GMP Technical Solutions manufactures and providing partitions, doors and equipments in the Indian Sub-landmass. GMP is the innovation pioneer in the range of Clean Room innovation and gives Turnkey clean room arrangements around the globe.

1. A presentation on
New Trends
in
Modular cleanrooms

2. Flow of Presentation
History of Clean Rooms
Introduction to Clean Rooms
Emerging Trends in
Cleanrooms
Need of Clean Rooms
History of Clean Rooms in
Healthcare

3. A cleanroom is an environment, typically used in manufacturing or
scientific research, that has a low level of environmental pollutants such as
dust, airborne microbes, aerosol particles and chemical vapors.
More accurately, a cleanroom has a controlled level of contamination that
is specified by the number of particles per cubic meter at a specified
particle size.
To give perspective, the ambient air outside in a typical urban environment
contains 35,000,000 particles per cubic meter in the size range 0.5 μm and
larger in diameter, corresponding to an ISO 9 cleanroom, while an ISO 1
cleanroom allows no particles in that size range and only 12 particles per
cubic meter of 0.3 μm and smaller (see table below).

4. Class
maximum particles/m³
FED STD 209E
equivalent≥0.1 µm ≥0.2 µm ≥0.3 µm ≥0.5 µm ≥1 µm ≥5 µm
ISO 1 10 2
ISO 2 100 24 10 4
ISO 3 1,000 237 102 35 8 Class 1
ISO 4 10,000 2,370 1,020 352 83 Class 10
ISO 5 100,000 23,700 10,200 3,520 832 29 Class 100
ISO 6 1,000,000 237,000 102,000 35,200 8,320 293 Class 1000
ISO 7 352,000 83,200 2,930 Class 10,000
ISO 8 3,520,000 832,000 29,300 Class 100,000
ISO 9 35,200,000 8,320,000 293,000 Room air

5. History of Cleanrooms
The Clean-room is a recent technology coming to the age as part of the
Atomic Age and greatly enhanced in the space-age.
However, its roots go back hundreds of years to swiss watch makers who
used to cover their precious watches with a small bell jars when they were
not working on them to prevent dust from falling on them.
The American Civil war (1861–1865) gave impetus to the next phase, when
due to immense loss of life due to bullet wounds surgeons recognised the
need for steps to prevent post traumatic infections. So, the methods were
developed to achieve this and sterility became a watchword in operating
suits and surgical tools.
As a final step the development of HEPA (High efficiency Particulate Air)
filter at Sandia Labs for Atomic Energy Commission after World War-II, in
1945 where deadly nuclear particles were isolated in process areas with
HEPA filters while allowing air to circulate in them.

6. History of Clean-rooms in Healthcare sector
• The first Clean-rooms in Healthcare were found in hospitals
• It was after Pasteur, Koch, Lister and other pioneer
microbiologists and surgeons over a 100 years ago established
that bacteria cause wound infections
• It was discovered that elimination of bacteria from hospital and
in particular Operating room should prevent infection
• This was the scientific basis for the first clean rooms
Joseph Lister
(1827 – 1912)
British surgeon
Heinrich Hermann Robert
Koch (1843-1910)
Prussian physician
Lister's Operation
Theatre (1869)

7. Why are Clean Rooms needed?
 Need
 To reduce contamination levels in the product or services performed
 To achieve compliance to world wide standards like cGMP, USFDA etc.
the manufacturing has to follow certain standards (ISO standards)
which makes clean-room a compulsion than a need.
 These standards can’t be achieved without following contamination
control technology, of which clean rooms are an important part.
 Contamination Control Technology :
 It deals with the removal of particles from the air and the levels of air
cleanliness that can be achieved
 How items are handled, cleaned and stored
 What equipment is used and the method of its use.
 What materials are used in the process and what changes take place to
that material,
 what are the contaminants, where do they come from and how can they
be eliminated

8. Sources of Contamination
1. Facilities (building)
Walls, floors and ceilingsPaint and coatingsConstruction material Air conditioning
debrisRoom air and vaporsSpills and leaks
2. People
Skin flakes and oilCosmetics and perfumeSpittle
Clothing debris (lint, fibers etc.)Hair
3. Tool Generated
Friction and wear particlesLubricants and emissionsVibrations
Brooms, mops and dusters
4. Fluids
Particulates floating in airBacteria, organics and moisture
Floor finishes or coatingsCleaning chemicals
Plasticizers (outgasses)Deionized water
5. Product generated
Silicon chipsQuartz flakesCleanroom debris

