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Sat Aug 26, 2023

Air Shower Clean Room Design

Air Shower Clean Room Design

Designing an air shower clean room involves integrating a specialized entry system that helps remove particulate contaminants from personnel and equipment before they enter a controlled environment. Here’s a detailed guide on how to design an air shower clean room:

 

1. Understanding Requirements

 

Clean Room Classification

Determine the clean room class based on the required cleanliness level. The classification (e.g., ISO 5, ISO 6) will dictate the design specifics.

 

Standards and Regulations

Familiarize yourself with relevant standards, such as ISO 14644, and industry-specific regulations.


2. Air Shower Design

 

Location and Integration

  • Entry Points: Position air showers at entry points to the clean room to ensure all personnel and materials pass through them.
  • Space Planning: Allocate sufficient space for air showers within the clean room layout.

 

Airflow and Filtration

  • HEPA/ULPA Filters: Use High-Efficiency Particulate Air (HEPA) filters or Ultra-Low Penetration Air (ULPA) filters to capture particles.
  • Air Velocity: Ensure the air velocity within the shower is between 20-30 m/s to effectively dislodge contaminants.
  • Air Changes per Hour (ACH): Design for adequate air changes to maintain the desired clean room classification.

 

Construction Materials

  • Walls and Floors: Use non-particle-shedding materials such as stainless steel or powder-coated steel.
  • Sealing: Ensure all joints and seams are properly sealed to prevent contamination ingress.

3. Operational Features

 

Automation and Control

  • Sensors: Install sensors for automatic activation upon entry.
  • Timers: Set appropriate shower durations, typically 10-30 seconds.
  • Interlocking Doors: Use interlocking mechanisms to ensure one door cannot open until the other is closed.

User Comfort and Safety

  • Noise Levels: Incorporate noise reduction measures to maintain user comfort.
  • Emergency Override: Include an emergency stop button for safety.

4. Maintenance and Monitoring

 

Filter Maintenance

  • Regular Inspection: Schedule routine checks and replacements for HEPA/ULPA filters.
  • Monitoring: Install differential pressure gauges to monitor filter performance.

 

Cleanliness Validation

  • Particle Counters: Use particle counters to regularly validate cleanliness levels.
  • Surface Testing: Conduct surface sampling to ensure contamination control.

5. Design Considerations

 

Workflow Integration

  • Material Transfer: Design separate air showers or pass-through chambers for material and equipment transfer.
  • Personnel Flow: Plan for efficient flow of personnel to minimize bottlenecks.

Energy Efficiency

  • Energy Use: Select energy-efficient blowers and control systems.
  • Heat Load Management: Design HVAC systems to handle the additional heat load from air showers.

 

Example Design Layout

 

Entry Area

  • Changing Room: Before entering the air shower, personnel change into clean room garments in a gowning area.
  • Pre-Shower Area: A space for personnel to queue before entering the air shower.

 

Air Shower Chamber

  • Dimensions: Typical dimensions are 4-6 feet wide, 6-8 feet high, and 6-8 feet deep.
  • Air Jets: Strategically placed to cover the entire body of the user.

 

Exit Area

  • Clean Room Access: Direct access to the clean room after exiting the air shower.

Air showers are self-contained chambers used to remove contaminants from people or objects before they enter a cleanroom or other controlled environment. It works by blowing high-velocity, HEPA-filtered air over the person or object to remove any particles that may be on their surface or clothing.

A HEPA (High-Efficiency Particulate Air) filter is a type of air filter that can remove at least 99.97% of particles that are 0.3 microns in size or larger. HEPA filters are commonly used in cleanrooms, hospitals, and other environments where air quality is critical. In an air shower, HEPA filters are frequently used to clean the air that is blown over the person or object being decontaminated. The HEPA filter removes any particles that may be present in the air, ensuring that the air shower is effective at removing contaminants. Overall, the combination of an air shower and a HEPA filter is a highly effective way to remove contaminants and maintain a clean environment in critical areas such as cleanrooms and laboratories.

