Overview
Datwyler Pharma Packaging India Pvt. Ltd.’s Maharashtra facility manufactures medical rubber closure caps and stoppers for pharmaceutical drug delivery systems. In this project, the facility implemented a modular approach to its clean rooms, focusing on non-progressive cleanroom walls and T-grid ceilings to enhance flexibility and adaptability.
Objective
Datwyler identified the need for a clean room layout that could be easily modified over time due to process upgrades, machinery upgrades, or other operational reasons. The goal was to design clean rooms that could accommodate future modifications with minimal downtime and optimal use of existing infrastructure.
Approach
To achieve modularity, non-progressive clean room walls were chosen. These walls, combined with T-grid ceilings, provided a modular framework for the entire cleanroom shell. An Indian manufacturer with expertise in non-progressive walls and T-grid ceilings was selected after thorough vetting of their past installations. This vetting process included visiting the manufacturer’s facility and inspecting their reference projects, which were operational. During installation, close supervision ensured the correct approach and sequence were followed to maintain quality standards.
Results
The implemented clean rooms offer exceptional quality and full modularity. Anticipated future modifications are easily achievable with the modular walls and ceiling concept:
- For upgrading the ISO classification, a ceiling tile needs to be replaced by a FFU with corresponding connections, and vice versa for downgrading.
- Modularity extends to lux levels, making it easier to add more lights to the ceiling.
- If new equipment larger than the door size needs to be brought in, only a limited number of wall panels need to be dismantled and reinstalled.
- Service wall panels for the down-take of pipes/cables up to equipment are easily achievable.
- In case of future equipment placement adjoining an insulated wall panel, the corresponding panel can be easily replaced by a service panel.
- The room geometry itself is easily modifiable.