Clean Rooms for Beverage & Food Industries

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Clean rooms for Beverage & Food Industries

We are Manufacturer, Supplier, Exporter of Modular Clean Rooms for Beverage & Food Industries, Cleanroom System and Clean Room, Clean Room For Pharmaceutical Manufacturing, Clean Room Design Pharmaceutical, Clean Room Design For Pharmaceuticals And Medical Devices, Soft Drinks Cleanrooms. We also provide Operation Theatre(OT) Design, Setup, Maintenance Services. Our setup is situated in Pune, Maharashtra, India and majorly we serve customers from Maharashtra, Gujarat, Tamil Nadu, South India.
At Kaizen, we serve you with the clean and hygienic environment to make your filling procedure pollution free. We design an excellent environment that could control particle count, temperature, humidity, and pressure. We create clean rooms based on rules and regulations from the health and safety department. The primary motive behind modular bottling clean rooms is to provide a contamination resistant environment with clean and disinfecting surfaces.

Benefits

Components included:

Kaizen designs modular cleanrooms for filling beverages and medicine bottling. Low cost and flexibility are the key features of our services. We use high-quality products for the cleanroom. We design the highly efficient environment for filling systems to increase productivity and limit rejection ratio.

1. Enclosure section:

It is made up of steel with an excellent finish to provide resistance from every contamination. The enclosure contains rock wool panel sandwiched between two steel plates that provides temperature resistance A15 fire rating. At Kaizen, we care about the environment at most. We design our products to keep the environment clean, safe and hygienic.


1.1 Structural frame

The construction of the structural frame is the first step in designing a filling room. A metal structure with anti-contamination coating supports the design strongly and creates a rigid frame. They are of two types as vertical and horizontal frames.


Vertical structure

Industrial filling systems need to be at a higher level than ground to provide extra care for contamination-free atmosphere. At Kaizen, we offer vertical columns to support the complete structure for filling. It keeps the floor at a level higher than ground. The vertical column is made up of stainless steel or powder coated steel.

Features of structural frame:
Ceiling structure

Ceilings are one of the most crucial parts. At Kaizen, we design a ceiling structure that complies with its limits for ISO class 9 level cleanliness. DIN EN ISO 14644-1 defines the maximum permissible limit for airborne particles inside the cleanroom.

Key features:

1.2 Partition

At Kaizen, we design a partition panel which is easy to demount and modify. We provide all types of partition panel for transparency and rigid support. Our designs comply with ISO class 9 designs includes the following partitions.

1.2.1 Transparent partition

Bottle filling process is a quite complicated process, and the majority of the filling work is fully automated. It requires a human interface to operate partitioning and malfunctioning in the filling process. With the controlled environment, it is not suitable to continuously visit the room. At Kaizen, we design tempered glass or polycarbonate panels which make it convenient to watch the filling process continuously without any trouble.

Key Features:

1.2.2 Metal partition

Metal partition is useful in cleanrooms as it protects direct contact between two rooms and maintains the cleanliness. At Kaizen, we provide the cleanroom metal wall to resist any contamination. With specially designed partitions it is possible to achieve ISO 7 cleanliness in the filling system. We offer a standard ultraclean panel made up of stainless steel.

Key Features:

1.3 Ceiling

Conventional ceilings fail to maintain the cleanliness standards. At Kaizen, we provide a standard ultraclean ceiling system for generating clean environments in industrial filling systems. We offer highly durable fire-safe ceiling panels with antimicrobial coating complying with international standards for cleanliness. Ceilings are composed of the sandwiched panel between two steel plates ensuring appropriate environment. It is built to accommodate the weight and dimensions of the fan filtration unit.

Key Features:

Technical Specification:

Variables

Specifications

Ceiling grid

T-joists with slide in dividers

Ceiling grid material

Powder coated MS/ Stainless steel

Material

Polypropylene

Fire-safe SS 304

Powder coated steel

Clear Acrylic

SDPVC

Edge finish

Paint sealed for improved cleanroom performance

Coating

Antimicrobial

NRC

0.70

CAC

CAC 41

Temperature range

0°C-49°C

Humidity

RH 99%

Thermal insulation

0.40 m2k/W

Weight

5.28 kgs/m2

Colour

White

1.4 Fan Filtration

Kaizens fan filtration unit, allows s fine and microfiltration of air inside the filling room. It works well with the HEPA filter. Fan filtration unit comprises of the motor-driven fan. It sucks contaminated air and blows it over HEPA filter for generating clean and hygienic working environment. We design this product with quite in operation and low in vibration with the sound intensity of approximate 50dB. It helps in providing a uniform flow of microfiltered air with cleanliness down to class 7.

