Clean Rooms for Beverage & Food Industries

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:

•   Chemical resistant
•   Temperature resistant
•   Bacteria resistant
•   Ultraclean coating

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:

•   Strong, firm structure
•   Ceiling suspension is not required
•   Space for standard integrated lightning
•   Allocation of the fan filtration unit

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:

•   Clean and transparent
•   It resists temperature, smoke, dust and fog

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:

•   Heat resistant
•   Ultraclean ambiance
•   Rigid and strong structural suppor
•   Customization as per requirement

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:

•   Customization as per your need
•   Cleanliness up to ISO class5 or ISO class8
•   Aesthetically designed
•   Smooth coving

Technical Specification:

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:

•   Ultra-cleaned environment
•   Two-stage filtration
•   Quiet operation
•   Automatic indication for changing the filter
•   Easy to install and maintain

Technical Specification:

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:

•   Convenient with Filler unit
•   Prevention of outgassing
•   Prevention of arcing
•   Maintain air pressure
•   Reduced risks of heating and EMI

Different types of lights

Type1: Florescent Lights Features:

•   Highly durable fluorescent lights
•   Available in panel and tube structures
•   Total lumens up to 3150
•   Customized dimensions and configuration
•   Certified with ISO standards for cleanliness
•   Protection against dust, water, and small items

Type2: LED panels performance specifications:

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:

•   Effective and reliable management
•   Reduced overall weight
•   Particles and outgassing free cables
•   Improved flex life
•   Separate lines for DC and AC supply

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:

•   Fully integrated locks with total security
•   Biometric scanners to unlock doors
•   Smart access
•   Automatic alarming section

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:

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:

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:

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.

2.1 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:

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:

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.

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: