How Continuous IAQ Monitoring Can Reduce Energy Costs in Cleanrooms

Today, cleanrooms and controlled environments are being installed in many facilities in a wide variety of industries, from pharmaceuticals and biotechnology to life sciences, microelectronics, and food packaging, to protect their products or processes from contamination. The control of airborne particles within these rooms is paramount, where contaminants—even those as small as a few microns—can wreak havoc, causing product defects, introducing data anomalies, and compromising research results.

To combat these contaminants, these specialized rooms rely on air purification and air changes per hour (the number of times per hour the air volume in a given space is replaced).

However, this comes at a cost. The sheer volume of air changes required to maintain pristine conditions means cleanrooms are significantly more energy-intensive than other areas within a facility. In fact, cleanrooms typically perform several hundred air changes per hour, making them more than 25 times more energy-intensive than non-classified areas within a facility.

In this post, we’ll explore the origin of high energy usage in cleanrooms and present a solution by which facilities can reduce these costs without compromising operational standards and maintain regulatory compliance.

IAQ Particle Count Monitoring and Regulations: Understanding ISO14644-1 Standards

ISO14644-1 standards are the globally recognized framework for cleanroom classification and operation. These classifications are primarily based on the maximum allowable concentrations of airborne particles (Table 1). For instance, a Class 4 cleanroom permits no more than 352 particles (0.5 µm in size) per cubic meter of air.

These size ranges are significant because these particles can remain airborne for extended periods and, due to their size, can easily carry contaminants or pathogens, posing a serious risk to critical processes and products within cleanrooms.

The ISO 14644-1 standards not only define the limits for particle counts but also set forth the testing methods necessary to certify a cleanroom’s compliance. Regular monitoring and adherence to these standards ensure that a cleanroom’s environment is kept within the specified particle concentration limits, thus maintaining the mandated level of cleanliness.

Navigating Compliance Challenges

Compliance with ISO14644-1 standards is not static, as the classification of a cleanroom can change based on the results of regular audits and particle count measurements. Cleanroom audits are necessary to document the facility’s compliance, including internal audits by the facility’s staff and external audits by an independent auditor or regulatory team.

Failure to comply with these standards can lead to significant repercussions, including the potential for product contamination, regulatory fines costing thousands of dollars, and damage to corporate reputation. The cost implications of non-compliance, coupled with the expenses related to conducting and potentially failing external audits, underscore the importance of investing in internal auditing with reliable, continuous IAQ monitoring solutions to ensure compliance.

The Role of IAQ Monitoring

IAQ monitoring plays an indispensable role in the operational management of cleanrooms. By continuously measuring particle concentrations, facilities can make data-driven decisions to adjust their air handling systems, ensuring optimal air purity levels while minimizing energy use.

Modern IAQ monitors can detect a wide range of particle sizes, collecting data that can be used to demonstrate regulatory compliance and inform operational adjustments. These devices often integrate seamlessly with Building Management Systems (BMS), allowing real-time adjustments to air filtration and circulation rates based on the current particle counts.

The High Operating Costs of Cleanroom HVAC Systems

The operational expenditure of maintaining a cleanroom is substantial, with the cost ranging from $100 to $1000 per square foot. Cleanroom HVAC systems are the cause, using up to 50% of a facility’s total energy usage. Air ventilation uses 25% to 46% of this energy consumption, largely due to the hundreds of air changes per hour.

However, it is not necessary for cleanrooms to have such a high number of air changes to maintain compliance. By optimizing the air change rate according to the measured particle count rather than a constant rate, a facility can lower the number of air changes to the actual need, leading to significant energy and cost savings.

Optimizing Air Changes to Provide Substantial Savings

Traditionally, cleanroom HVAC systems operate continuously, regardless of the particle concentration, leading to an unnecessarily high air change rate. This 24/7 approach is unnecessary, as most particles come from personnel.

Introducing demand-controlled filtration (DCF), where ventilation speeds are reduced based on real-time particle counts, has been shown to reduce energy consumption by as much as 70%, according to recent studies. Such optimization not only yields savings but also ensures compliance with regulatory standards.

Continuous IAQ Monitoring: The Key to Optimization

The success story of EMD Millipore (now MilliporeSigma) highlights the potential savings achievable through continuous IAQ monitoring. By integrating IAQ monitors as particle counters with their Building Management System (BMS), they achieved a staggering 69% reduction in energy use, translating to significant financial savings. Their continuous monitoring allowed for real-time adjustments to the HVAC system, ensuring efficient energy usage without risking non-compliance.

Evolving IAQ Technologies

Advancements in IAQ technology have made it easier for cleanroom operators to maintain compliance and operational efficiency. From sophisticated sensors capable of detecting minute particles to AI-driven analytical tools that predict when air quality may deteriorate, these technologies provide a comprehensive approach to managing cleanroom environments. Coupled with data analytics, continuous monitoring facilitates informed decision-making, enhancing both compliance and cost-effectiveness.

By embracing continuous monitoring technologies and integrating them with existing BMS, facilities can ensure compliance with ISO14644-1 standards, protect their processes and products, and optimize energy usage, paving the way for more sustainable and efficient operations.

An IAQ Monitor for your Exact Air Quality Needs

The introduction of the Flair IAQ monitoring device represents a leap forward for cleanroom facilities. This device works round-the-clock, providing data to the facility’s BMS and adjusting air change rates as needed. With the Flair, facilities can maintain compliance with the exact amount of energy required, avoiding unnecessary costs.

To further empower facility managers, the Flair comes with access to the Airlytics Dashboard (Figure 2), which gives both average users and expert facility managers access to real-time insights into their cleanroom air quality, along with many other tools. The Flair, along with the Airlytics dashboard, are invaluable for making informed decisions about IAQ measures and optimizing operational efficiency.

Final Thoughts

High energy consumption has long been a concern for facilities operating cleanrooms. However, with advances in IAQ monitoring technology and a strategic approach to HVAC system management, it’s possible to significantly reduce energy costs. Continuous monitoring represents this sound financial strategy, turning cleanrooms into more sustainable operations.

For those in the field, embracing these technologies and strategies can lead to substantial benefits, both environmentally and economically. If you’re looking to optimize your cleanroom’s operations, consider a complimentary personalized IAQ monitoring assessment to start saving on energy costs today.

For more information and to request a free assessment, click on the link above and embark on the journey to more efficient and cost-effective cleanroom operations.