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  • The Importance of Cleanrooms in Semiconductor Manufacturing
    The Importance of Cleanrooms in Semiconductor Manufacturing
    • October 08, 2021

    It is a scenario that everyone is familiar with: you are using your cell phone to look up information – a street address, telephone number or very crucial TV trivia and your device freezes. Or worse, it shuts off entirely. Likely, the episode doesn’t stop there but continues to plague you until the phone is fixed or replaced. What causes this to happen? To understand what goes wrong, one must first understand how a cell phone chip – the brain and communicator of the entire phone – is made. And to understand that, one must be familiar with semiconductors and the way they are manufactured. Semiconductors are crystalline or glassy solids with distinct electrical characteristics. They are defined by their unique conductive behavior, somewhere between metal and insulator. Their electrical properties can be modified to allow amplification and energy conversion. Devices that use semiconductors pass currents more easily in one direction than the other with variable resistance and sensitivity to light or heat. To manufacture electronic technology, such as a cellular phone, semiconductors for integrated circuits are produced. This process begins with one of the most common elements on earth, silicon. Silicon is found primarily in sand and from there is refined to 100% purity before it qualifies for manufacturing. Absolute clarity is necessary to produce chips that function properly. Even the slightest imperfection can radically affect the quality of the manufactured product. To achieve this, pure silicon is heated until it reaches a molten state. Next, a perfectly structured silicon “seed” is lowered into the molten silicon. The chemical properties of the molten silicon allow a chemical bond to be formed between the seed and the chunk of solid silicon, which can slowly be pulled from the silicon as it cools, forming and solidifying around the seed. When the process is complete, the finished portion, a block, will mimic the physical characteristics of the original seed matter. The block is then carefully sawed into thin wafers. After all production steps are complete, a final protective layer is put over the entire wafer. With dimensions so minuscule, even the tiniest speck of dust can destroy the functionality of an entire chip.1 In order to accomplish this, pristine working conditions must be employed; hence, the creation of the “Cleanroom”. A cleanroom is an environmentally controlled environment where products are manufactured. Cleanrooms are defined as specially constructed, enclosed spaces where contaminants in the air are highly controlled with respect to airborne particulates, temperature, humidity, air pressure, airflow patterns, air motion, vibration, noise, living organisms, and lighting. The Importance of Cleanrooms in Semiconductor Manufacturing The level to which these particles need to be removed depends upon the standards required. The most frequently used standard is the International Organization for Standardization, ISO 14644 which establ...

  • Medical Cleanroom Garment Storage: How To Keep Cleanroom Garments Clean
    Medical Cleanroom Garment Storage: How To Keep Cleanroom Garments Clean
    • October 04, 2021

    Cleanroom garments are as clean as the places where they are kept. They play a vital role in protecting your cleanroom and employees, so it’s essential to take care of them properly. Let’s dive into the importance of keeping cleanroom garments clean, the difference between reusable and disposable garments, and the cleanroom garment storage you’ll need to always have sterile and fresh items on hand. MEDICAL CLEANROOM GARMENTS Cleanroom garments are an essential part of medical cleanroom operations. Garments are meant to prevent particles from the wearer from shedding and contaminating the cleanroom. In many medical cleanroom applications, they also protect the wearer from contaminants or harmful substances. Wearing garments outside of the sterile environment of a cleanroom can attract contaminants. The inside of the garment is also contaminated by particles from the wearer. It’s important to use clean garments each time a worker enters the cleanroom environment to protect sensitive products and processes within the controlled space from these particles. Properly cleaning protocols and cleanroom garment storage — whether for reusable garments or new disposable ones —  are important to protect workers and the cleanroom from possible contamination. If garments are contaminated, both the integrity of your work and the safety of your employees are at risk. Particularly in medical cleanrooms, there’s no room for error. Contamination could interfere with test results, corrupt substances, compounds or devices, and potentially endanger patients’ lives. REUSABLE VS. DISPOSABLE CLEANROOM GARMENTS Reusable cleanroom garments can be cleaned in-house or by a third-party cleaning service. Disposable garments are typically meant to be worn once, though it depends on the product and the manufacturer’s recommendations. REUSABLE CLEANROOM GARMENTS Reusable garments must be washed with a special process (and extremely hot water) to remove particles and sanitize them safely without compromising or degrading the protective material. If cleaned by a third party, you’ll also need to ensure transport to your facility is sterile and that no contaminants are introduced to your cleanroom from an outside source. DISPOSABLE CLEANROOM GARMENTS Some medical cleanrooms with critical sterilization protocols and stringent requirements opt for disposable garments because it is the safest and most cost-effective option. Disposable garments should be high quality so they are comfortable for workers and won’t break down when in use. Be sure to buy quantities and sizes that are appropriate for all personnel. Many medical cleanrooms use a combination of both reusable and disposable garments. For example, gowns and face shields may be cleaned, sanitized, and reworn, but disposable nitrile gloves and boot covers are replaced after each use. All garments, whether reusable or disposable, must be kept in appropriate cleanroom garment storage. MEDICAL CLEANROOM GARMENT STORAGE Adequate cl...

