A design engineering firm came to us to design a medical environmental control system (ECS) that could maintain <3% relative humidity (RH) and 75°F temperature ±2° for automated packaging of biotherapy reagents, some of which were highly sensitive to moisture and sensitive to heat. The desiccant humidity control and temperature regulation system would be located in an ISO 8 cleanroom space with ambient air from 65-77°F (18.3-25°C) and at 35-75% RH. In addition, some of the packaged items would include liquids that would introduce an evaporative load into the environment prior to the placement of heat seals. The heat sealing equipment would introduce 400W of heat to the environment. Finally, the machine would contain a stainless steel, pressurized dry-environment enclosure air-locked to minimize the introduction of ambient air.
In order to dehumidify the system to the required conditions, Air Innovations introduced a desiccant dryer with pre-filtered air into the design of this environmental control system. Re-circulated air is then returned to the acceptable ambient temperature and passed through HEPA filtration to maintain the cleanroom environment, while the hot exhaust is ducted away from the ECS. The system was designed to sit below floor level, though the end location was ultimately moved onto floor level. The air change rate was designed to ensure a recovery time of less than 30 minutes anytime after the doors opened.
- Relative Humidity controlled to ±0.5%, and set to <3% RH with 0.011 µg/min. continuous evaporation latent load plus moisture leakage loads.
- Temperature controlled to 75°F ±2°F
- ISO 8 cleanroom level HEPA filtration (99.97% to 0.3µ)
- Environmental Control System designed to fit in a 37.5” x 52” trench
- PID loop controls for temperature and humidity
- Stainless steel 304 exterior
- Airflow designed for 90 CFM – Max. external static pressure of 1”
- Hot-gas bypass refrigeration control
- 1kW electric reheater
The medical environmental control system controls humidity to desiccant levels and maintains a steady temperature in the ISO 8 cleanroom space. The system also employs HEPA filtration.
- Meets all key specifications
- Addresses humidity requirements through both creation of a vapor barrier and use of return air via a desiccant dryer to counteract internal evaporative loading.
- Meets UL standards
- Features stainless steel 304 exterior.
Additionally, we have whitepapers available covering the aerospace industry, the semiconductor industry, and our Micro Environments product line. The whitepaper page can be found here. If you would like to read case studies for other industries, view our general case studies page. If you are interested in viewing more case studies for the pharmaceutical industry, look at the items below.
Interested in explosion-proof HVAC in other industries? Read more
Air Innovations’ Cleanroom Systems division was asked to design a Class I, Div I Enclosure. This form of environmental control system (ECU) is used to control the process air needed for solvent-based coating of pharmaceutical tablets. The final environmental control solution needed to dehumidify the ambient air in a single pass (versus re-circulating air) – which is a critical parameter for the fluid-bed coating process – in an explosion-proof environment.
Read our pharmaceutical whitepaper: A Healthy Environment
We configured the explosion-proof air conditioner to provide once-thru air to a single LDCS-PRO coater. The explosion-proof HVAC system was designed for near continuous operation to ensure a non-condensing environment and to provide thermal stability. The electrical panel, humidifier, and compressor are encased inside the pressurized cavity of the ECU to protect against sparks, to keep out volatile gases, and to remain isolated from other compartments.
- Ambient inlet conditions range from 21°C to 24°C temperature and from -12°C to 16.7° C dew point
- Design output conditions maintained at 22°C ±2°C temperature and at 10°C ±1°C dew point
- Ambient change rates over a 1-hour period are no more than 1°C temperature and no more than 5% RH
- Electrical and mechanical sections are pressurized with purge gas via a Cyclops system, with max external static pressure 0.5”
- System airflow 750-1000 CFM
- Fan is an explosion-proof direct-drive impeller wheel
- The heater is a 5.0kW electric reheater, Class 1 Division 1, Groups C&D, T2D (max 215⁰C)
- UL approved
- All design specifications and parameters were met, incl. Class 1, Division 1 requirements (for the fluid-bed coating applications)
- The explosion-proof air conditioners were designed for near continuous operation, as outlined.
- All controls were mounted behind a viewing pane.
- Stainless-steel construction
- First piece delivered in 5 months (within quoted lead time).
We have whitepapers available covering the aerospace industry, the semiconductor industry, and our Micro Environments product line in addition to our case studies. The whitepaper page can be found here. If you would like to see case studies for other industries, view our general case studies page. If you are interested in reading more case studies for the pharmaceutical industry, look at the items below.
Proper technology is needed to control close-tolerance cold and dry environments in order to protect on-board process reagents. The company brought an initial concept for a custom chemical process control system to Air Innovations. Our task was to refine the design to meet the customer’s performance, serviceability and space specifications, and to prototype, test and ramp up the unit for manufacturing.
Developing the right chemical process control solution for this client required us to overcome a number of challenges. Since the client sells these FDA approved units to a worldwide customer base, we had to design a system that could hold temperature and humidity levels across a broad range of differing environmental conditions while operating 24/7 year-round.
Air Innovations designed a chemical process control solution that relies upon two independent cooling coils and process fans operating on an alternating basis managed by software and various sensor inputs to determine switchover intervals. This ensured the cooling coils continued to operate without defrost interruptions well below the point of freezing, while fitting into the required space equivalent of a small microwave.
1. All designed specifications were met by Air Innovations.
2. An environmental control system with two independent cooling coils and process fans was designed, prototyped and manufactured.
3. The system controls close-tolerance cold and dry environments, protects onboard process reagents, and meets all performance, serviceability and space specifications, while holding temperature and humidity levels 24/7.
If you’re ready for a custom solution from Air Innovations, contact us by submitting a quick Project Inquiry today.
We also have whitepapers available in addition to our case studies. These whitepapers cover the aerospace industry, the semiconductor industry, and our Micro Environments product line, and can be found here. If you would like to read case studies for other industries, view our general case studies page. If you are interested in viewing more case studies for the pharmaceutical industry, look at the items below.
Two separate pharmaceutical packaging firms required unique air conditioning technology. In one case, a returning customer requested precisely controlled conditions to provide an exact level of uniform drying for fluid bed dryers used by the manufacturer to coat capsules, pills and caplets. The second pharmaceutical company required a single packaged system containing humidification and a cooling system, plus a desiccant dryer, for a blister pack packaging machine. The company requested broad flexibility in environmental control in anticipation of future requirements in the industry.
Read our pharmaceutical whitepaper: A Healthy Environment
For the first company, Air Innovations delivered a precision pharmaceutical process control unit supplying air to the process tools with the ability to add or remove humidity and maintain a 50°F dew point level. For the second company we developed a multiple device pharmaceutical HVAC system designed to provide either a very dry or a very humid environment on demand.
1. All design specifications were met in both pharmaceutical HVAC systems.
2. For the first company an environmental control system supplying air to the process tools that could add or remove humidity and maintain 50°F dew point level was designed.
3. For the second company Air Innovations developed a multiple device system that could provide either a very dry or very humid environment — on demand.
In addition to case studies, we have whitepapers available covering the aerospace industry, the semiconductor industry, and our Micro Environments product line. The whitepaper page can be found here. If you would like to view case studies for other industries, see our general case studies page. If you are interested in seeing more case studies for the pharmaceutical industry, look at the items below.