9. Key Elements of Contamination Control
 Cleanroom Construction: Cleanrooms construction material should
be non-shredding, Chemically stable/ resistant, with minimal places
for dust-settlement.
 HEPA(High Efficiency Particulate Air Filter) They filter particles as
smallas 0.3 microns with a 99.97% minimum particle-collective
efficiency.
 Cleanroom Architecture: Cleanrooms are designed to achieve and
maintain a airflow in which essentially the entire body of air within a
confined area moves with uniform velocity along parellel flow lines
(laminar flow). As, turbulence can cause particle movement.
 Filteration: In addition to the HEPA filters commonly used in
cleanrooms, there are a number of other filtration mechanisms used to
remove particles from gases and liquids. These filters are essential for
providing effective contamination control.
 Cleaning: Cleaning is an essential element of contamination control.

10. Key Elements of Contamination Control
Laminar Air-Flow Turbulent Air-Flow

11. Pharma Industry Dynamics
Pharma Industry Development

12. Disadvantages of Brick-walls
 It shreds particles and Gets chemically effected very fast
 Paint peals off very fast leading to high maintenance cost (frequent
painting)
 Absorbs moisture expediting the paint peal-off and particle shreding.
 No modularity. In case of any change required the area will need to be
shut down for weeks together.
 Re-validation will be required after any changes.
 More down time due to maintenance reasons.

13. Emerging trends in Cleanrooms

14. Types of Cleanroom Construction
Trends in clean room partition materials
1900 s 1980 s 2000 s 2006
Plaster /
Blockwork
Plasterboard
/Studwork /paint
Solid core panel
“monoblock”+factory
applied paint finish
Hollow core/ 2
part panel
/factory applied
finish
GI & HPL Pre-
Engineered Panels
GRP
Panels

15.  It is a general partitioning system, which is being used in pharmaceutical cleanrooms just
because of lower price.
 These panels are not Pre-engineered & all cut-outs, conduits, view-panels are done manually at
site. This drastically reduces the final finish quality.
 Thickness of 50mm is not very sturdy and doesn’t allow many utilities and switch-boards to fit
into it.
 The paint is wet type and paint thickness is just 20-25 microns. So, the scratch resistance is very
poor as compared to powder coating.
 CRC sheets used in making panels instead of GI. This increases the risk of rusting at later stage.
 C-Type floor-track is used to fix the panel on the floor. This leads to a direct contact between the
panel and any kind of seepage/ spillage/ leakage of water etc. Resulting in bacteria formation.
 Removal of partition is very difficult after installation.
 Hanging system is used for ceiling (load-bearing capacity of 70-80 Kg/m2) and very less
movement space over ceiling. Also the ceiling cut-outs are done at site and covered with channels
from outside (not welded), hence reduced strength of panels with cut-outs.
 PVC covings and corners in standard colours is provided
 Overall final finish is not very good
Disadvantages of thin pre-painted panels

16. Major highlights:
 Integrated system specially designed for Pharmaceutical industries.
 Pre-engineered system (panels, cut-outs, conduits, view-panels are
designed and manufactured in factory) as per design requirements.
 Inbuilt risers for low-level air discharge resulting in better aesthetics and
better space utilization.
 Raised type floor-track can be provided to accommodate epoxy coving.
This results in total flushing of epoxy coving with walls.
 Truss system used for ceiling hanging for sturdy ceiling (load-bearing
capacity of 150 Kg/m2) and more movement space over ceiling.
 Aluminium Powder coated covings and corners to match colour, gloss as
of partitions and for better life.
 Doors and accessories are specially designed to suit the clean-room
requirements.
Pre-engineered Partitioning System

17. Pre- Engineered, Pre-Designed
(different sized panels as per
requirement)
Progressive / Non-Progressive (Both
types) are provided as per layout
requirement.
(Please see an Example of Pre-
Engineered panels in next slide)
Pre-Engineered Panels
Standard Design
Standard Length and
Width panels are
supplied and are cut at
site to make any changes
Pre-engineered
80 mm Partitions
Normal Partitions