Key Features:

Technical Specification:

Particle retention at fine filtration

3 to 5micron

Particle retention at HEPA filter

0.3 micron

Ceiling height

27430mm

Noise level

50dB

Cleanliness class

ISO Class 7

Floor area

Standard and Customized

1.5 Light fixtures

Clean and hygienic lighting plays a vital role in keeping the area contamination free. At Kaizen, we design a sealed enclosure to separate internal lightning from the surrounding environment. We develop the lighting fixture to maintain the required visibility. The light fixture is free and protective from effects of fumes and other attacks. We introduce the lights that help in generating intra-cellular ROS, i.e. Reactive Oxygen Species to target and eliminate bacteria.

Key Features:

Different types of lights


Type1: Florescent Lights Features:

Type2: LED panels performance specifications:


Variables

Specifications

Power

49-77W

Ceiling grid (module length)

300-600 mm

Light source

Replaceable LED

Mains voltage

220V/50-60Hz

Ceiling type

Exposed T-bar ceiling

Colour

White

Color rendering index

>80

Average life

25,000-70,000 hours

Driver failure rate

1% per 5000hours

Ambient temperature

+25 °C

Operating temperature range

-20°C to +35°C

Connection

Push in connector

ISO class

2-9 Fraunhofer certified

Certification

IP65

Housing material

Sheet steel

Cover material

Tempered glass

Internal optic material

Aluminum

Heatsink

Aluminum sheet steel

LED type

Square LED

Rectangular LED

Luminous flux (In l m)

3600, 3900, 6000, 6300

6000, 6300

Color temperature

3000 or 4000 k

3000 or 4000 k

Initial luminaire efficiency

109- 120 l m/W

109- 120 l m/W

Luminous flux tolerance

+/- 10%

+/- 10%

Dimensions

596x596 mm

1196x296 mm

1.6 Cable Management System

At Kaizen, we design a reliable cable management system for signal integrity with reduced particle and outgassing for contamination free environment. Whether the requirement is for EMI shielding, continues flexing, MTW rating or drive cables to resist electrical and mechanical and electrical shocks. We design cables with outer jackets to prevent leak of particles caused by friction between cables.

Key Features:

Variables

Specifications

Materials

Steel and Aluminium

Guides

Plastic T guides

Finishes

Black/ White powder coat paint

Cable capacity

12 bundle swivels

Accessory rods

2/4

Assembly

Centre track assembly

Spools

4 half spools (Not included in 150 and 200mm)

Size

Customized

Cable Management

Single sided/ Double sided

Hinges

Duel hinge for front and rear panel

Cable Management

Single sided/ Double Sided

Hinges

Dual hinge for front and rear door

Materials

Steel/ Aluminium with plastic guides

Colour

Black/ White

Size

Standard and customized

Accessory rods

2/4 rods

1.7 Intelligent Doors

Biometric doors for cleanroom prevent unauthorized personnel from entering the room without prior permissions. At Kaizen, we design highly stable doors for an industrial filling room. These doors prevent the entry of any contaminants from the door with prior filtration. At the entrance, it blows clean air to disinfect any person entering the clean room. Also controls the complete operation as per the present state of the door.

Key Features:


Door type

Manual door

Door

Sliding door

Swing door

Panels

Acrylic/PVC

Acrylic/PVC

Panel type

Puff panel

Puff panel

Frame

Aluminium

Aluminium/Stainless steel

Dimensions (In mm)

1016x2083

914x2057 (Single swing)
1829x2057 (Double swing)

Door type

Automatic door

Door

Sliding door

Double slide door

Dimensions

2438.4x2336.8

3754.75x2336.8

Panels

Glass/PVC/Customized

Glass/PVC/Customized

Panel type

Puff panel

Puff panel

Frame

Aluminum

Aluminum

Compliance

UL, NFPA

UL, NFPA

Finish

Clear/Dark bronze

Clear/Dark bronze

Door interlocking

Electromagnetic door locks

Resistance

Up to 225 kg force

Access type

Iris scanner

 

Fingerprint scanner

 

Prox Pad card scanner

 

Keycard reader

Notification alarms
(Audible and visible)

Smart door alarm

 

LED display bar

 

Smart message panel

Surveillance

CCTV

1.8 Wall Panel:

Kaizen provides easy to clean and sterile wall panels for constructing an enclosure for filling systems. These panels have high flexibility with center mount design complying with international standards. We deliver customized configurations for wall panels to meet the client’s requirement.

