Laminar flow box for GMP production line

Rapid custom development and batch production project for a new pharmaceutical plant. The specific size and assembly requirements compounded the challenge for the laminar clean hood design.

Industry:

PPE & Air Purification Equipment

Medical Devices

TRL:

2 → 9

Project duration:

1.5 months

Challenge

The customer from the pharmaceutical industry approached EnCata with an urgent need to quickly design and produce a batch of laminar boxes for their new pharmaceutical plant. A small but important omission in the plant’s clean area design endangered the project’s commissioning and GMP certification plans. I.e., the plant procurement failed to deliver the clean hoods that should fit in the developed and nearly finished floor plan. 

The client thus demanded a very aggressive 1.5 month deadline for the rapid development and production of clean hoods.  We enthusiastically took on the challenge.

Our Role

  • CAD engineering development
  • CFD analysis
  • Prototype manufacturing
  • Electrical engineering
  • Electronics development
  • Full engineering documentation development
  • Prototype manufacturing
  • Batch production

Technologies Used

Centrifugal fan

Centrifugal fan

HEPA air filtration

HEPA air filtration

CFD simulations / analysis

CFD simulations / analysis

Airflow pressure sensor

Airflow pressure sensor

RS485

RS485

Programmable logic controller (PLC)

Programmable logic controller (PLC)

CNC milling

CNC milling

CNC laser cutting

CNC laser cutting

CNC metal bending

CNC metal bending

Stainless steel welding

Stainless steel welding

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In-house batch production

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Approach & Solution

The laminar clean chamber is an independent piece of equipment that creates laminar flow inside the clean area in a plant’s weighing area.

In addition to the specific air quality and dimensions requirements, it was required to assemble the hoods on-site as the plant line construction was already completed and there was no gate to facilitate placement of the preassembled hoods in the building. 

The designed system had a filter clogging control built-in, SCADA-compatible electronics software and automatic regulation of the clean area’s airflow rate. The electronic control unit provides the human interface for the system control as well as a remote system performance control.

Drone Station case
Drone Station box
Autonomous Drone Station Box

Results

It took 1 month for EnCata to develop the engineering documentation and an additional 2 weeks to produce, validate, and test the first hood prototype. 5 more units were produced and delivered within the next 2 weeks, enabling the client to achieve their initial plant commissioning plans.

22 w. days 

required to design the documentation for the production start


6 units

delivered as part of this project in 30 working days


1.5 mounth

in total required to finish the task starting the design from scratch

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