  • Proper Way to Breathe Using a Face Mask
    Proper Way to Breathe Using a Face Mask
    • October 01, 2021

    Face masks are an essential element for various environments, including; hospitals, research laboratories, clean rooms, and more. to use one incorrectly could be detrimental to the clean room as well as to the products and supplies. The Interim Guidance of the World Health Organization (WHO) states “Using a mask incorrectly, however, may actually increase the risk of transmission, rather than reduce it”. It seems as if this would be an intuitive matter, but I have seen face masks used improperly too many times! So lets talk about how to breathe! 1. It is important to wash your hands before wearing a mask. If in a clean room environment, it is best to use antibacterial soap in order to reduce the risk of contamination. If you can not use or find hand soap, alcohol disinfectant will suffice. Once the face  mask is in place, if you feel that it becomes contaminated, you should leave the room and take off the mask. Be sure to wash your hands after removing the mask and before putting on a new one as well. 2. To properly fit a mask to your face , it should first be covering both your mouth and your nose. This is definitely more uncomfortable than just covering ones mouth with the face mask because you are breathing back in some of the exhaled air. However, some sacrifices must be made in the name of safety!Woman Breathing Wearing Face Mask. 3. Once the face mask has been placed over both your mouth AND your nose, check the sides to make sure that no air is escaping and that there are no leakages. Depending on the type of mask, you may be able to fit the mask by pressing your fingers around the edges to conform the face mask to your face. 4. Once the mask is secure, now you can breathe! You MUST breathe in through your nose and out through your mouth. This is essential for you as well as your the environment. By breathing in through your nose, the cilia (hairs inside of your nose) will catch particles coming into your body verses breathing in through your mouth, the particles will go directly into your body / lungs (it also helps to warm the air that you are breathing). By breathing out of your mouth into the face mask simply lets air escape faster and releases pressure. 5. Now, you may breathe freely!

  • Disposable vs Washable Cleanroom Apparel
    Disposable vs Washable Cleanroom Apparel
    • September 30, 2021

    Cleanroom apparel can be one of the most significant costs in a cleanroom, and people often ask whether it’s better to buy disposable cleanroom clothing or launderable cleanroom garments that can be washed and reused multiple times. The answer: It depends. Pros And Cons Of Disposable Cleanroom Apparel The beauty of disposable cleanroom apparel is that it’s easy to use. No need to launder anything, just wear it and toss it out. Particularly with the stricter classes of cleanrooms (e.g. Class 1 or Class 2 cleanrooms), disposable garments tend to be the most effective. However, the costs for using something just once (or several times, depending on the manufacturers’ specifications) can add up, as you constantly have to replace the protective garments. Some of the less expensive types of disposable cleanroom garments tend to rip more easily, which means that they might not even make it through a single work shift. Also, reusable cleanroom clothes might need to be disposed of differently than ordinary waste, so those costs and protocol need to be considered. Pros And Cons Of Washable Cleanroom Apparel The primary benefit of washable cleanroom apparel is that this type of cleanroom clothing and accessories can cost less, over the long haul. While reusable clothing and garments typically cost more to purchase, the fact that you can get multiple uses out of them dramatically reduces the cost per use. Washable cleanroom apparel also tends to be made out of fabrics that are more “breathable,” which makes them more comfortable to wear. The downside of using launderable cleanroom apparel is that you need to find a safe, consistent, and effective way to wash the clothing between uses. If you’re using an outside company to launder your cleanroom garments, you need to ensure that their transportation and cleaning processes conform to your cleanroom class requirements. The Best Of Both Worlds: Disposable And Reusable Apparel Often, when setting up a cleanroom environment and protocols, people will choose to use a combination of reusable and disposable garments. For example, they might choose washable cleanroom coveralls , but opt for disposable bouffant caps. To make a good decision about what to do for your cleanroom, you might consider setting up a spreadsheet and listing each individual item of clothing you need and whether it would be better to use a disposable or reusable version of the item (weighing in cost, comfort, convenience, and cleanroom conformance requirements). Common Types Of Cleanroom Apparel The most common types of cleanroom apparel that are available in disposable and washable options include: •cleanroom suits •cleanroom coveralls •cleanroom coats •cleanroom wipers •cleanroom frocks •cleanroom sleeves •bouffant caps •hoods •gloves •masks •shoe and boot covers