18. Pre-Engineered Panels

19. - Panels have a profile all around and
channels are welded to the sheet to
give more strength
- The wall panels supports the load-
bearing ceiling. i.e. Panels are self-
supporting
- Stiffeners are provided where-ever
required in ceiling panels and hence
more strength.
- Better chemical resistance due to 70-
90 microns of powder coating.
Panels Having more strength
Panels are made of sheets pasted on
the frame of GI or Aluminium resulting
in lower strength
Also some panels doesn’t have any
supporting profile/ frame
80 mm Partitions Normal Partitions

20. Raised Floor Track
Raised type Floor Track
‘C’ Type Floor Track
80 mm Partitions Normal Partitions
Disadvantages of C-Type Floor Track:
PVC or Al. Coving is only option in this case.
Since panels are resting just on the C
Channel; Any seepage of water will enter
the area behind coving and also panels
bottom and create bacterial formation/
Contamination
Advantages of Raised Floor Track:
This allows total flushing of Epoxy coving with
wall panels thus giving total flush surface and
also avoids Water contact with the panels, so
no chance of any bacterial growth.

21. Truss Hanging
ROOF HANGING
Rod Hanging
Truss Type Hanging Normal Partition

22. RETURN AIR RISER
Inbuilt Risers
In 80 mm Panels
Advantages of In-built risers:
 Smooth surface of wall, as internal
ducts acts as risers.
 Proper space utilization is possible, as
no obstacles are there in the rooms in
terms of external riser ducts.
 Easy duct connections at the top.
 More clear area inside the rooms.
 Easy cleaning of rooms is possible as
wall surfaces are in straight lines.

23. RETURN AIR RISER
Projected Type Risers
Normal Partitions
Disadvantages of Projected risers:
 Non-Smooth surface of wall, as the externs
ducts creates a many projections in the wall.
 Proper space utilization is not possible, as
many obstacles/ projections are there in the
rooms in terms of external riser ducts.
 Duct-connection at the top of riser is difficult.
 It decreases clear area inside the rooms.
 Cleaning of rooms is difficult due to presence
of projected risers as wall surfaces are in not in
straight lines.

24. 80 mm pre-engineered
partitions
Normal Partitions
Paint Quality
Paint Type: Pure Polyester
Method: Powder coating , oven baked
Paint Thickness: 70 to 90 Microns
Gloss level: 25 % Maximum
Cross-cut/ Paint Adhesion Test: Done
Paint Peal-off test: Done
Impact/ Drop Test : Done
Chemical Resistance: Yes
ADVANTAGES:
- Better final finish
- Low fatigue in working (low gloss)
- More life
- Better Scratch and Chemical resistance
Paint Type: Wet PU paint
Method: pre-painted sheets used to
make partitions
Paint Thickness: 20 to 25 Microns
Gloss level: above 35%
Paint Adhesion Test: Not Done
Paint Peal-off test: Not Done
Drop Test : Not Done
Chemical Resistance: Very low
DISADVANTAGES:
- Poor final finish
- Higher fatigue due to higher gloss
- Lower life
- Poor Scratch and Chemical resistance

25. Chemical Resistance chart of Powder Coating

26. Bend Test
Different tests for powder coating
Scratch Test
Weight drop Test

27. Different tests for powder coating
and bar coding
Gloss level
test
(20±5%)
Dry film thickness
test (70-90 micron)
Bar coding for
easy
identification

28. Factory Made cut-outs with conduits
fitted in factory:
-With and Without Lip cut-outs
possible for ceiling
- Conduits are fitted in factory in wall
cut-outs
- All cut-outs are covered with
channels fitted inside them, which are
welded
- These results in proper sealing (i.e.
Infill is not in touch with wires/
connections. Hence less fire hazards)
- Proper welding of channels results in
higher strength.
- Machine made cut-outs give better
finishing.
80 mm Pre-engineered Partitions
Wall/ Ceiling Cut-outs and Conduits

29. Cut-outs are done manually at site
- Only Through cut-outs possible for ceiling
- Conduits are fitted at site in wall cut-outs,
which are also done at site
- Only ceiling cut-outs are covered with
external covering channels. These are just
put on cut-out in pieces with no welding
etc.
- No covering channels in the wall cut-outs
results in no sealing (i.e. Infill is in touch
with wires/ connections. Hence more fire
hazard)
- No welding of channels results in lower
strength.
- Man made cut-outs results in poor
finishing.
Normal Partitions
Wall/ Ceiling Cut-outs and Conduits