An air shower is a two doors walk-through dust removal system, which is fitted prior to cleanroom entrance. The objective of setting up Air Shower System is to control the risk of spreading contaminants in the cleanroom environment by removing particulate matter on the personnel by throwing class 100 airflow. The Air Shower Machine throws high velocity HEPA filtered air through jet nozzles which removes particulate matter (includes solid and liquid particles suspend in air and some of them are hazardous in nature). The contaminated air is again filtered and re-circulated. With-in seconds, the person entering into air shower comes out entirely cleans i.e. free from harmful dust. Electronics and Pharmaceutical productions and animal breeding laboratories are some of areas where air showers are widely used.

Accumax India is an ISO and CE certified air shower manufacturers in India. Accumax India has an in house facility of design, construction and installation of air shower entry systems for laboratories, clean rooms and manufacturing areas etc. These systems are carefully constructed at our factory, tested at various parameters then dispatched to the client's site. Our Air Shower Cabinets are designed with corrosion resistant materials (Stainless steel or powder coated MS), fitted with easy to use controls and safety arrangements; filters are easily replaceable whenever needed.

 

Our air shower entry systems are custom designed and constructed as per requirements of the customers and sold at industry leading price in India.

 

                                                                                                      


Air shower Specifications
1 Dimensions WxDxH :  900x1000x2000 mm (Inner Area)
WxDxH: 1400x1075x2150 mm (Outer Area) Or Customized
2 MOC Galvanized Iron Powder Coated / Stainless Steel 304
3 Blower Assembly

Dynamically And Statically Balanced Motors And Blowers

 

4 Motor Make Eyaani
5 Nozzles Made Of Stainless Steel Rotating And Adjustable Fixed Either Side Of Wall And Top Ceiling Velocity 70 Meters/Sec
6 Blower CFM 25-30 Meters/Sec
7 Face Velocity 20-22 Meters/Sec (3937-4330 FPM)
8 Air Flow 20-22 Meters/Sec (3937-4330 FPM)
9 Class 10000
10 Interlocking of Doors Interlocking Facility Of Doors, One Door Lock Automatically When Other Is Opened With Electromagnetic Lock, With Timer Setting
11 Flooring Aluminium Checker Sheet Anti Skid Or Stainless Steel
12 Door Frame Made Of Stainless Steel / Galvanized Iron Powder Coated Interlocking Facility, Half Toughened Glass
13 Hingle, handle Make Harrison/Godrej Or Equivalent
14 Light LED
15 Prefilter Washable Prefilter Down To 10 Microns, Particulate At An Efficiency Of 90% Duly Tested
16 Hepa Filters With 0.3 Microns Particulate Of 99.978% Efficiency And DOP Tested, Frame Of Aluminium, Microfiber Glass Media Epoxy Sealed, Non Washable
17 Operations Automatic Actuation Operation And Adjustable Timer Trough Microprocessor Based Controller
18 Noise Level Less Than 75 Db
19 Safety Emergency Switch In Chamber
20 Electric Supply Work On 220v AC 1 Phase Or 3 Phase (To Specify)

 


Inner Size: (W X D X H)

 

  • 900 x 1000 x 2000mm (2 Persons)
  • 900 x 1500 x 2000mm (3 Persons)
  • 900 x 2000 x 2000mm (4 Persons)
  • 900 x 2500 x 2000mm (5 Persons)
  • 900 x 3000 x 2000mm (6 Persons)
  • 900 x 3500 x 2000mm (7 Persons)
  • 900 x 4000 x 2000mm (8 Persons)
  • 900 x 4500 x 2000mm (9 Persons)
  • 900 x 5000 x 2000mm (10 Persons)

Cleanroom Air Shower Tunnels Prevent Contamination between Cleanrooms

Cleanroom Air Showers can be integrated to create self-cleaning air shower tunnels for environments where two or more cleanrooms are being utilized. Cleanroom Air Shower Tunnels successfully remove particles as personnel and products travel between cleanrooms, significantly reducing the risk of contamination between work areas that have different ISO ratings. Up to five Cleanroom Air Showers can be combined based on your requirements.


How to Select an Air Shower for Decontamination Purposes?

Decontamination Air Showers are commonly used for cleaning gowned personnel before entering a clean environment. However, they are also used to remove particulates from workers as they leave hazardous work areas and mingle with the general public. Further, an exit decontamination air shower can prevent cross-contamination when moving from one workspace to another. 


Air Shower Design considerations 

Modular Clean Room Air Shower designs and configurations accommodate specific requirements for industry, as well as the number of personnel using the cleanroom. Modular cleanroom entry systems also simplify shipping and assembly.
 