  • Antibacterial finishing in cleanroom workwear should be widely adopted after 2021
    Antibacterial finishing in cleanroom workwear should be widely adopted after 2021
    • September 28, 2021

    FDA published a document in June 2020 that clearly outlines the best practice for drug and biological product manufacturing. This thirteen-page document focuses on strict CGMP requirements and quality risk management principles in which an emphasis on microbiological control in the cleanroom workplace, as well as amongst staff members were mentioned. It recommended using facilities that could guarantee adequate air filtration and positive air pressure to ensure the proper function of a working environment. Whilst the world economy gradually moves on in 2021, Covid variants continue to swipe around the world. The occurrence of unpredictable breakthrough infections causes demanding challenges to cleanroom workplaces in various sectors such as food packaging, semiconductors and aerospace industries. The complexity brought by post-pandemic foreground a crucial question: what would be a new normal in cleanroom workplaces? To go beyond the FDA recommendations for unprecedented quality control protocols, AFC narrowed down the question to day-to-day, even minute-to-minute scale and focused on upgrading personal protective equipment for cleanroom professionals. Antibacterial finish - Futureproof cleanroom workwear for a new normal AFC exclusive technology applies an antibacterial finishing to the garments. They use advanced germ trap technology proven to provide utmost protection against pathogens such as coronavirus. The well-designed fabric has an antiviral coating that is safe to touch, protects the hazardous virus protection points of the nose, ears, and mouth while eliminating the likelihood of cross-contamination from saliva droplets. AFC Cleanroom Fabric series consists of a diverse range of high-performance fabrics. They are ideal for various applications such as cleanroom workwear, cleanroom shoes as well as cleanroom wipes. All the products are scrutinised for particle filtration efficiency before launching to the global market. AFC Cleanroom Fabric series complies with regulations for Cleanroom Class 10 ~ 100K with excellent functionalities that guarantee protection against contamination. Redefining cleanroom garments with eco-friendly yarns Another undeniable aspect of a futureproof quality assurance protocol is humanity. The COVID-19 crisis has also led to an urgent call for eco-friendly cleanroom products and a shift in the market’s focus on waste management. Effective management of industrial cleanroom waste requires proper identification, collection, separation, transportation, treatment and disposal. AFC’s J-series (left) and R-series (right & bottom) cleanroom fabrics Besides standard cleanroom fabric, AFC has been producing a range of sustainable yarn using specialised fibres that are genetically eco-friendly, introducing new applications for a more sustainable future in cleanroom textiles. All the garments are tested with autoclave and can endure up to 50 washing cycles. Their on-site R&D Team examine the performance of cleanro...

  • Will Today's Approach to Critical Cleaning Work Tomorrow?
    Will Today's Approach to Critical Cleaning Work Tomorrow?
    • September 27, 2021

    It’s only natural that critical cleaning in today’s world of critical environments is in a constant state of evolution. After all, the complexities of facilities and processes flow from the increasing intricacies of end products. And throughout the continued development of environmental monitoring programs, it pays dividends to recognize that what works today may not be the best solution for the future. For example, take the manufacturing of integrated circuits. As interconnected layers multiply while geometries shrink, yesterday’s inconsequential particle may become tomorrow’s killer defect. Medical device and pharmaceutical manufacturing are no different—requirements for enhanced impurity and pathogen elimination continue to grow as technologies become more sophisticated. But even as cleaning protocols change, the consequences of failing to comply remain consistently disastrous. Wet wiping is a cornerstone of critical clean room cleaning. A liquid’s ability to penetrate and sanitize the nooks and crannies of a surface—coupled with a process-appropriate sorptive material for absorption—will remain crucial to critical environments across industries. Alcohol is a lasting standard for wet wiping. While it doesn’t have the broadest kill spectrum or the highest surface penetration, it is a gentle yet effective sanitizer and reliable dissolver of ionic compounds and common organics. Alcohol also evaporates cleanly enough to be used as a chemical residues remover for many other cleaning chemicals. Pairing alcohol—often in a 70% IPA/30% USP purified DI water mixture—with a knitted polyester or polyester-cellulose wipe has been a reliable choice for wide-ranging critical cleaning applications. But it’s necessary to consider that the process you designed two years ago may not be effective two years from now. If this transpires, will your current supplier be able to meet unanticipated process needs? While it’s important to recognize the potential costs of product evaluation and risks associated with changing suppliers, assessing your supplier’s innovative and evolving capabilities is an equally important consideration. In the case of IPA sprays, the ability to produce a validated sterile product is critical—but may not be enough. Does your supplier innovate with options such as Water for Injection quality? If your needs become even more specialized, is your supplier capable of making customized IPA sprays? As for wipers(like microfiber cleanroom wipers), it’s probable that certain processes will need to be improved for labor and material savings without making sacrifices to quality and sterility. How many substrates can your supplier provide in validated sterile, presaturated form? What options for sachet packaging, saturant chemistry, or custom solutions will you be able to access in order to support both your short and long-term requirements? Asking yourself these questions will help your organization stay in front of regulations while ensuring that proc...

