Cleanroom Particle Filtration System

Cleanroom Pre-Filters

Pre-filters capture larger particles before air reaches HEPA and ULPA filters, protecting these sensitive filters from clogging. They should be replaced about six times a year, which, although frequent, is cost-effective compared to replacing HEPA and ULPA filters. Using pre-filters properly can extend the lifespan of the more expensive filters and save on overall maintenance costs.

Key Features:

1. Pre-Filters for Larger Particles: These filters capture larger particles before air reaches HEPA and ULPA filters.

2. No Specific Particle Size Requirement: Pre-filters are generally responsible for larger particles without specific size requirements.
3. Frequent Replacement: Pre-filters should be replaced about six times a year.
4. Cost-Effective: Pre-filters are more affordable than HEPA and ULPA filters, making them a cost-effective option.
5. Extends Lifespan of Sensitive Filters: Proper use of pre-filters can extend the lifespan of HEPA and ULPA filters by preventing bulky contamination and reducing the need for costly replacements and repairs.

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Cleanroom HEPA Filter

HEPA (high-efficiency particulate air) filters are designed to meet specific efficiency standards, removing at least 99.95% (ISO, European Standard) or 99.97% (ASME, U.S. DOE) of particles with a diameter of 0.3 μm. They capture a wide range of particles, including pollen, dust, bacteria, and some viruses. HEPA filters were commercialized in the 1950s and are used in various applications requiring contamination control, such as in hospitals, manufacturing, and homes.

Standard HEPA Filters: Standard usually used is the European Union Norm EN 1822:2009
Classes Of HEPA Filters
Classes of HEPA filters by their retention at the given most penetrating particle size (MPPS):

Key Features

Mechanism: HEPA filtration works by mechanical means unlike the Ionic and Ozone filtration.

Safety:  Use negative ions and ozone gas respectively So, the chances of potential pulmonary side-effects like asthma and allergies is a much lower with HEPA purifiers.

High Efficiency: HEPA filters capture at least 99.97% of airborne particles as small as 0.3 micrometers, ensuring a high level of air purity.

Particle Removal: They effectively remove a wide range of contaminants, including dust, allergens, bacteria, and viruses, which is crucial for maintaining cleanroom standards.

Airflow Control: HEPA filters help maintain laminar airflow, which is essential for preventing the recirculation of contaminants and ensuring a controlled environment.

Regulatory Compliance: Use of HEPA filters is often required to meet stringent regulatory standards and guidelines, such as those set by the FDA and ISO.

Enhanced Equipment Performance: By reducing the presence of harmful particles, HEPA filters help protect sensitive equipment, extending its lifespan and improving overall productivity.

Application

• Pharmaceutical and Biotechnology
• Semiconductor and Microelectronics
• Healthcare
• Aerospace and Automotive Manufacturing
• Food and Beverage Production

Specification

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Cleanroom ULPA FILTER

Ultra-Low Penetration Air (ULPA) filters are designed to capture and retain ultrafine particles with an efficiency rate of 99.999% for particles as small as 0.1 microns. These filters are essential in environments requiring extremely low airborne particle counts, such as ISO Class 4 or ISO Class 5 cleanrooms.

Standards for ULPA filters

ISO 29463: This international standard defines the performance and testing criteria for ULPA filters. It classifies filters into different groups based on their efficiency, ranging from ISO 50 U to ISO 75 U.

EN 1822: The European standard EN 1822 also covers ULPA filters, classifying them into classes U15 to U17 based on their efficiency and penetration.

IEST-RP-CC001: This standard from the Institute of Environmental Sciences and Technology (IEST) provides recommended practices for testing and evaluating ULPA filters.

Classification and Efficiency ULPA filters

ISO 50 U to ISO 75 U: These classifications under ISO 29463 indicate the filter’s efficiency, with ISO 75 U being the highest, capturing 99.999995% of particles.

U15 to U17: Under EN 1822, these classes represent the highest levels of filtration efficiency, with U17 capturing 99.999995% of particles.

Key Features:

Critical Applications: These filters are essential in environments requiring extremely low levels of airborne particles, such as ISO Class 4 or ISO Class 5 cleanrooms.

