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2500m² Modular softwall cleanrooms for VDL-ETG
Case study:
The 2500m² Modular softwall cleanrooms
At the VDL-ETG premises in Almelo, our engineers have successfully completed the construction of several modular softwall cleanrooms. The entire project, consisting of various phases, and the interconnected cleanrooms now span more than 2500m² of floor area and are constructed entirely using the modular softwall cleanroom system. More detailed information regarding phases x1 and x2 can be found in the case study.
Modular Softwall cleanroom
Due to prefabrication, modular cleanrooms offer shorter lead times and can be installed efficiently on-site. As operational or process requirements evolve, modular cleanrooms can easily be expanded, downsized, reconfigured, or relocated—one of the key reasons VDL opted for our modular cleanroom system. The initial capital expenditure for a modular cleanroom is significantly lower than for traditional construction. These characteristics deliver time savings, flexibility, and cost reductions.
The total floor area of the softwall cleanrooms is distributed across three interconnected production halls. The cleanrooms are utilized for the clean assembly and testing of large high-tech semiconductor modules. These facilities are equipped with modern fan filter units that are highly energy-efficient and generate minimal thermal load. The fan filter units ensure optimal airflow within the cleanroom, resulting in an ISO Class 5 validation in as-built status. When fully furnished and operational, an ultra-clean working environment (exceeding ISO Class 7) will be comfortably maintained.
Overpressure control
Due to the scale of these interconnected cleanrooms, the decision was made to divide the fan filter units into distinct groups/zones. Each group is connected to an individual differential pressure gauge, enabling VDL-ETG to regularly inspect the status of the HEPA filters and monitor pressure buildup across the H14 HEPA filtration system.
- Lower differential pressure than standard baseline readings may indicate a leaking HEPA filter, potentially allowing unfiltered particles to enter the cleanroom area.
- Higher differential pressure than standard baseline readings may indicate a clogged or saturated HEPA filter. Depending on the ambient air pulled into the fan filter unit, a HEPA filter lasts an average of 5 to 7 years before becoming too saturated to maintain effective filtration performance.
The airflow within each zone can be individually adjusted to the required velocity. Substantial objects such as furniture and equipment inside the cleanroom can affect airflow dynamics. To achieve proper room flushing and maximize particle removal during cleaning operations, the laminar airflow from the fan filter units is set to the recommended velocity of 0.45 m/s (meters per second) +/- 20% on average.
Cleanroom validation
Curious about your cleanroom's performance? Contact us to have one of our qualified CTCB-I engineers validate your cleanroom or laminar flow cabinet. Validation is conducted according to a predetermined protocol measuring airborne particle counts, particle sizes, and laminar airflow velocity. The number of sampling locations is determined based on the targeted ISO classification and facility dimensions. Following testing, a comprehensive validation report is prepared and issued.
Validation interval
In accordance with ISO 14644-1:2015, cleanrooms and laminar flow cabinets must be validated following a maintenance and validation program tailored to the specific process requirements. In practice, this typically leads to a 12-month validation interval for cleanrooms operating at ISO Class 6 or higher. For cleanrooms or flow cabinets operating at ISO Class 5 or lower, the validation interval is generally 6 months.
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