  • Cleanroom Cleaning: Proper Surface Technique for Wiping Windows
    Cleanroom Cleaning: Proper Surface Technique for Wiping Windows
    • September 23, 2021

    Windows are among the most essential parts of a well-maintained cleanroom. Here are tips for cleaning windows in your cleanroom. Windows and other glass surfaces within the cleanroom should not be overlooked when developing a cleanroom maintenance routine. Window can be large or small, and their purpose can vary from monitoring and observation to an architectural feature of the building. They also happen to be one of the tougher surfaces to keep clean. If the cleanroom’s windows are cloudy with residue or smudged, it’s easy to tell! Selecting the proper cleanroom equipment can not only make the process easier, it can also help prevent harmful contamination. Next, we’ll take a look at one method for cleaning windows within the cleanroom. Surface Prep: Detergents Vs. Disinfectants A detergent is needed to first remove all the dirt and soil from the surface. The detergent is going to act as an agent to break up anything that is stuck on the ledges and window surface. The disinfectant agent is going to actually kill the microorganisms on the surfaces afterward. Depending on the cleanroom and its specific uses, the cleanroom manager will have to consider what type of agents are needed. Detergent Do’s & Don’ts Some key factors to keep in mind with a detergent is that it should be non-foaming. It must be a neutral and non-ionic solution and compatible with the disinfectant. Otherwise, the detergent’s residue could counteract the disinfectant’s effect. Disinfectant Do’s & Don’ts There are many requirements when choosing a disinfectant for a clean room. First, make sure the disinfectant meets regulations and guidelines specific to your cleanroom. This includes how it is used. Two different disinfectants in the rotation are required in order to meet GMP regulations. Good disinfectants have rapid action, which means they kill bacteria quickly. They should also have a wide spectrum of activity. This refers to the range of bacteria that it is able to eliminate. Window Cleaning Once the cleaning agents are prepared, it’s time to clean the windows,also we could use clean room wipers to finish those jobs.

  • Cleanroom Wiper Testing: Good News and a Little Guidance
    Cleanroom Wiper Testing: Good News and a Little Guidance
    • September 13, 2021

    Cleanroom Wipers are necessary to clean any cleanroom, but they need to be tested to ensure they’re non-linting. Here is some information as well as good news on testing. Wiper-based cleaning is one of the most effective methods of cleanroom cleaning. Test data to confirm that wipers are non-linting is a USP 797 requirement. However, there is no recognized test, procedure, or recommended practice that will determine the right wiper for a specific cleanroom, process, or activity. So what do you need to know about finding the right wiper? There is a recommended practice for determining wiper contamination characteristics, so this is a good place to start. These are found in the IEST-RP-CC004.3, Evaluating Wiping Materials Used in Cleanrooms and Other Controlled Environments.  Here you’ll find descriptions of contamination characteristics and contamination levels like: Particle. Fiber. Non-speciated extractable matter. Ionic contaminant. In addition to these factors, however, are those aspects that are difficult to quantify, like: User process needs. Impact of activities (cleaning spills and surfaces, holding manufactured parts and pieces, etc.) Impact to product yield. Impact to manufacturing costs. All of these elements factor into what will provide the most appropriate cleaning and contamination control. So when it comes to testing and documenting, how do you know what type of wiper to start with? Here are three considerations for choosing the wipers to test: Wipers used in ISO Class 3-4 cleanrooms are usually knit polyester wipers with edges that are most likely sealed but can be cut if the durability process allows it. Wipers used in ISO Class 5-8 are usually nonwoven polyester/cellulose wipers. Both contamination and performance characteristics, like sorption capacity and rate, impact selection decision. Sorption capacity = amount of liquid a wipe can hold; sorption rate = how fast a wiper can sorb liquid. Your particular needs are based on your cleaning solvent/solution and protocol. While validating nonwoven cleanroom wipers without a definite test or guideline is frustrating, there is good news. A group of wiper manufacturer industry experts, cleanroom consumable distributors, and end-users of wipers are making headway. This group is the IEST’s Working Group 4, and they are revising the recommended practice: Evaluating Wiping Materials Used in Cleanrooms and other Controlled Environments. Part of their revision is dedicated to standardizing the test methods used to evaluate wipers.

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