Why Elearning Solves The Manufacturing Training Dilemma
Why Elearning Solves The Manufacturing Training Dilemma
Rooms
What is a clean room?
A cleanroom (GMP cleanroom), in my mind, is a combination of engineering design,
fabrication, finish and operational controls (control strategy) that are required to convert a
“normal” room to a “clean room”. This blog will attempt to explain the necessary
characteristics of a regulated company clean room not producing potent chemicals or active
or hazardous biologicals. If there are significant containment requirements, the requirements
would be outside the scope of a “simplistic” blog like this. In a pharmaceutical sense, clean
rooms are those rooms that meet the code of GMP requirements as defined in the sterile code
of GMP, i.e. Annex 1 of both the EU and PIC/S Guides to GMP and other standards and
guidance as required by local health authorities.
In a nutshell, if you manufacture a non-sterile medicinal product, you should be very careful
about classifying or grading your clean areas, for example, classifying a room as “Grade D”.
Whilst not a code requirement, many regulators, like the Australian TGA will expect you to
fully comply with all of the requirements for a Grade D room as defined in Annex 1, even if
it’s not a GMP code requirement. Therefore, if you have classified the room as Grade D, you
will need to live with the consequences and costs of maintaining this level of cleanroom
cleanliness during operation.
If you are a manufacturer of sterile medicinal products, you must follow the EU or PIC/S
GMPs, namely Annex 1.
For aseptic (processed), sterile, or low bio-burden and liquid medicinal products, the
opportunistic microorganisms usually will find supportive media in which to flourish, or in
the case of an aseptically processed product, a single microorganism could be catastrophic.
So these facilities are typically designed with “dirty corridors” as you want to keep potential
organisms out of the cleanroom. Also, unlike powders, droplets of liquid don’t generally
“leap up” and float around the facility.
Designs can become complicated if the products or raw materials are highly potent, which
cause occupational health and safety issues or a need for biological containment. These are
outside the scope of cleanroom basics, reading this blog on dedicated facilities could assist. If
you want to know more, our clean room designers can help.
Annex 1, Clause 47 specifically states that sliding doors are not permitted in sterile
plants as they typically create uncleanable recesses, projecting ledges and recesses. For
these reasons, they should not be used in non-sterile facilities either.
What are the sources of contamination in a cleanroom?
It should be noted that cleanrooms do not eliminate contamination; they control it to an
acceptable level.
Our genuine concern is microbial contamination in most cases. Traditionally the technology
did not exist to measure microbial contamination in real-time directly, so the “all airborne
particulates” limits were used and extrapo
So the GMP’s set out defining and controlling sources of particulates to prevent possible
“microbial contamination”.
Personnel present in a cleanroom usually are the highest source of airborne particulates, and
microbial contamination risk, so proper gowning and limiting the number of staff into a room
must be carefully controlled to be within the cleanroom design.
Each of the three items above is equally important. Let’s look at them in more detail:
not generate their contamination, i.e., don’t create dust, or peel, flake, corrode or
provide a place for microorganisms to proliferate
are easy to clean, i.e., all surfaces are easily accessible, there should not be any ledges
or recesses
are rigid and robust and won’t crease, crack, shatter or dent easily.
There are a wide variety of suitable material choices, ranging from the more expensive
Dagard panelling, as shown in the photo below, with sliding doors (not recommended as
mentioned earlier), or the best and most aesthetically pleasing option is glass, i.e., as at the
end of the corridor. Among the cheapest options can be plaster-board with a two-pot epoxy
coating, and there is a range of other options available.
Particles (contamination) in the air tend to either float around. Most airborne particles will
slowly settle, with the settling rate dependent on their size.
A well-designed air handling system should deliver both “fresh” and “recirculated” filtered
clean air into the cleanroom in such a way and at a rate so that it flushes the particles from the
room. Depending on the nature of the operations, the air taken out of the room is usually
recirculated through the air handling system, where filters remove the particulates. However,
high levels of moisture, harmful vapours or gases from processes, raw materials or products
cannot be recirculated back into the room, so the air in these cleanrooms is often exhausted to
the atmosphere. Then 100% fresh air is introduced into the atmosphere of the facility.
Rooms occasionally experience high airborne particulates during routine operation, such as in
a sampling room or dispensary. In these cases, the room needs to be cleaned quickly between
procedures to prevent cross-contamination.
The volume of air introduced into a cleanroom is tightly controlled, and so is the volume of
air removed. This is because most cleanrooms are operated at a higher pressure to the
atmosphere, which is achieved by having a higher supply volume of air into the cleanroom
than the supply of air being removed from the room. The higher pressure then causes air to
leak out under the door or through the tiny cracks or gaps that are inevitably in any
cleanroom.
As a rule of thumb, the room you need to be the cleanest operates at the highest or the lowest
pressure within a facility.
