Cleanroom for Injection Moulding, Ross-On-Wye

Monmouth Scientific

Background

We work regularly with Monmouth Scientific and were delighted to be chosen as their partner for this new cleanroom for Meadex, who are specialists in injection moulding.

Requirement

Meadex needed a new cleanroom to ensure their production meets product specification and regulatory guidelines. It required personnel doors and a sliding door for ease of access. The cleanroom is split into three separate rooms measuring 9.00m x 9.00m x 3.15m high in total.

Solution

Thicker ceiling panels (150mm versus 80mm for the walls) were required for the HEPA air filtration system. To maintain the hygienic specifications of the cleanroom, panels have an easily cleanable laminated finish. Vision panels will ensure that production can be overseen from outside the cleanroom area. Our experienced installer team finished installation in just four and a half days.

Installer team were very good and end user was very happy.

David Pomeroy, Monmouth Scientific

Outside view of cleanroom suite for injection mouldings

Personnel hinged door for injection moulding cleanroom

Sliding access door for injection moulding cleanroom

Location	Ross on Wye
Building use	Injection Moulding
Panel Core	PIR
Panel Supplier	Kingspan
Panel Thickness	80mm, 150mm
Panel Facing	Laminated Food-Safe Finish 120 Micron Thick
Doors/Floor	Personnel Doors, Heavy Duty Sliding Chiller Doors
Panel Requirements	248.5m²
Other	Vision Panels

Advanced Research Laboratory, University of Sheffield

University of Sheffield

Background

Following a glowing reference from a cleanroom project on an alternative site, Stancold were recommended for these works with the University of Sheffield.

Process

The Advanced Manufacturing Research Centre (AMRC) were continuing to expand their operations within their powder manufacturing and processing facility.

Utilising our strong industry experience, Stancold developed the concept and produced a design proposal for the works, which was then finalised through a site survey with the project management team.

Solution

Our team were responsible for installing Kingspan Quadcore panels of 80mm thickness and a walk-on ceiling of 100mm to form the laboratory. Alongside this, the integration of hinged personnel doors and vision panels were completed.

Stancold also undertook the installation of the accompanying air conditioning and humidity control functions, so that the facility was able to maintain a consistent 20°C. This was crucial for the activities taking place within the lab.

This project was successfully completed in four weeks and Stancold left site with a satisfied end user.

Successfully developing the lab's concept and design was due to strong industry experience.

Lee Duffield, Project Manager

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Pharmaceutical Cold Storage, Liverpool

Boulting Environmental Services

Background

After working together previously, respected specialist cleanroom contractor, Boulting Environmental Services, invited Stancold to tender for the cold storage works in their latest pharmaceuticals project.

Process

Alongside over 4000m² of composite cleanroom panels, the large project required Stancold’s expertise and experience to integrate three pharmaceutical cold stores, including refrigeration, within the new Fill Finish facility. The end user, a worldwide manufacturer and supplier of vaccines, required facilities to house their products and materials under controlled temperature conditions.

Solution

Stancold installed Kingspan panels of 100mm thickness to create the three cold stores measuring 18.5m x 7.8m, 10m x 3.7m and 10.3m x 6.5m, and were integrated with insulated rapid roller doors, fire escape doors and insulated sliding doors for efficient product and personnel access. Two cold stores on the ground floor required a ‘controlled not classified’ status while the third, located on the first floor, needed to achieve ISO 8 (Grade D) standard. The units have been constructed to achieve a temperature range of +2°C to +8°C in order to meet the requirements of the product.

Like in many pharmaceutical cleanrooms where the value of the product being stored is so high, all cold stores required 100% backup, so if any equipment fails, the rooms will still remain fully operational.

This project demonstrated Stancold’s full capabilities in installing pharmaceutical cold storage, using our extensive technical knowledge to meet the needs of our clients.

With a difficult design to follow, it was an excellent install.

Steve Daly, Boulting Environmental Services

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Fully Flush ISO 8 Cleanroom Suite For Probiotics Production, Somerset

NGS Cleanrooms

Background

Stancold have a long-standing relationship with cleanroom specialists, NGS Cleanrooms, who undertook the design and construction of an ISO 8 cleanroom suite for their client, a probiotics manufacturer in Somerset.