Technical specifications:

Variables

Specifications

Standard Size (WxH)

1200x3000 mm

Thickness

25 to 150 mm

MOC

Powder coated/Precoated galvanized steel/ Stainless steel

Infill

PUF (Polyurethane Foam)
PIR (Poly Iso Rinate)
Mineral Wool/Glass wool/Rockwool
FRP
CPVC

Profile

Aluminum/GI

Fire resistance class

F130 under EN 13501-2

Compliance

ISO 5

1.9. Windows:

Kaizens windows allow the user to view the internal operations of the filling room without entering inside. We provide clear, easy to clean and durable windows for filler systems. Kaizen provides customized configurations to meet complex requirements and offer complete customer satisfaction. Premium quality windows are available as framed and frameless with single or double-sided construction with customized configurations as required.

Technical specifications:

Single sided window

Double sided window

Construction

Nominal dimensions
(In mm)

Window material

Construction

Nominal dimensions
(In mm)

Window material

Framed window

14325.6x10972.8
10972.8x14630.4

Tempered glass

Framed window

14325.6x10972.8
10972.8x14630.4

Tempered glass

 

 

Fire-rated glass

 

 

Fire-rated glass

 

 

SDPVC

 

 

SDPVC

 

 

Polycarbonate

 

 

Polycarbonate

 

 

Acrylic

 

 

Acrylic

Frameless windows

14325.6x10972.8
10972.8x14630.4

Tempered glass

Frameless window

14325.6x10972.8
10972.8x14630.4

Tempered glass

 

 

Fire-rated glass

 

 

Fire-rated glass

 

 

SDPVC

 

 

SDPVC

 

 

Polycarbonate

 

 

Polycarbonate

 

 

Acrylic

 

 

Acrylic

1.10 Filler Room Flooring:

Kaizen provides flooring raised from ground level up to customized height for generating international standard cleanliness in filling rooms. Standard and heavy-duty high-tech matrix floor panels are available with customized configurations.

Technical specifications:

Variables

Specifications

Coating

Vinyl powder coated

Roll Dimensions (WxL)

2x20 m

Tile format

608x608 mm

Colour

Blue/Grey/Customized

Thermal conductivity

0.25 W/(m.k)

Fire rating

Bf1-s1

Slip resistance

R9

Heat resistance

0° to 50°C

Air cleanliness class

ISO 4

Load resistance

40 kg/sq. cm

Static electrical propensity

<2000V

Electrical resistance

>1011 Ω

Particulate cleanability

85.66% reduction in particle contamination

The action of micro-organism on the flooring

Inert and resistant

Chemical resistant

Excellent

Resistance to gaseous H2O2

No damage

Compliance

CE Marking

1.11 Smart Access Control:

Kaizen’s filling room can be integrated with smart security access with door interlocking. The system prevents cross-contamination and slows down the filling machine when the door gets opened for some maintenance purpose during operation. Security control with tailored customization enables to maintain cleanliness standard inside the filling chamber.

2. Filling Room Supplies Section

2.1 Pass-Through Chambers:

Kaizens pass-through chambers allow the easy supply of any material inside the cleanroom. It prevents external contamination. We design the customized pass through chambers to meet complex requirements.

Technical specifications:

Variables

Accessories

Chamber material

Stainless steel

Construction

Double wall design

Mounting

Floor/Wall

Dimensions

Customized

Latch

All steel

Viewing window

Tempered glass

Accessories

Automatic doors

Alert alarms

ULPA filtered air shower

LED lights

Smart access control

2.2 Air Shower

Kaizens air shower prevents entry of contaminants into the cleanroom. We develop the air shower system based on scrubbing action by a high-velocity air jet. Air showers can be installed at the entrance of cleanroom with customized configurations.

