When it comes to adding to an existing cleanroom or building a new one from scratch, working with a company with proven experience in cleanroom design and construction is vital to the project’s success. In 2022, PAC cleanroom experts embarked on an ISO 7 class cleanroom design and build project for a global product realization services company. At PAC, our cleanroom experts provide end-to-end support whether you’re building a new cleanroom, adding onto an existing one, or needing furniture, equipment, or consumables. For this project, PAC lent our expert services for a ground-up build, resulting in a successful cleanroom and a long-term customer relationship.
The Customer & Their Needs
This customer is a leading engineering and manufacturing partner for top-tier companies in the semiconductor capital equipment industry. Their expertise spans vertically integrated precision machining, electronics manufacturing, and full-system assembly, providing comprehensive support throughout the product life cycle. They offer world-class capabilities, including complex precision machining and custom design engineering solutions for critical subsystems.
The customer initially contacted PAC experts requesting information on PAC’s CleanPro® Air Showers. From this conversation, our experts learned the customer was also looking to start a project for a new ISO Class 7 cleanroom where they would manufacture semiconductor processing tool components. After learning about our cleanroom expertise and services, the customer decided to bring PAC on to design and build their new cleanroom.
Constructing the Cleanroom
From the ground up, PAC worked to build a state-of-the-art, 7,200-square-foot facility that currently houses 10 rooms. They specially designed one room to achieve conditions as close as possible to an ISO 6 cleanroom, meeting the stringent demands of precision manufacturing.
Wall System
For this project, the customer needed a structure that would meet semiconductor manufacturing standards while allowing for the accessible movement of large objects in and out of the cleanroom. With this in mind, our experts went with a modular wall system with specialty sliding and roll-up doors. Modular cleanrooms offer scalability and flexibility, making them the preferred option for semiconductor manufacturing. The cleanroom features three-inch-thick FRP (Fiberglass Reinforced Plastic) walls, offering a durable, easy-to-clean surface ideal for maintaining strict environmental controls. Additionally, the cleanroom features specialty automatic sliding and roll-up doors, which were selected to accommodate the large, custom stainless steel equipment manufactured within. These doors allow for efficient and seamless transfer of equipment in and out of the cleanroom, ensuring productivity and preserving cleanroom integrity during operations.
Airflow Design
PAC experts opted for a recirculating airflow design combined with laminar (unidirectional) airflow to maintain a consistent and controlled environment. This design ensures that clean, filtered air flows smoothly across the cleanroom space, minimizing the risk of contamination. The cleanroom also incorporates a plenum wall system. This wall supports efficient air distribution and helps maintain pressure control, which is critical for meeting the stringent requirements of semiconductor manufacturing. The advanced airflow setup guarantees high air quality while optimizing the overall performance of the cleanroom.
FFU’s
The cleanroom has advanced digital Fan Filter Units (FFUs) featuring ECM (Electronically Commutated Motor) technology. A CAT5 cable connects each digital FFU to a control module, allowing real-time monitoring and airflow adjustment. This sophisticated system allows comprehensive control over critical environmental factors such as pressure differential, temperature, and humidity. Five strategically placed particle counters track particle levels, pressure, temperature, and moisture throughout the cleanroom.
This setup enables remote control and monitoring, allowing adjustments to be made without entering the cleanroom and ensuring immediate alerts for any changes in environmental conditions. This helps maintain optimal performance and compliance with strict industry standards.
The Outcome
This cleanroom project was a success, with PAC’s expertise in design and construction delivering a state-of-the-art facility tailored to the customer’s semiconductor manufacturing needs. Since its completion, the cleanroom has been operational for two years, equipped with CleanPro® components and maintaining the highest environmental control standards. The project’s success led the customer to consider PAC for an upcoming expansion, with plans to extend the cleanroom by an additional 2,000 square feet. This new project is now in the pipeline, reflecting the strong partnership and trust built through PAC’s proven capabilities in cleanroom construction.
Upgrading or Building a New Cleanroom?
CleanPro®, a division of Production Automation, is a trusted ally of enterprises, research facilities, and government agencies. We leverage 100 years of cleanroom experience to draft, design, schedule, and deliver production ready cleanrooms.