Process

Stancold worked closely with NGS Cleanrooms and Puracore, producing detailed design plans for the large bespoke cleanroom build.

Solution

The project required the installation of 1250m² of FM Approved Puracore Aluminium Honeycomb Cored panels, fully flush vision panels and rapid roller shutter doors to form 28 processing rooms. Stancold also supplied and installed an integrated one-hour firewall, using Kingspan Mineral Fibre Cored 100mm panels. This included the fitting of double ‘hold open’ fire-rated personnel doors and all firestopping to achieve maximum fire integrity. Stancold were responsible for the suite’s cold storage facility, constructed using Kingspan Quadcore panels and completed with a white food-safe finish to match the rest of the Grade D cleanroom suite. There were a number of intricate and complex details to the project, such as the seamless integration of motion-sensor service points for doors and air return columns. Stancold’s specialist expertise and strong cleanroom experience enabled the 6-week bespoke project to be completed successfully.

Stancold's expertise in this field really shone on this project.

Lee Duffield, Stancold Project Manager

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Cleanroom installation for pharmaceuticals

Fully flush vision panels for cleanrooms

Fire-Rated Cleanroom Partitions for Modular Building, Coventry

Catfoss Group Manufacturing

Background

As part of an ongoing expansion for an R&D manufacturing campus, Catfoss Group Manufacturing were constructing a modular building and required a number of clean fire-rated areas.

Process

As an offsite modular construction, site surveys could only be completed once everything was in place on site, where Stancold then worked efficiently to complete the necessary surveying and design tasks prior to installation.

Solution

Working to a tight programme of works, Stancold supplied and installed approximately 250m² of fire-rated partitions, 80mm thick Kingspan Mineral Fibre Cored panels, to create several clean areas with a corridor.

The team also installed 8 no. 60 minute fire-rated double hinged personnel doors, which were compliant to DDA standards. This was in conjunction with firestopping products to the partitions to ensure a fire-rating of up to two hours throughout.

Stancold worked well, especially in the conditions you were working in

Andrew Noble, Catfoss Group Manufacturing

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Warehouse fire-rated clean partitions, Coventry

Fire-rated clean partitions for warehouse

Cleanroom Partitions For Medical Technology Provider, Devon

Haldons Construction

Background

After successfully working with Haldons Construction Consultants at a medical technology company in 2017, Stancold were asked to complete a second cleanroom partitioning project on the same site.

Process

As this was a complex project and was to be conducted in a live environment, the Stancold team attended numerous site visits with Haldons and the end client to discuss finer details of the installation process. Working closely with both parties provided the necessary support in the pre-construction stage of the project.

Solution

As per the client’s requirements, Stancold dismantled and removed the temporary walls in place and then erected 500m² of new cleanroom partitions using Kingspan Quadcore 80mm panels integrating a hinged personnel access door.

Using our strong expertise of working in a live environment, appropriate measures were implemented to ensure no construction debris left the area outside of the temporary screens and panels were cut away from the construction area, allowing the client’s working operations to continue as normal.

Communication from Stancold is always brilliant

Simon Buchanan, Haldons Construction

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Cleanroom partitions with hinged personnel door

Cleanroom 80mm partitioning on site at medical device manufacturers

Cleanroom partitions for medical device manufacturers

Cleanroom Suite & Firewall Partitions for Aeronautical Research & Development

Precision Manufacturer

Background

Using our unique experience of cleanroom design and construction and fire-rated enclosures, Stancold were awarded the project after winning a competitive tender through Principle Contractor, Merit Holdings.

Process

The suite of new cleanrooms was built to grade D classification and the fire-rated enclosures were designed to be clean not classified.

Solution

We installed 6m high freestanding walls with integrated flush cleanroom windows connected to an aluminium T-Bar suspended ceiling grid which formed the plenum and low-level return air cooling coils. The return air ducts were formed using 50mm FM approved Puracore cleanroom walls to a height of 6m and we also provided temperature controlled cleanrooms with Eurobond panels to a height of 8m.

This project showcases our cleanroom expertise

Paul Towse, Project Manager

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Puracore honeycomb panels for aeronautical research cleanroom

Aeronautical cleanroom facility installed by Stancold

Cleanroom installation including flush cleanroom windows

Cleanroom panels in viewing gallery for aeronautical research

ISO 6 Cleanroom for Precision Engineering Manufacturer

Specialist Manufacturer

Background

With their business expanding, this manufacturer was looking to build a new multi-room cleanroom. Our technical expertise means we partner regularly with Monmouth Scientific on cleanroom projects.