Technical specifications:

Variables

Specifications

Air change

Up to 743/hr

Initial airflow velocity

20-22 m/s

Number of nozzles

6-36

Air shower duration

12 seconds

Persons/min

4-23

Person per cycle

1-6

Pre-filter

85% Arrestance, 20% efficiency

HEPA filter

99.99% efficient @ 0.3micron

Frame

Electro galvanized steel

Coating

White oven baked epoxy powder coated

Electrical

220-240V/50-60 Hz
110-130V/50-60 Hz

Dimensions

Customized

Included accessories

Photophilic pressure gauge

Control panel

LED lights

Ionizing bars

Fan filtration unit

Compliance

UL listed

3. Air Treatment Section

3.1 Air Conditioning:

Industrial Filler Systems require a controlled environment inside filling room chamber. Such controlled environment prevents the growth of bacteria. Kaizen offers air conditioning with customized configurations as per client’s requirements.

Technical specifications (Air cooled DX unit):

(23.9°C DB, 16.1°C WB, 11.1°C DP) 44.6% RH

Total

BTU/hr

54000 to 220000

 

kW

15.9 to 64.4

Sensible

BTU/hr

54000 to 220000

 

kW

15.9 to 64.4

(26.7°C DB, 17.1°C WB, 11.1°C DP) 37.8% RH

Total

BTU/hr

57000 to 231000

 

kW

16.7 to 67.7

Sensible

BTU/hr

57000 to 231000

 

kW

16.7 to 67.7

(26.7°C DB, 18°C WB, 11.1°C DP) 32.2% RH

Total

BTU/hr

60000 to 242000

 

kW

17.5 to 71.0

Sensible

BTU/hr

60000 to 242000

 

kW

17.5 to 71.0

Electric Reheat

Housing

Stage aluminum

Capacity (kW)

6 to 18

Number of elements

2 to 6

Number of stages

1 to 3

Supply

230V/50-60 Hz

Hot Gas Reheat (24°C)

Capacity (kW)

9.5 to 13.5

Humidification

Capacity (kg/hr)

5 to 8

Power input (kW)

3.7 to 6

Flush cycle

Auto

Evaporator Blower

Blades

Backward curved

Motor

Direct drive EC motor

Nominal horsepower

3.8 to 4

CFM @ 50Pa

3500 to 12600

Technical specifications (Water cooled DX units):

(23.9°C DB, 16.1°C WB, 11.1°C DP) 44.6% RH

Total

BTU/hr

55000 to 254000

 

kW

16.0 to 74.4

Sensible

BTU/hr

55000 to 254000

 

kW

16.0 to 74.4

(26.7°C DB, 17.1°C WB, 11.1°C DP) 37.8% RH

Total

BTU/hr

57000 to 269000

 

kW

16.8 to 78.8

Sensible

BTU/hr

57000 to 269000

 

kW

16.8 to 78.8

(26.7°C DB, 18°C WB, 11.1°C DP) 32.2% RH

Total

BTU/hr

60000 to 284000

 

kW

17.7 to 83.2

Sensible

BTU/hr

60000 to 284000

 

kW

17.7 to 83.2

Electric Reheat

Housing

Stage aluminum

Capacity (kW)

6 to 18

Number of elements

2 to 6

Number of stages

1 to 3

Supply

230V/50-60 Hz

Hot Gas Reheat (24°C)

Capacity (kW)

9.1 to 12.7

Humidification

Capacity (kg/hr)

5 to 8

Power input (kW)

3.7 to 6

Flush cycle

Auto

Evaporator Blower

Blades

Backward curved

Motor

Direct drive EC motor

Nominal horsepower

3.8 to 4

CFM @ 50Pa

  1. 12600

3.2 Dehumidification Module:

Humidity control is critical in filling room environments. We design and develop dehumidification module to meet the client specific requirements. Kaizen offers international standard, customized and configured dehumidification module., as it enables to achieve better control over products shelf life.

Technical specifications:

Variables

Specifications

Housing

Stainless steel

Coating

Zinc coat

Desiccant material

Silica gel

Material size

2-5 mm

 

Humidity @21°C temperature

Adsorption rate

50% RH

498.9 to 2994 g/hr

30% RH

362.9 to 2268 g/hr

10% RH

136.1 to 816.5 g/hr

 

Nominal Dimensions
(mm)(WDH)

Process Airflow
(CFM`)

Reactivation Airflow
(CFM)

Weight
(kg)

Full Load AMP

Reactivation Heat
(BTUH)

Power
(Watts)

Voltage

756x311x559

50

15

39

12

3,240

1,400

120V/60Hz

924x622x692

150

45

86

18

9,725

3,850

240V/60Hz

1130x845x819

300

90

136

32.9

19,448

6,900

240V/60Hz