Transforming a Stainless Steel Cleanroom into an Efficient Plastic Cleanroom Solution

Case Study: Transforming a Stainless Steel Cleanroom into an Efficient Plastic Cleanroom Solution

This case study highlights the challenges faced by a pharmaceutical company due to a stainless steel cleanroom and how transitioning to a plastic-based cleanroom solution resolved inefficiencies, improved accessibility, and optimised space utilisation.

Initial Challenges
The pharmaceutical company operated in a stainless steel cleanroom that was intended to meet regulatory requirements but created significant operational inefficiencies:

Wasted Workspace:
The cleanroom design included bulky stainless steel shelving that consumed excessive floor space.
Poorly organised storage led to cluttered aisles, reducing walking space and making equipment access cumbersome.
Obstructed Windows:
Shelving and equipment placement blocked critical windows, limiting visibility and natural light flow.
This created a closed-off environment, making monitoring and communication between zones difficult.
Maintenance Issues:
Stainless steel surfaces were prone to smudges, scratches, and corrosion in certain areas due to chemical exposure.
Cleaning these surfaces required significant time and effort, impacting overall efficiency.
Lack of Accessibility:
The layout restricted movement for personnel and equipment, creating bottlenecks in workflows.
Storage systems were not modular or adjustable, leading to underutilized vertical space.

Plastic Cleanroom Solution
To address these issues, the company transitioned to a custom-designed plastic cleanroom solution. The new design focused on maximising space utilisation, improving accessibility, and enhancing overall efficiency.
Key Features of the Plastic Cleanroom:

Optimised Space Utilisation:
Plastic shelving replaced bulky stainless steel units. These shelves were specifically designed, allowing better use of vertical space.
The new layout freed up walking paths and created open areas for easier movement of personnel and equipment. These Modular Units are on casters and can be moved accordingly to requirements.
Clear Windows for Better Visibility:
Shelving and equipment were strategically placed to clear all windows, allowing natural light to flow through the workspace.
Improved visibility enhanced monitoring capabilities and communication between cleanroom zones.
Ease of Maintenance:
Plastic surfaces were resistant to corrosion, scratches, and chemical exposure, reducing cleaning time.
Non-porous materials ensured minimal particle generation and easy sterilisation with standard cleaning agents. With the shelving and storage units on castors, everything can me moved out of the way to ensure deep cleaning and maintenance can be done.

Improved Accessibility:
Wider walkways were incorporated into the design, making it easier for staff to navigate the cleanroom without obstructions.
Modular shelving allowed for quick adjustments based on changing storage needs or equipment requirements.
Energy Efficiency:
The lighter construction materials reduced HVAC strain by maintaining consistent airflow patterns more effectively than heavier stainless steel structures.
Improved airflow also enhanced contamination control in critical zones.

Results
The transition from a stainless steel cleanroom to a plastic cleanroom solution delivered significant improvements:
Space Optimisation: The new layout increased usable workspace by 25%, providing more room for operations without expanding the cleanroom footprint.
Enhanced Efficiency: Cleared windows improved visibility and communication between zones, while wider walkways reduced workflow bottlenecks.
Reduced Maintenance Costs: Plastic shelving required less cleaning effort and was more resistant to wear and tear compared to stainless steel.
Improved Workflow: Engineered shelving allowed staff to quickly reconfigure storage as needed, ensuring adaptability for future process changes.

This case demonstrates how transitioning from a poorly designed stainless steel cleanroom to a well-thought-out plastic cleanroom can significantly improve operational efficiency in pharmaceutical environments. By addressing wasted space, accessibility issues, and maintenance challenges, the plastic solution created an environment that was cleaner, more organised, and adaptable—all while enhancing productivity and compliance with regulatory standards.