New Cleanroom Facility

Overview

Airology was commissioned to design, supply and install a multi-functional cleanroom facility within an operational production environment to GMP Grade D standard. The project encompassed a combination of new installations, decommissioning of existing systems, and infrastructure upgrades to support the client’s operational and regulatory requirements. The works were delivered allowing the client to maintain operations whilst the cleanroom facility was created.

Challenge

The client required a complex cleanroom solution integrating new and existing infrastructure, including:

Provision of turnkey GMP Grade D cleanroom facility underneath existing mezzanine within existing warehouse building
Decommissioning and removal of existing warehouse air conditioning systems without disrupting operations
Provision of upgrades to electrical distribution, lighting and 3-phase power supplies for critical machinery
Provision of pass-through hatches for product movement
Provision of clean room sinks and associated plumbing
Provision of galvanized steel crash barriers as a protective measure around the cleanroom facility

Additional challenges included maintaining project timelines during the scheduled works and accelerating the programme where possible to meet operational requirements.

Solution

Airology delivered a fully integrated, customised cleanroom solution, incorporating multiple elements to enhance functionality, safety, and environmental control:

Cleanroom Construction:
- Construction of multi-room GMP Grade D facility using steel faced clean room insulated panels
- Installation of vinyl flooring complete with cap and cove skirting with colour differences to create designated classified and unclassified areas
- Installation of clean room grade suspended ceiling
- Installation of lighting and small power including 3-phase machine power
- Installation of large stainless utility sink with shower style tap for utensil cleaning and stainless steel knee operated sink for Gowning area including associated plumbing works
- Installation of 8 no. stainless steel mechanically interlocked pass through hatches for efficient product movement between rooms
- Installation of galvanized steel crash barriers around the cleanroom perimeter for operational safety
Mechanical & Electrical:
- Decommissioning and removal of existing warehouse air conditioning systems
- Installation of new sub mains cable, distribution board and small power
- Installation of LED lighting to 500 Lux lighting level
- Installed of 3-phase power supply for client machinery
- Installation of 4-way magnetic door interlock system to maintain controlled environments
- Upgrade existing lighting underneath mezzanine surrounding the cleanroom and above the clean room facility for void lighting
Environmental Control:
- Installation of individual filtration systems for each area to meet GMP Grade D classification
- Installation of air conditioning systems for temperature control

Installation of analogue magnehelic pressure gauges for pressure monitoring within each room

Outcome

The completed facility provides the client with a modern, fully functional cleanroom environment that supports both current and future operational needs.

Airology’s solution delivered:

Enhanced operational safety with protective barriers and environmental segregation
Flexible and controlled cleanroom areas
Seamless integration of new systems with minimal disruption
Improved electrical distribution and power supply for critical machinery
A scheduled approach that maintained continuity of operations throughout the project

This project highlights Airology’s ability to deliver complex, multi-room cleanroom facilities tailored to the precise needs of regulated environments.

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They required a GMP Grade B, C and D cleanroom facility with temperature control, filtration, pressure monitoring and ventilation.