Utilizing a 90-degree design, users enter on one side and exit to the right or left at a 90-degree angle. This allows the Air Shower, with nozzles on two opposing walls cleans workers with ease.This configuration has fewer air nozzles than the straight-through design and requires the worker to turn 360 degrees to make sure that they’ve been thoroughly cleansed. Other designs may have double doors or even three doors for entry and exit. Configurations include cart/parts-cleaning air showers, which are used for carts, conveyors, pallets and continuous-part operation. Low-profile air showers accommodate facilities with ceilings less than 96 inches. ADA air showers are sized so a wheelchair can turn around in the air shower.

 

Accumax India offers many different standard and custom sizes and shapes of air showers for cleanrooms. Many of the standard varieties for personnel passage include straight through showers, 90-degree turn showers, and many lengths of tunnel-style air showers. These can also be designed according to the site conditions. We supply many other equipment like Biosafety cabinets, Fume Hood, Pass Box, etc.
 
The number of persons that need to enter your cleanroom in each amount of time will have a major impact on the size of the air shower and filtration system that is required. Designs range from single batch systems where one person uses the shower at a time, to tunnel systems for larger groups to pass through quickly.Air Shower Tunnels are becoming more common because of the amount of cycle time needed for a shift change.


Doors 

Like air locks, air showers have entrance and exit doors that cannot be opened at the same time. Workers enter one side and exit on the opposite side. When one door opens, the other door’s magnet energizes, preventing it from opening. During the cleaning cycle, both doors are locked to prevent anyone entering or leaving before the cycle is completed.


Materials

High-quality air shower shells are constructed of steel and painted with a strong, durable cleanroom-compatible finish. For some medical, pharmaceutical, or extremely wet environments, stainless steel construction is ideal.

Some manufacturers offer economy units made of laminated particleboard. However, this option has major weaknesses, including temperature and humidity fluctuations that can cause delamination. The materials are also easy to damage and susceptible to joint loosening. Any of these conditions may generate particulate or biological contamination.


5 Types of Cleanrooms that Use Air Showers

 

 
If you own and operate a cleanroom, you know that people are the single largest source of entering contaminants. Cleanrooms serve to limit potential contamination from reaching your work, but even constant filtration, garments, and gloves can only do so much — there will always be particles that make it through. These particles not only threaten your ability to reach your cleanroom classification, but could pose hazards to delicate work — from semiconductor manufacturing to defense system calibration, medical research, and more.
 
The next layer of defense for sensitive environments are air showers. Air showers are another step before entering the cleanroom that removes lingering particles, providing additional protection for your environment and the critical work you do. How do air showers work and what types of cleanrooms can benefit from air showers? Let’s answer these questions and more.
 

How Do Air Showers Work?

Air showers are chambers installed at the entrance of a cleanroom or pass-through to a more secure part of a cleanroom that use concentrated bursts of air to remove particles from entering workers, carts, and supplies. They are an added layer of protection for people and products moving from a less secure to a more secure area.
 
Air used in air shower is concentrated, high-velocity, and ultra-filtered to dislodge any particles that have settled on garments or surfaces. Once it has served its purpose, “dirty” air, full of the removed particles, is pulled out of the chamber through the exhaust system.
When appropriately installed and utilized, air showers are an effective means of reducing potential contaminants and protecting sensitive work at a relatively low cost.
 
5 Types of Cleanrooms That Use Air Showers
Air showers aren’t required in all types of cleanrooms, but various applications can benefit from the added step of particle removal. Industries that require strict cleanliness standards per their cleanroom classification have the most to gain including air showers in their cleanroom design. 
 
Let’s look at 5 such applications that use air showers.
 
1. Air Showers in Medical Research Cleanrooms
Medical research and highly sensitive equipment used in that research can both be compromised by entering contaminants. To keep the environment as free of particles as possible and reach stringent ISO Class 5 or lower standards, these types of cleanrooms use air showers for researchers and doctors to “rinse off” before entering the controlled environment. 
In some medical cleanroom applications, such as those working with bio-hazardous materials, infectious diseases, or toxic fumes, what’s inside the cleanroom may be more dangerous than the outside. In addition to negative pressurization to isolate internal contaminants, air showers may be placed within the cleanroom to remove particles from workers exiting the controlled environment as an added defence.
 
