The Return On Investment (ROI) from choosing a modular cleanroom over a standard construction is significant. Modular cleanrooms are the lower cost and higher ROI solution because they offer faster installation, superior design removes expensive features, are easy to modify, can be moved to new location, have superior tax treatment and can offer longer life.
Figure 1. Modular vs Standard built cleanroom timeline
1 - Modular cleanrooms have faster and cleaner installation
All modular cleanroom components are prefabricated in factory.
Modular means no cutting or painting on-site.
Modular turnkey assembly means no waiting for each standard construction subcontractor (framing, painting, ceiling, electrical, HVAC, sprinklers, flooring etc.) to do their scope.
Figure 2: modular cleanroom recirculating design
Figure 3. Old inferior design – air handler ducted to HEPA filters
2. Modular cleanrooms have superior negative pressure plenum design
No need for custom air handlers for AC
No need for expensive ducting to every HEPA
Better air flow distribution and no need for monthly balancing
Figure 4. Addition to a modular cleanroom
3. Modular cleanrooms are easy to modify.
Modular walls are like LEGO set. Modular cleanrooms can easily add additional space, doors, and internal walls without disrupting cleanroom operations. Standard construction modifications are very dirty and slow.
Modular cleanrooms can easily upgrade cleanroom classification by adding HEPA fan filter units and return air walls. Standard construction requires new AC custom air handlers and extensive ducting to new HEPA filters.
Figure 5. Truck with crated modular cleanroom
4. Modular cleanrooms can be moved to new location
All components are modular so cleanroom can be easily disassembled and re-assembled at new location in same or new configuration. Standard construction cleanrooms cannot be moved.
Figure 6. Modular Cleanrooms Get Superior Tax Treatment
5. Modular cleanrooms get superior tax treatment
Modular cleanrooms can be classified as temporary equipment enclosure for faster equipment depreciation rate.
6. Modular cleanrooms can have longer life
Standard construction epoxy painted gypsum board walls break down over time when subject to frequent acid/base cleaning regimen required for CGMP pharmaceutical cleanrooms. The repair of standard construction walls can be expensive, slow and dirty.
Modular cleanroom walls can be fabricated with chemically resistant FRP, painted aluminum or even stainless-steel surface. Modular cleanroom walls core materials such as aluminum honeycomb are non-organic and will not feed microbial growth.
Cleanroom needs change over time and the ease of modifying modular cleanrooms is big advantage to extending life of cleanroom.
Modular cleanrooms offer better ROI than standard construction cleanrooms because modular cleanrooms are faster install, modular design lowers cost, are easy to modify, can be moved to new location, get superior tax treatment and can have longer life.
The author Anthony Chien has worked at American Cleanroom Systems for past 12 years. He has more than 40 years of cleanroom experience. Anthony has a BS and MS in Electrical Engineering specializing in semiconductor manufacturing from the University of Illinois. American Cleanroom Systems is a design build modular cleanroom manufacturer based in Rancho Santa Margarita CA. It is expert in ISO-5 through ISO-8 (class 100 to class 100k) modular cleanrooms for pharmaceutical cleanrooms, medical device cleanrooms, and industrial cleanrooms.
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