Approach

This project required a cleanroom environment for a precision engineering manufacturer. We offered a cost-effective solution that ensured all requirements for a controlled environment were met.

Solution

The cleanroom measures 18.00m x 4.35m x 2.825m high and is split into 4 different rooms. There are 14 (1220mm x 610mm) ceiling openings for HEPA filters and 8 vision panels. The main compartment is ISO 6 standard.

To ensure that the air in this space meets those specifications, Stancold installed two airlock rooms that are controlled with maglock door system.

Another high spec cleanroom that meets ISO6 Standards

Lee Duffield, Stancold

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Installing a multi-room cleanroom for a precision engineering manufacturer

Cutting panels for a cleanroom installation

Cleanroom ceiling with openings for HVAC filter system

Triple Compartment Cleanroom, Preston

BSRIA

Background

BSRIA are a test, instruments, research and consultancy organisation who were opening an office in Preston and needed a cleanroom for the new site.

Requirement

A triple compartment cleanroom, comprising of a temperature lab, pressure lab and blower door rig. Stancold installed four hinged clamp frame personnel doors, one hinged emergency exit door and a heavy duty sliding chiller door as well as seven single pane vision panels.

Solution

Installed in the existing building, the new cleanroom was to be used for accredited product testing. Each room allows for different forms of testing in a controlled, hygienic environment. The heavy-duty sliding chiller door allows easy access for large pieces of equipment and the vision panels enable people to observe the testing from outside the cleanroom environment.

We were all hugely impressed with the job, everything was done very well. If we ever have need of such work again I would definitely use you.

June Davis, BSRIA

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Sliding door access for triple compartment cleanroom

Compartment cleanroom with vision panel and personnel door

The build continues of a triple compartment cleanroom

Building a triple compartment cleanroom in Preston

Pharmaceutical Temperature Controlled Storage

Dribuild

Background

Based just outside London, in Ashford, the transport and logistics company, GEFCO Forwarding, were expanding due to business growth and needed a new chiller and office.

Requirement

The chiller will be used by their customers to store pharmaceuticals. The temperature controlled room will sit inside the building. Measuring 14m x 15m x 7m, the interior was fitted out with high racking for storing of the pharmaceuticals, to ensure maximum capacity.

Solution

Stancold worked closely with Dribuild to ensure that the design of the chiller, which required 125mm panels for the ceiling rather than the usual 80mm, allowed for all of the services to go across the top of the chiller. A rapid rise door was installed for easy access.

We were happy with Stancold's quick response to changes and providing information that was requested. Stancold kept Dribuild up-to-date throughout the project with regards to lead times etc.

Joe Black, Dribuild

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Panels installed for pharamceutical storage facility

During the cold storage installation process

Fire rated and hygienic panels for pharmaceutical storage

Hygienic Partitioning for Pharmaceutical Distributor

Envoplan

Background

Sigma Pharmaceuticals Plc is a family-owned business that was started in 1975 and has since grown into one of the largest pharmaceutical distributors in the country. It services over 3000 pharmacies and 1000 hospitals. The company is expanding and needed to build a new distribution warehouse.

Requirement

The hygienic insulated panelling needed to fit in the structure of an existing warehouse. Sigma Pharmaceuticals required a clean environment and good U-value as well as a 1-hour fire-rated partition wall between the offices and the warehouse.

Solution

Working closely with Envoplan, Stancold’s project management team designed the internal warehouse to fit around the existing building, including the roof and fittings such as gutters. To prevent damage to the panels during the everyday use of the space, 2mm thick 5 bar aluminium tread-plate protection was installed to a height of 1.25 metres.

Thank you for your efforts, well executed and looking very professional.

Greg Howarth-Hough, Envoplan

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Hygienic panels for pharmaceutical distributor in Watford

Hygienic environment for pharmaceutical distributor

Internal panel fit-out with tread plate protection

Cleanroom for E-Liquid Production, Birmingham

Zeus Juice

Background

Zeus Juice required a cleanroom to manufacture their product because of new industry regulations and the growing popularity of e-cigarettes.