2. Pharmaceutical Cleanrooms
Pharmaceutical cleanrooms are trusted to develop, test, and produce life-saving drugs and compounds. Any contamination of their processes could negatively affect test results or consumer health. Pharmaceutical cleanrooms must meet high cleanliness standards, and frequently implement air showers to help reach them. The additional layer of protection ensures that personnel traveling from the ante chamber to the compounding room are not carrying potentially dangerous contaminants.
 
3. Air Showers in Aerospace Cleanrooms
Too many particles in an aerospace cleanroom can result in a compromised sensor or a malfunctioning piece of electrical equipment. On a small scale this may not seem like much, but when applied to a complex machine like aircraft or spacecraft, every piece of equipment must be in optimal condition to ensure worker safety and project results. These types of cleanrooms use large air showers at the entrance and exit of the cleanroom to remove particles from personnel, products, and parts to maintain a clean, contaminant-free environment.
 
4.Precision Manufacturing Cleanrooms
Not all manufacturing environments require stringent particle control, but the manufacturing of highly sensitive products, such as radar systems, sensors, and computer hardware must be completed in a controlled space, often a cleanroom. Defence cleanrooms, for example, often employ air showers because the potential for excess particles can threaten the development of complex parts and equipment, weapons, and security systems.
 
5.Air Showers in Microelectronics and Semiconductor Cleanrooms
Semiconductor cleanrooms and cleanrooms that manufacture, handle microelectronics have some of the most strict requirements for particle control. Typically ISO Class 5 and lower, these types of cleanrooms rely on many layers of protection, including air showers, to reduce the potential of contaminating particles entering the cleanroom environment. Highly sensitive integrated circuits are easily compromised by particles carried in on personnel. Adding air showers to semiconductor cleanroom design can help prevent the corruption of these valuable materials. 

Conclusion

Air Showers are an expensive but effective way to clean cleanroom personnel. They are most popular in semiconductor industry that typically have large ISO-5 and ISO-6 cleanrooms with many employees going in and out. Beware of lower cost imported Air Showers that does not have sufficient air velocity and air changes per hour to effectively clean personnel and material.

Designing an air shower clean room involves meticulous planning and adherence to industry standards. It requires a balance between effective contamination control and user comfort while ensuring energy efficiency and maintainability. Consulting with clean room design experts and using advanced design software can help achieve optimal results.


                                     

Frequently Asked Questions

 

1. What material is Air Shower?

Accumax India manufacture Air Showers constructed of Stainless Steel.

 

2. What is the size of an Air Shower?

 The standard size of an Air Shower is 900x1000x2000 mm (Inner Area) and 1400x1075x2150 mm (Outer Area)

 

3. What is the cycle of an Air Shower?

This is one of the important aspect of an Air Shower effectiveness.Studies suggested that 20-30 seconds of Air Shower is effective to remove contimantion 

 

4.What is the nozzle velocity of an air shower?

To specify the most effective air shower, look for one that produces nozzle velocities of 7,800 feet per minute (fpm) and circulates 1,900 cubic feet per minute (cfm) of air. Velocity is measured at the nozzle, and cleaning effectiveness deteriorates as distance from the nozzle increases.

 

5.What are the different types of air showers?

Common geometries or types of air showers include: cart, single door, straight, tunnel, L-shaped, S-shaped, U-shaped and three-door air showers.

 

6. What are the benefits of integrating cleanroom air showers in controlled environments/ facilities?

Installation of Accumax India cleanroom air showers enables seamless entry/exit of personnel in and out of the controlled environment. The “scrubbing” effect of the high-velocity air showers on particulate matters or surface contaminants allows mitigation of potential cross-contamination; thereby increasing cleanroom and process integrity.
 
7. Can Accumax India cleanroom air showers measure the differential pressure across filter?
Standard models of Air Shower are not designed with a device to measure and display differential pressure across filter. Upon customer's request, Accumax India can customize cleanroom air showers to have add-on magnahelic gauges to display differential pressure value across filters.
 

8.How Accumax India cleanroom air showers shipped?

Depending on client's request and dimensions of ordered air shower, Air Shower can be shipped in assembled, module or unassembled form.

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