30. Load bearing capacity of 150 kg/m2
Load Bearing Ceiling
80 mm Pre-engineered Partitions
Truss system for hanging and self-
supported system
(Wall panels supports the ceiling panels
and are rested on it)

31. Load Bearing Ceiling
Load bearing capacity of 90-100 kg/m2
Normal Partitions
Turn- Buckle system for
hanging is used;
This results in poor mobility
space over ceiling and lower
load bearing capacity

32. VIEW PANELS
Factory fitted View Panels
Advantages of Factory
fitted view panels :
-View-Panels are fitted in factory
in controlled environment and
hence no dust/ moisture etc. Is
present.
- Cavity is made on CNC
machines resulting in high
quality and finish.
- SS channels inside the two
glasses gives even better finish.

33. DOOR FIXING
Door Fixing in partitions
Advantages of Pilaster joints in
doors:
Easy Removal of door is possible by
removing both sides pilasters. This is
extremely useful in case any big machine/
item needs to be transferred to/ from the
room. After removing the door the height
and width of open space is increased.
 Conduits for Door-interlocking/ Access
control etc. Can easily be accommodated
inside the plaster joints on both sides of
the door.
Pilaster fixing of doors

34. Aluminium frame cut in parts
and fixed at site
DOOR FIXING
Normal Partitions
Disadvantages of Aluminium
frame in doors:
Removal of door is not possible or is very
difficult. Even if the door is removed the
door over panel (DOP) can’t be removed.
So, any removal/ shifting of bigger
machines becomes very difficult.

35.  Factory Fitted View-panels
 Different sheet thickness of door
frame and door leafs is considered for
better strength.
 Press fit type door seal is used
resulting in better finish and low
maintenance.
 Powder coating on doors and frames
for better appearance (same colour for
frame and door leafs) and life.
 Good quality of accessories are used
(door closure (Dorma), SS ball bearing
hinges, SS handles, Drop seals etc.)
DOOR Features
Pre-engineered Partitions Normal Partitions
 Site Fixed View-panels
 Aluminium frame (generally without
paint) and same thickness pre-painted
sheet (as of the partitions) is used to
make door leafs resulting in poor
strength.
 Pasted type door seal is used resulting in
poor finish and more maintenance.
 Pre painted sheet for doors and bare
frames results in poor appearance/ life.
 Normal accessories are used instead of
specially designed clean-room
accessories, which results in frequent
failures and poor performance.

36. COVING
Normal PartitionsPre-engineered Partitions
Advantages of Aluminium Powder
Coated covings and corners:
-Aluminium powder coating of covings have very
good strength and life.
- Exactly same colour and gloss level as of
partitions is maintained resulting in better look
and finish.
- If required to remove and re-fix, it will not
break-up as in case of PVC covings.
Disadvantages of PVC covings
and corners:
- PVC covings have poor strength and life.
- Colour as not possible to match resulting
in poor look and finish.
- If required to remove and re-fix, it will
break-up, as it becomes brittle after some
time.

37. Pre-engineered Partitions- Final Finish

38. Advantages of HPL Partitions
- Panel skin is non-metallic and hence no static
charge. So it is suitable for areas requiring low
static charge.
- HPL is having very good scratch resistance due to
melamine coating done on the skin.
- The panel skin is having very good mechanical
properties i.e. no denting or breaking due to
impact.
- Final finish of the project is excellent and there is
no waviness in panels.
- No rusting/ deformation in due course of time

39. HPL Installation photos

40. Advantages of GRP partitions
- Panels are molded out of resins with reinforcement
of fibers. Material is virgin in nature.
- Chemical resistance of GRP is very high. Even can
withstand high potential acids.
- One service panel after each solid panel.
- Inbuilt / molded covings.
- High capacity return-air risers (150mm depth) are
provided within wall.
- Bigger view-panels provided.
- Mechanical strength of product is very high.
- Repairable at site in case of any kind of damage.

41. GRP Installation photos

42. CRUX of the presentation
80mm Pre-engineered partitions system design
is most suitable for pharmaceutical cleanrooms.
However GRP partitions are best suited for
more critical facilities like Oncology, Hormones
etc. which needs frequent fumigation by using
harsh chemicals.

43. Presented by:
GMP Technical Solutions Pvt. Ltd.
Works: Gunai Road, Mandhala, Via Barotiwala, Distt. Solan, Himachal Pradesh, India
Website: www.gmpcleanrooms.com
E-mail: ajaymehta@gmptech.net