Manufacturing Cleanrooms (ISO 7-8) | Consab

In general manufacturing, cleanrooms and controlled environments are primarily used to maintain the visual and functional quality of the finished product. Unlike highly regulated sectors where contamination threatens safety or critical functionality, the industrial challenge lies in preventing cosmetic defects and costly scrap.

A particle on a surface before the application of automotive paint creates a permanent visible defect. In plastic molding, the inclusion of contaminants can weaken the structure. These defects, while less critical than in the pharmaceutical or microelectronics industries, lead to productivity losses and compromise a company’s reputation for quality.

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Understanding the Challenges for Industrial and Manufacturing Companies
What Shapes Our Designs in This Industry
Our Achievements Specific to This Sector

Typical classifications: ISO 7 and ISO 8

The manufacturing industry generally operates in ISO 7 or ISO 8 environments, and sometimes in ISO 6 environments for particularly sensitive applications.

ISO 8 allows up to 3,520,000 particles of 0.5 microns per cubic meter with 20 to 48 air changes per hour. ISO 7 reduces this limit to 352,000 particles with 60 to 90 air changes per hour.

This difference directly affects costs. ISO 7 requires approximately three times the filtration capacity and air changes per hour compared to ISO 8. For many industrial applications, ISO 8 provides an adequate level of control, while ISO 7 is used for the most demanding processes.

Applications Requiring Environmental Control

Painting and coatings: Application of automotive, aerospace, or industrial paint requiring flawless finishes. Paint booths typically operate under ISO 7-8 conditions to prevent the inclusion of particles that cause visible defects.

Precision Molding and Assembly: Manufacturing of optical components, assembly of non-implantable medical devices, and production of precision mechanical parts.

Automotive electronics: Assembly of sensors for autonomous vehicles, driver-assistance systems, and LiDAR components that require a clean environment to prevent malfunctions.

Optimized Approach: Targeted Encapsulation

Full encapsulation of a manufacturing plant is generally neither necessary nor economically justified. We help identify the critical areas that truly require strict control—often just a few meters around a paint line or an assembly station rather than the entire facility.

This targeted approach reduces the initial investment by 60 to 80 percent compared to a fully enclosed facility, while still adequately protecting critical process steps. The decision to invest is based on an analysis of scrap rates, rework costs, and reputational impact.

A

Materials and Finishes for Durability

Industrial environments are subject to intense operating conditions—forklift traffic, movement of heavy equipment, and frequent cleaning with chemicals. The materials selected must withstand this repeated use.

Coating systems for industrial cleanrooms require chemical resistance to the solvents, acids, and alkalis used in processes and cleaning. The finishes must prevent cracking, chipping, or discoloration that would compromise visual cleanliness.

Floors often bear heavy loads and are subject to mechanical impacts. Epoxy or polyurethane coatings offer durability while maintaining a smooth, easily cleanable surface.

B

Architectural Choice: Modularity vs. Permanence

The choice between modular and permanent systems depends on the stability of the production lines and future needs.

Modular systems: Suitable for changing production lines, frequent reorganizations, or temporary installations. Can be disassembled, relocated, or expanded without requiring a complete rebuild.

Permanent systems: Justified for long-term, fixed applications, particularly when intensive cleaning protocols are required or when architectural integration with the building is a priority.

Hybrid solutions: A combination of permanent infrastructure (ceilings, HVAC systems) with modular partitions that offers flexibility while maintaining performance.

C

Temperature and Humidity Control for Processes

Beyond particulate matter, several industrial processes require precise environmental control.

The application of paints and coatings generally requires a temperature of 20–25°C and relative humidity of 40–60%. Excessive humidity causes application defects and slows drying. Insufficient humidity causes drying to proceed too quickly, leading to adhesion and appearance issues.

The molding of engineering plastics and precision assembly also benefit from stable temperature and humidity control, minimizing dimensional variations and adhesive failures.

D

Directional airflow and inspection lighting

Critical areas operate under positive pressure to prevent the intrusion of contaminants. Air flows from clean areas to less clean areas, creating a barrier against contamination.

For paint booths, the airflow must also effectively remove solvent vapors while maintaining cleanliness. The design incorporates appropriate exhaust and air renewal while maintaining ISO classification.

High-quality visual inspection requires uniform lighting without shadows—systems with a CRI > 90 and an illuminance of 800 to 1,000 lux enable precise color discrimination to detect finish defects.

E

Adaptation to Operational Constraints

Manufacturing facilities generally operate continuously with limited downtime windows. Our approaches enable:

Phased installation: Segmentation that allows for gradual commissioning without a complete production shutdown
Temporary design: Barriers and partitions that allow construction to take place adjacent to active operations
Close coordination: Detailed planning that minimizes the impact on production, with teams working during shutdowns or night shifts

Consab expert analyzing control systems

THE CONSAB DIFFERENCE

Our strength lies in our ability to offer you unparalleled consulting services thanks to our:

Independence from manufacturers:

Recommendations based on your actual needs, budget, timelines, and technical requirements—not on a pre-determined catalog.

Integrated design-build expertise:

The ability to manage both design and construction, allowing us to anticipate on-site challenges as early as the consultation phase—helping you avoid surprises, delays, and additional costs.

Agile and personalized approach:

We offer either full-service management of your project or a more targeted approach for a specific phase.