High Filtration Efficiency: ULPA filters capture at least 99.999% of airborne particles as small as 0.12 microns.

Mechanisms of Filtration: They utilize multiple mechanisms to capture particles, including inertial impaction, interception, and diffusion. Each mechanism targets different particle sizes, ensuring comprehensive filtration.

Maintenance and Lifespan: While ULPA filters offer unmatched purification, they require regular maintenance to ensure longevity and sustained performance. Their lifespan generally ranges from 3 to 5 years, depending on the air quality and volume passing through the filter.

Cost Considerations: ULPA filters are typically more expensive than HEPA filters, reflecting their advanced technology and higher efficiency.

Application

1. Microelectronics Manufacturing

Purpose: Ensures an ultra-clean environment to produce semiconductors and microchips.

Importance: Prevents defects caused by microscopic particles, ensuring high-quality and reliable products.

2. Pharmaceutical Industry

Purpose: Maintains sterility in the manufacturing of drugs and medical devices.

Importance: Ensures products are free from contaminants, meeting stringent regulatory standards.

3. Biotechnology and Biomedical Laboratories

Purpose: Provides a sterile environment for research and development of sensitive biological materials.

Importance: Critical for experiments and production of biotechnological products, preventing contamination.

4. Healthcare Settings

Purpose: Reduces the risk of airborne infections in critical areas like operating rooms and intensive care units.

Importance: Protects patients and healthcare workers by maintaining a sterile environment.

5. Aerospace Industry

Purpose: Maintains clean environments for the assembly and testing of spacecraft and aircraft components.

Importance: Ensures no particulate contamination affects the performance and reliability of aerospace systems.

Specification

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Cleanroom Fan Filter Units (FFU )

Filter Fan units offer a versatile and cost-effective method for eliminating particles from the recirculated air in both turbulent and unidirectional type cleanrooms.

Filter fan units are self-contained systems featuring an integrated HEPA filter, fan, and control mechanism. They deliver purified air to cleanrooms and laboratories in the life sciences, food and beverage, and microelectronics sectors by eliminating harmful airborne particles from recirculating air. Unlike pressurized cleanroom ceiling plenums, FFUs generate positive room pressure, thereby minimizing the risk of contamination from potential ceiling bypasses.

Standard:

FFUs are engineered to provide consistent airflow, meeting standards such as Federal Standard 209E

Features:

Integrated HEPA/ULPA Filters: FFUs are equipped with High-Efficiency Particulate Air (HEPA) or Ultra-Low Penetration Air (ULPA) filters. HEPA filters can remove 99.97% of particles as small as 0.3 microns, while ULPA filters are even more efficient, capturing 99.999% of particles as small as 0.12 microns.

Variable Speed Control: Many FFUs come with adjustable speed controls, allowing users to regulate the airflow to meet specific cleanroom requirements.

Low Noise Operation: FFUs are designed to operate quietly, which is crucial in environments where noise levels need to be minimized.

Energy Efficiency: Modern FFUs often feature energy-efficient motors, such as electronically commutated motors (ECMs), which reduce power consumption and operational costs.

Compact and Modular Design: FFUs are typically designed to be compact and modular, making them easy to install in various configurations, including ceiling grids and wall mounts.

Durable Housing: The housing of FFUs is usually made from robust materials like aluminum or steel, ensuring durability and longevity.

Advanced Monitoring Systems: Some FFUs are equipped with monitoring systems that provide real-time data on filter performance and alert users when filters need to be replaced.

Positive Pressure Maintenance: FFUs help maintain positive pressure in cleanrooms, reducing the risk of contamination from external sources.

Major Applications:

Filter fan units (FFUs) are self-contained systems that include a HEPA filter, fan, and control mechanism. They deliver clean air to environments such as cleanrooms and laboratories in the life sciences, food and beverage, and microelectronics sectors by eliminating harmful airborne particles from the air. Unlike pressurized cleanroom ceiling plenums, FFUs generate positive room pressure, which minimizes the risk of contamination from potential ceiling leaks.

1. Life Sciences: Ensuring sterile environments for research and medical applications.
2. Food and Beverage: Maintaining clean air to prevent contamination during production.
3. Microelectronics: Providing particle-free air for the manufacturing of sensitive electronic components.

Specification

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