Reduce Risk of Cleanroom Non-compliance Using CFD
GMP Compliance
Risk mitigation
Identify poorly ventilated zones and assess potential airborne particle accumulation.
Data-Driven Redesign
Product safety
Customized evaluation of critical operator positioning to assess particle concentration risks and potential contamination.
Increased energy efficiency
Lower OPEX
Optimize airflow rates to minimise fan energy consumption, prevent system over-dimensioning, and maintain compliance.
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Challenge
The client required collaboration for accelerating of their cleanroom design without compromising compliance, while optimising for energy efficiency—particularly fan power consumption.
Meeting GMP requirements is inherently complex and can often lead to overdesign. However, issues with particulate concentration typically only become evident once the facility is operational. This is why early-stage risk assessments are essential: they help avoid unnecessary design redundancies, reduce long-term costs, and enhance overall energy performance.
Approach
Aerotak applied our state-of-the-art virtual cleanroom testing using CFD to predict performance. The model tracked air particles and visualized airflow patterns, pinpointing areas of concern. Enabling rapid evaluation of design alternatives and worst-case scenarios before physical implementation.
Result
The customer received a comprehensive performance analysis of the reference cleanroom design, accompanied by targeted improvement recommendations. Following alignment on feasible optimisation scenarios, a comparative assessment of the baseline and optimised designs was delivered to support data-driven decision-making. The final design significantly reduced project risk, fan power consumption, and commissioning time. These outcomes were achieved in record time thanks to the use of virtual testing methodologies.
Advanced simulation insights
Through advanced simulation, Aerotak identified critical airflow patterns that informed strategies to enhance energy efficiency and reduce the risk of particulate contamination originating from operators. These insights enabled the optimisation of ventilation system design—cutting emissions and energy consumption while maintaining full compliance with regulatory standards.