Requirement

A cleanroom with a hygienic finish which includes an airlock to enable staff to change into appropriate gowns whilst maintaining the integrity of the clean space beyond. The self-supporting ceiling allows for services apertures. The cleanroom needed to fit into a space with limited headroom due to the mezzanine above.

Solution

Due to the limited head height, Stancold worked with the client to select the panels and take into account weights of the equipment and apertures required, as well as a suitable insulation value and clean finish. The 100mm insulated ceiling provides suitable thermal efficiency as well as allowing structural support. The cleanroom was finished on time and satisfied the customer’s request.

The end product looks amazing! We are very happy with how it all went.

Zeus Juice

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Inside an e-liquid manufacturing cleanroom

Bio Storage Chambers

Laboratory Services Provider

Background

Our customer is a trusted provider of first-class bio storage chambers, services and laboratory testing for global healthcare and pharmaceutical companies.

Requirement

To install four stainless steel bio storage chambers. Each chamber has the dimensions of 3.16m x 2.56m x 2.86m high with two doors, suitable for temperature-controlled bio storage for the preservation of test samples and pharmaceutical substances.

Solution

Stancold installed these high quality insulated bio storage chambers using thermally efficient PIR walls and ceiling panels coated with hygienic stainless steel, preventing bacteria growth and ensuring that joints are tight with no dirt traps for easy wash-down and maintenance.

You are our no 1 contracted supplier for environmental chambers.

Director of Manufacturing

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Semi-Flush Cleanroom

Snazaroo

Background

Due to continuous growth in product ranges and increase of global demand, our customer required a semi-flush cleanroom for the mixing of fine powder pigments and cosmetic ingredients to produce their 100% skin friendly paraben and fragrance-free paints.

Requirement

Our scope of works consisted of a semi-flush ISO 8 cleanroom installation accommodating machinery and air vents, complete with a built-in atrium functioning as a high care changing area.

Solution

Stancold engineered a solution with a cleanroom panel system suitable for the application and achieving considerable savings for the customer.

Stancold specified a panel system capable of supporting 4 apertures for filters, supplied 3 vision panels, 3 transparent swing doors for better light conditions and security reasons.

You are very professional. We are very pleased with the installation and would recommend you to anyone.

Adrian Ryan, Snazaroo

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ISO 7 Cleanroom

Monmouth Scientific

Background

Our client was contacted by a leading manufacturer of conductor and fibre optic cables for the aerospace and defence industries who had the requirement for a new ISO 7 cleanroom.

Requirement

A 90m² footprint self-supporting cleanroom complete with Airlock compartment. Our client also required the design to perform with multiple ceiling openings to accommodate the lighting and Hepa filters, all built to a tight deadline and in a working laboratory environment.

Solution

Stancold provided Kingspan insulated wall and ceiling panels, expertly fitted with doors and windows and designed to take the ceiling loads. The project required close project management due to the restrictive programme and site conditions; access was tight and limited. Our experienced team once again rose to the challenge leading to another satisfied client. Watch the project’s timelapse video here.

Excellent, a job really well done.

Dave Court, Monmouth Scientific

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ISO 7 cleanroom with insulated wall and ceiling panels

ISO 7 cleanroom with insulated wall panels

Research Laboratories

Johnson Matthey

Background

Johnson Matthey are a leading international chemicals and precious metals company headquartered in London.

Requirement

Stancold were contracted to build 2 research laboratories the area of 72m² and 36m², ladder enclosure and suspended ceiling in a high security environment.

Solution

In the absence of a structural beam, Stancold have created a specialist galvanised angle to suspend the ceiling from. The walk-on ceiling has provided the customer with easy access to their pipework ring main, thus reducing potential downtime in production areas. The ladder enclosure has provided excellent dust control which is of particular importance due to the product inspection requirements.

I will certainly recommend you and your installation team.

Mark Wall, Johnson Matthey

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Environmental Rooms

Bioscience Company

Company

This international bioscience company are widely acknowledged as leaders in the field of controlled environmental rooms and chambers, stability storage equipment and services in the pharmaceutical industry.

Application

To install 7 Chambers at the company’s facility in California, USA using high specification Puracore cleanroom panels. To delegate Stancold installation team overseas and coordinate the project from start to end.

We see Stancold as a partner and integral to our future business.

Manufacturing Director

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