How well does FFM-C fit with the item system?

Over the past 30 years, the item-profile-system has established itself in cleanroom technology like no other. While initially it was mainly racks and frame systems that were used for tables and shelves in cleanrooms, the range of applications has now expanded to include many other system solutions. From machine bases and transport systems to cabin solutions and entire room systems, item solutions can be used to realise a wide range of applications. Nevertheless, it has been a long journey. When COLANDIS built its first cleanroom (50 m²) in 1999, its competitors responded with nothing but negative comments. Today, small to medium-sized room solutions are built by almost all suppliers using aluminium profile systems.

Of course, aluminium profiles alone do not constitute the cleanliness solution. An appropriate clean air supply is also required. For many years, this has been achieved through the use of fan-filter-units (FFUs). These modules are available on the market in a wide range of solutions and variants and can be purchased worldwide.

The use of such fan-filter-modules in conjunction with aluminium profile systems presents a number of challenges. These include, for example:

1. Compact design in which the filter element is firmly connected to the other functional elements.
   👉 In the COLANDIS-fan-filter-module, the patented filter element is designed to ensure that the filter frame also acts as the housing frame for the entire module. The design of these modules therefore fits perfectly with the item building block system. Extensively anodised surfaces create a uniform appearance.
   
2. The range of self-supporting structures depends heavily on the load, which mainly comes from the fan-filter-modules. “Lightweight” modules are also easier to handle for installation and servicing.
   👉 Due to the minimal use of materials, COLANDIS-fan-filter-modules have a lower weight compared to many competitor products, which affects the selection of the necessary item profiles. When comparing competing products, it should be noted that many suppliers specify the weight of the body with the fan and filter separately. The specifications for the COLANDIS-fan-filter-module include the filter.
3. Many fan-filter-modules cannot be used for applications requiring horizontal airflow, as they are designed exclusively for installation in cleanroom ceilings (the fan-module rests on a filter and is not permanently attached to it). Furthermore, the fans installed in many modules are large and heavy and therefore less suitable for vertical installation, as this reduces their service life.
   👉 Whether for workstations or minienvironments, horizontal airflow is usually superior to vertical airflow, as when an employee intervenes, contamination is less likely to be transferred from the hand to the product and more likely to be transported to the outside via the airflow along the shortest route. Horizontal airflow often achieves better airflow around the product, as it avoids backflow areas (in the form of turbulence).
4. Due to the construction height (usually 400 mm and higher), the total height and thus the ceiling height of the cabin is limited when constructing a cleanroom cabin in an existing room, for example (observe the requirements of the Workplace Directive).
   👉  Most fan-filter-modules available on the market have a height of 400 mm+. The COLANDIS fan-filter-module is 200 mm high, with a pre-filter 300 mm high. 
   When cleanrooms and/or cleanroom cabins need to be retrofitted into existing rooms, the given ceiling heights often impose restrictions. This limits the use of many modules on the market. With an existing room height of 2.80 m and a fan-filter-module with a height of 400 mm, the room height in the cleanroom or cleanroom cabin is less than 2.40 m. The Workplace Directive stipulates a minimum height of 2.50 m for rooms up to 50 m². The prescribed room height increases for larger dimensions. A COLANDIS-fan-filter-module without a pre-filter could be used there.
   The item-modular-system is one of the most commonly used systems for retrofitting. Its flexibility, combined with the COLANDIS-fan-filter-modules, makes it ideal for this purpose.
5. Aluminium constructions are also chosen frequently for applications in high-tech areas, e.g. in the semiconductor industry and similar technologies (e.g. optics, lasers, sensor technology). These applications require filter qualities in U16 quality (99.99995% separation efficiency), in materials with low or no boron content and with low outgassing rates (Fabsave).
   👉 In this regard, the COLANDIS-fan-filter-module barely differs from other FFUs on the market. Almost all suppliers also have the entire spectrum of filter classes in their portfolio. The COLANDIS-Fabsave-fan-filter-modules are unique among Fabsave-FFUs in that they are not only manufactured with low-outgassing components, but all other assemblies and components, right down to the cable insulation, are also designed to meet this requirement. In addition, the COLANDIS-team already offers such a high level of industry knowledge that the correct necessary specification can be offered when designing the respective fan-filter-modules.
6. Black designs are often required for optical and laser applications. They can be easily achieved using item system components. To ensure that the design is completely black throughout, the fan-filter-module used should also be completely black, including the filter surface.
   👉 Black profiles from the modular system and, if necessary, post-anodised profiles, together with the black fan-filter-modules from COLANDIS (patented), create technical solutions that prevent almost 100% of disruptive stray light. The image shows the black filter surface of the modules inside the cabin on the right. Although the lighting in the cabin was switched on, the filter surface, which is otherwise always white in HEPA filters, cannot be identified at first glance.
   
7. For cluster machines whose base frame is constructed from item-components, the corresponding fan-filter-module should also have this hexagonal shape.
   👉 Cluster machines are machines or their enclosures that deviate from the square base and are usually designed as regular hexagons or octagons. These machine enclosures can be constructed very easily using item components, as shown in the image. 
   To construct such systems efficiently and cost-effectively, it is advisable to use plug & play components. COLANDIS can achieve this with customised base frames that are supplied with the respective module. Additional functions, such as ionisation systems and lighting, can be integrated in advance, which simplifies the installation of these modules in the respective machine enclosure à Plug & Play.
   
8. In order to reduce installation costs for end customers, the modules used should be available in all customer-specific sizes. Plug and play plays a very important role here.
   👉 In addition to the honeycomb-FFU as a plug & play variant, it is also advantageous to have a wide range of dimensions (L x W) available. Special dimensions can certainly always be realised, but costs play a very important role here, especially when it comes to individual items. COLANDIS offers a wide range of ‘standard sizes’ that enable optimal cleanliness conditions to be achieved with a large filter area. All these requirements are covered by the COLANDIS-fan-filter-modules.

At COLANDIS, we focus on standard dimensions that are easy for filter manufacturers to implement. These dimensions are based on the Anglo-Saxon measurement system of the ‘foot’ (12 inches = 0.3048 m, or approx. 305 mm), so that the following dimensions can be easily implemented:

Different dimensions can be requested. COLANDIS offers a wide range of design options, allowing almost any practical size and shape to be realised.

In recent years, the topic of ‘technical cleanliness’ has become one of the most important tasks, especially in the automotive industry. There are already a number of guidelines dealing with the concept of cleanrooms. COLANDIS developed its clean air module SRM for cleanroom applications several years ago. This module is not equipped with a HEPA or ULPA filter, but with an inexpensive F9 fine dust filter. This SRM is ideally suited for item solutions in the cleanroom sector.

Of course, users have a wide range of other modules and options at their disposal. From very small to oversized, with options such as ionisation, heat exchangers, lighting, etc., with particle filters or molecular filters, or even in combination, from the simplest solution to the cloud version. item has also summarised a few more examples of the perfect fit. Here you will find a few more application examples.

In summary, it can be said that almost all COLANDIS-FFU-solutions have been developed with the item-profile-system in mind, so that one can speak of system integration. Speaking of ‘speaking’, please contact us.