A good air handling system makes sure that air is kept moving throughout the cleanroom.
The key to good cleanroom design is where the air is brought in (supply) and taken out
(exhaust).
For sterile or aseptic processes that need Grade A air, the airflow typically mimics a plug
flow from top to bottom and is unidirectional or “laminar”. Therefore, careful consideration
should ensure that the “first air” is never contaminated before it comes into contact with the
product.
This involves:
This refers to the number of times the air is changed within a cleanroom. It is calculated by
taking the total volume of air introduced into the cleanroom over an hour and dividing it by
the volume of the room. It is expressed as air changes per hour (ACH), and for cleanrooms,
this is normally between 20 and 40 air changes per hour.
Table
Micron
A micron (or micrometre) is a millionth of a metre. A human hair is around 100 microns
thick—particles less than 50 microns. Bacteria measure 1 or 2 microns.
HEPA filters
HEPA stands for high-efficiency particulate air. HEPA filters are one of the most critical
elements of a cleanroom. They consist of a large, box-shaped filter that removes airborne
particles of specific sizes very efficiently. They must also be monitored and tested regularly
to make sure they are still integral.
HEPA filters are composed of a mat of randomly arranged fibres, typically composed of
fibreglass with diameters between 0.5 and 2.0 microns. Key factors affecting function are
fibre diameter, filter thickness, and filter face velocity.
Dispersed oil particle testing or integrity testing is a testing procedure to ensure that a HEPA
filter meets its efficiency specification and is properly seated and sealed in its frame.
Airlock
An airlock is a room where personnel, materials or equipment are transferred into or out of a
cleaner environment. It can be the size of a small “cupboard” or a large room where
personnel change into and out of cleanroom garments or where a forklift can enter.
This refers to the level of cleanroom particulate cleanliness based on many airborne particles
of a specific size per cubic metre. ISO 8 is the starting cleanroom level. For example, a sterile
cleanroom for the pharmaceutical industry will need to achieve ISO 5. Classes better than
ISO 5, ISO 4 are generally only required for the electronics industry.
Grades A through D refer to cleanroom cleanliness for sterile products only, these Grades can
be related to the ISO Classes, but they are not the same.
The classification of 100, 10,000, and 100,000 particulates per cubic foot refer to the
withdrawn FED-STD-209 E Airborne Particulate Cleanliness Classes in Cleanrooms and
Clean zones cancelled on 29 Nov 2001 U.S. General Services Administration (GSA).
This was superseded by International Standard ISO 14644, Cleanrooms and controlled
environments-Part 1: Classification of air cleanliness, and Part 2: Specifications for testing
and monitoring to prove continued compliance with ISO 14644-1.
The time it takes from a contamination event to the room regaining its designed cleanliness
level as per the GMP requirements.
Particle count
A test that samples a fixed volume of air and captures, filters and counts airborne particles by
their size. This is performed when the cleanroom is “at rest” or “in operation”. Both airborne
viable (alive) and non-viable (not live) particle counts are performed for pharmaceutical
operations. This is performed as part of the certification of a cleanroom and during regular
environmental monitoring.
Cleanroom certification
If you would like to know more, you can follow the links below.
A clean room explained in simple terms, 15 things you should never see in a clean room, 12
deadly clean room sins, what is your clean room costing you, optimising your clean room,
getting QA buy in, now you know it all, take the clean room quiz.
FED-STD-209E: https://en.wikipedia.org/wiki/FED-STD-209E
WHO Annex 5:
https://apps.who.int/prequal/info_general/documents/TRS961/TRS961_Annex5.pdf
Thanks
Dee, thanks for the clarification request, I should have been clearer in my blog.
In my mind, one of the basis tenants of GMP or QMS are, “say what you are going to
do” and the “do what you said”, it you don’t you are not complying with your own
QMS and any auditor should cite the non compliance.
Specifically relating to this subject, if the company assesses the risk associated with
your (non-sterile) product requiring Grade D air classification, then the regulatory will
assess your company against this standard.
So good.
sir can u elaborate why we dont want fungus inside clean room or sterile
preparations?
although we avode gram negative bacteria bcoz of it has cell wall as endotoxin. Bt
fungi dosent have any cellwall even terminal sterilization kill spores also so stil why
we avoide fungi?
1.
o Cleanroom Equipment Manufacturer
Very specific information on the clean rooms. now sir can you help me to get the
information for three different condition for pressure differential. WHO says 5 to 20
Pascal’s will be safe limit but if I want to decide NLT limit for these different
conditions. only one limit for each condition (no lower and upper limits).
1. What will be the DP limit for classified to unclassified rooms
2.What will be the DP limit for classified to classified rooms with different grades e.g.
C to D.
3.What will be the DP limit for classified to classified rooms with same grades e.g. D
to D.
Hi Lucky,
Great question ! The guidelines for differential pressures between areas of
different grades varies a little between the regulatory bodies. Generally
however, we aim for 15Pa between areas of different classification (or
unclassified to Grade D), you will meet all guidelines. Often designer increase
this to 20Pa to accommodate any calibration tolerances of differential pressure
instrumentation.
There are no mandated requirements for pressure differentials between room
of the same grade, however you would be expected to have a design drawing
showing your differential pressure regime that supports your contamination
control strategy (see Trevor’s explanation of the ‘clean corridor’ concept).
Also, if you process potent/toxic materials in an Isolator, the room should
provide Secondary Containment by having a lower pressure relative to
adjoining areas.
If you need any help, please get in touch with the PharmOut team and we’d be
happy to assist you further.
With an increasing emphasis on maximizing product yield, improving quality control
and ensuring safety, companies throughout many industries are looking to install
clean-rooms in their facilities.
What is the consensus of clean room expert in using a pneumatic tube terminal?
Hi
Nice article, thanks!
What classification do you expect after the last purification step in a synthetic API
production for parenteral DP? Which legislation can you refer to and what are the
arguments?
Sir..Can i know what is the differential pressure maintain from Grade A to Grade D in
differential pressure (Pa) units?
Typically you should have between 10 to 15Pa between each change in grade,
you can have bubbles and sinks, so you don’t necessarily end up with
12.5+12.5+12.5+12.5=50Pa in the grade A area, in high potent drug facilities
or biologicals you may have the clean rooms negative to atmosphere. When
working in Indonesia a few years ago they insisted in higher levels of
separation, and doors, I think, I counted 13 doors to get to the grade B/ A core.
in Australia it could be roughly half that, so watch out for your local
requirements too.
Hi
Just a quick question
If I have gmp facility in Australia can I have my drying room next to my extraction
room
The whole facility is GMP in Australia
could the dynamic pass box be installed between Iso-7 classified area (in operation)
and non classified area for transffering materials?
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Selecting materials and components for cleanrooms
5-Jul-2013
Choosing which materials to use for a cleanroom construction is increasingly complex due to
the wide variety of options now available. Jorge Nuero, Telstar, looks at key considerations
for optimising cost and ensuring safety and quality
When deciding on the materials and elements to be used in the construction of a cleanroom, it
is necessary to keep in mind the specific requirements and working conditions of each area.
Only through appropriate design will the cost of installation be optimised and the resulting
facility offer long-term safety and quality standards that meet user requirements.
The traditional building methods – where the walls and ceilings are constructed on site from
raw materials, followed by the application of a PVC or epoxy finish coating – are rapidly
being replaced by the use of modular elements built using self-supporting, factory-made
sandwich panels.
This transition has occurred due to the many advantages offered by the use of modular
elements, including:
The main disadvantage of the modular method is that it is less flexible when the time comes
to make changes in design, since it needs to be fully specified and designed in advance,
which also requires that joints be added between existing elements to provide transitions
between exiting and new construction.
There are a wide number of options when considering the use of sandwich panels, which in
turn enable an optimal solution to each specific set of requirements to be attained.
The need for more modular designs has led to increased use of layered panels
The fundamental parameters applicable to defining a panel are as follows: thickness; core
material; material and thickness of the skins (exterior surfaces); external finish; type of
jointing or fastening system; whether or not a perimeter frame is required, and behaviour and
resistance to flames. It is important to distinguish between ‘behaviour’ and ‘resistance’, as
failure to do so can result in specification errors.
Fire certification, from Class A (inert materials) to Class F (highly combustible materials)
Level of smoke production, from S1 (low smoke production) to S3 (high smoke production)
Level of production of liquid droplets, from d0 (does not produce droplets) to d2 (high
number of droplets)
The fire resistances (previously RF) of elements that comprise an enclosure are regulated by
Norm UNE-EN-11501-2:2009, which defines that fire resistance is primarily based on three
parameters: bearing capacity (R), integrity (E) and insulation (I). For example, a material
with a resistance of REI-60 will maintain each of these three characteristics for at least 60
minutes.
This norm also states the types of tests to be performed for partitions that separate two
independent fire sectors, which is not common in cleanrooms, except in certain instances
(ATEX rooms, partitions for separation from other areas, such as storage areas, offices,
technical zones, etc.).
The norm that should be followed when working with insulating sandwich-type portable,
double-faced metallic panels is Norm EN 14509:2005.
From a process perspective, the most critical element to consider is the material used for the
surface or skin that will be in direct contact with the room’s inner environment. In this
respect, it is important to know the cleaning and sanitation methods that will be employed
and to select the finishes accordingly.
For example, for a washing area where pressurised water is used daily, partition surfaces in
stainless steel can be justified. In addition, use of slip-resistant flooring with appropriate
slope towards the drain is required. Such considerations would not apply to a packaging area,
where an impact-resistant panel is more appropriate.
