blue-chip industrial organisations, from the UK to the Far-East.
Nanoco simulate their client’s production environment, to allow accurate prototype development for semiconductor device applications. A clean-air environment is key to this, so back in 2009 Nanoco invested in a Connect 2 Cleanrooms modular cleanroom.
The modular construction of the cleanroom facilities meant that when Nanoco needed to extend their space in February 2012, Connect 2 Cleanrooms were able to provide an efficient value proposition. The cleanroom was re-located, extended and re-commissioned in the space of just 4 days; simultaneously bringing the cleanroom facilities up to date and retaining the value of their initial investment.
The extension grew the original cleanroom from 47.7m² to 104m². This more than doubled the capacity of the classified ISO 14644-1 Class 6 area. Additional remote variable speed controllers were installed to give economic and efficient zone control for a total of 7 zones.
"It was a logical decision to go with Connect 2 Cleanrooms for the relocation and extension of our cleanroom facilities as we were happy with the way our existing facilities worked. The installation went smoothly as their engineers worked around other contractors on site and we found them very accommodating,” explains Torsten Schanze, Nanoco, Manchester, UK. "The cleanroom meets all our expectations.”
MORCHER® is one of the leading international manufacturers of medical products for eye surgery. Specialising in intraocular lens eye implants (IOL), the company use the latest micro-manufacturing methods to develop and produce implants for cataract surgery. Connect 2 Cleanrooms create freestanding cleanroom solutions, which use HEPA filtration to produce an exceptionally clean environment.
The two companies met at MEDTEC exhibition in Stuttgart, where MORCHER® was able to appreciate the flexibility and modular construction of Connect 2 Cleanrooms’ solutions. MORCHER® dealt with Connect 2 Cleanrooms German Head of Sales, Stephen Trundle, throughout the project, who enabled a quick turnaround with the cleanroom installation and commissioning lasting just three days.
With a modular cleanroom design, Connect 2 Cleanrooms can quickly and easily create a localised clean area within any area of an existing building to meet specific production requirements. The cleanroom installed at MORCHER® uses HEPA filtration, which is 99.99% efficient at 0.3 micron with in-built fan units, to meet particle count and air change requirements of ISO 14644-1 Class 7.
The modular cleanroom’s HEPA filtration delivers its outstanding performance thanks to a combination of low sound, low watts and a low profile. Measuring only 51 dBA, the 600mm x 1210mm HEPA filter fan unit (FFU) provides one of the lowest sound levels of any FFU. Running at 220 watts at 0.45m/s outlet velocity, the unit provides a versatile, compact and quiet solution for modular clean rooms.
"We would recommend Connect 2 Cleanrooms as they simplified the process, due to their non-bureaucratic way of working and their fast completion of the project,” says Olaf Morcher, CEO, MORCHER® GMBH, Germany.
Connect 2 Cleanrooms are industry leaders in creating modular cleanroom solutions for critical environments, both in the UK and internationally. The company designs and manufactures hard and soft wall cleanrooms in-house and delivers quality cleanroom solutions to meet the ISO 14644-1 standard required. Its consumables division, cleanroomshop.com, supplies a full range of consumables, equipment and furniture to the cleanroom industry worldwide.
For further information please visit: www.nanocotechnologies.com, www.morcher.com, or www.connect2cleanrooms.de.
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