Stainless steel is ideal for areas where harsh cleaning chemicals will be used
For areas where hydrogen peroxide is used as a disinfectant or bio-decontamination agent, the
use of special insulation (type PET, PVDF) and surfaces of epoxy laminated resins
intertwined at high pressure (HPL) or the use of stainless steel needs to be considered. In this
case, decisions would be influenced not only by cost but also by the sanitising method
employed, the frequency of application and the concentration of the particular chemical
agent.
The purpose of the room also needs careful consideration. For example, it is not necessary to
achieve the same level of air tightness in a laboratory for quality control, working under
positive pressure as that in a zone where vaccines or cultures with biological hazards are
present. In this latter case, it is necessary to perform tests that demonstrate the absence of
leaks in ceilings and walls, secondary barriers of the containment area, and to design with
double sealing of all panels, utility, electrical and mechanical penetrations, light fixtures and
filter assemblies. In addition, doors may require inflatable joints and drains may require
hydraulic seals.
Flooring options
Floors that are typically installed in cleanrooms are of two basic types: epoxy resin or PVC.
The selection of which floor material to employ depends on several factors. Resin floors are
recommended for rooms where water is present or high humidity is expected, i.e. washing
areas, steam outlets, etc. Another factor to consider is the mechanical load that will be
presented when objects are moved. In this respect resin floors provide a higher resistance and
strength.
PVC floors in a tile format or laid from a roll (welded joints in both cases) are considerably
more economic and easy to install and replace. They are recommended for labs, hallways, or
rooms that do not handle a high volume of traffic or movement of heavy objects.
In certain areas where humidity is low or where there is an ATEX classification, conductive
floors (made of resin or PVC) are used to prevent static electricity. Following installation, it
is necessary for a certified contractor to perform some conductivity measurements to confirm
the correct installation and grounding connection.
Critical points that need to be taken into consideration during the design and installation
phases include:
Use of a vapour barrier that prevents any humidity infiltration that could produce bubbles of
gas or water (in the case of PVC) or cracks (in the case of resins). The relative humidity in the
existing slab should be measured before installation and an interior humidity of less than 3%
is recommended.
The surface should be smooth, clean and level, due to the fact that the finished surface will
replicate the defects found in the base, including any slope, cracks or irregularities in the
surface. The use of a self-levelling substrate or surface levelling compound can correct these
defects to a degree, but can use large amounts of material.
Particular attention should be paid to the proper treatment and sealing of the expansion
joints and the connection with other critical elements such as panels, drainage, etc., which
tend to be weak points.
The European norm for PVC floors is EN 14041 and EN 13813:2002, for industrial multi-
layer pavements (epoxy resin). Floors should also comply with the requirements established
by 2033/94/ECC relating to GMP recommendations.
Locating viewing panels
The design and location of the viewing panels within the cleanroom is important, not solely
from an aesthetic perspective but also for providing user comfort and operational efficiency.
For example, the use of view panels in a partition separating a filling line from its respective
packing line enables operators in both rooms to have visual contact and provide simple
instructions without having to leave their post. For this reason, considered location during the
design phase is critical.
From the aesthetic point of view, frequently the viewing panels are located in wall panels of
visiting and inspection halls, which permit the facility to be visited or supervision tasks of the
operators and equipment to be carried out without the need to disrupt the operation and
without needing to follow the strict protocols for admittance into controlled areas. The use of
view panels to the exterior is also very helpful to the operators when working on repetitive
tasks because it enables them to better take brief periods of relaxation while working without
having to leave their area.
Usually, the requirements are for viewing panels to be flush on both sides of the wall and the
void between each pane should contain drying agents to prevent humidity condensing. In
addition, the glass used should be tempered, so that in the case of breakage, it shatters into
small pieces, not shards or sharp fragments. In special cases, such as evacuation routes,
laminated glass should be utilised. In ATEX zones or walls dividing different sectors,
windows must be reinforced and fire resistant. In the case of photosensitive products, where
decontamination is performed through ultraviolet methods, the windows are usually protected
with coatings or films that filter the respective wavelength.
The design of cleanroom doors should be kept as simple as possible, avoiding the use of
elements that are difficult to clean, that have areas difficult to access or utilise rails or
complex mechanisms. Swing doors are recommended for most applications; they are simple
and more easily cleaned than roll-up or sliding doors. However, with swing doors, it is not
recommended to use perimeter joints due to the fact that they deteriorate with time and are
often placed on rails that are very difficult to keep clean.
For the same reason, the use of electrical, mechanical or hidden hinge devices to close the
doors is not recommended. Both sides of the door should be flush with the wall, to avoid
uneven surfaces when it comes time to clean.
Companies
Telstar Group
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