Traditional vs. Modular Cleanrooms: Which One is Best for Your Industry?
Stick-built cleanrooms—permanent structures constructed within a facility—were long the standard for industries that required strict contamination control. These traditional cleanrooms, made with solid components and seamlessly integrated with HVAC systems, provide optimal environmental stability required for processes across many industries. However, as facilities expand and production needs shift, modular cleanrooms have become an increasingly popular alternative. Deciding between traditional vs. modular cleanroom systems is a crucial first step in planning your facility’s contamination-free environment.
Comparing Stick-Built and Modular Cleanrooms
While stick-built cleanrooms are trusted for their robust contamination control, modular cleanrooms can provide the same level of protection with additional benefits. These flexible systems offer the adaptability and efficiency that many industries now demand—evolving alongside your operations with minimal disruptions to your operation. Here are some of the primary distinctions between traditional vs. modular cleanroom systems:
|
Feature |
Stick-Built Cleanrooms |
Modular Cleanrooms |
|
Installation Time |
Takes months; can require significant facility downtime |
Installed in days or weeks with minimal disruption |
|
Flexibility |
Permanent structure; difficult to modify |
Adaptable to facility changes; can be reconfigured as needed |
|
Cost |
Higher on-site construction and maintenance costs |
More cost-effective, prefabricated cleanrooms with components manufactured off-site |
|
Maintenance |
Requires significant effort and potential downtime |
Easier access to clean, replace, or upgrade components |
|
Construction Impact |
Requires on-site construction and permitting |
Prefabricated components minimize on-site construction |
|
Long-Term Investment |
Durable but expensive to modify over time |
Higher upfront costs, but adaptable for long-term ROI |
Understanding Compliance in Traditional vs. Modular Cleanrooms
Both traditional and modular cleanrooms can meet stringent industry compliance standards. Similar to stick-built cleanrooms, modular systems can integrate with HVAC systems, feature sophisticated airflow and air pressure controls, and include prefilters, HEPA filters, or ULPA filters depending on the size of particles that need to be removed.
There are several types of modular cleanrooms that suit different levels of compliance. Softwall cleanrooms, built with coated sheets or panels, are a flexible and cost-effective type of modular cleanroom with a slightly lower level of airflow, temperature, and humidity controls. Another option, rigidwall cleanrooms, function similarly but come with clear, flat panels that showcase manufacturing processes. If you’re seeking the most stringent protections, hardwall cleanrooms are modular cleanroom systems that offer the most robust contamination control.
Here are how these modular cleanrooms align with ISO standards:
- Hardwall Modular Cleanrooms: Ideal for all ISO classifications (ISO 1-8)
- Rigidwall Modular Cleanrooms: Suitable for ISO classes 5-8
- Softwall Modular Cleanrooms: Best for ISO classes 7-8
Whether you choose a traditional or modular cleanroom, the key is selecting a solution that aligns with your industry’s compliance requirements while allowing room for future scalability.
Customizing Modular Cleanroom Systems for Your Industry
Modular cleanrooms are particularly well-suited for industries requiring flexibility and scalability. Some industries that benefit the most from modular systems include:
- Pharmaceuticals: Strict regulatory requirements make modular cleanrooms an ideal choice, allowing facilities to adapt to changing compliance needs.
- Electronics & Semiconductor Manufacturing: Modular cleanrooms can provide precise environmental control for even these sensitive components.
- Plastic Injection Molding: Cleanroom environments are necessary for medical-grade plastics, and modular solutions can be equipped for contamination-free production.
- Medical Device Manufacturing: The ability to customize cleanroom layouts makes modular cleanroom systems highly beneficial for evolving product lines.
While modular cleanrooms excel in these industries, stick-built cleanrooms remain the preferred choice for ultra-large-scale facilities requiring permanent contamination control solutions.
How to Choose Between Stick-Built vs. Modular Cleanrooms
Selecting the right cleanroom depends on several factors:
- Budget: If you’re looking for a cost-effective solution with long-term adaptability, modular cleanrooms may be the best choice. While customizations may mean higher initial costs, you’ll save on future upgrades, renovations, or ongoing maintenance expenses.
- Future Growth & Flexibility: Modular cleanrooms allow for easy expansion and reconfiguration, making them ideal for facilities expecting future changes.
- Contamination Control Needs: If your industry requires extreme contamination control (ISO 1-3), a stick-built or hardwall cleanroom may be the best choice. For ISO 5-8, modular cleanrooms are highly effective.
- Project Timeline: If speed is a factor, modular cleanrooms offer significantly shorter installation times compared to stick-built options.
Encompass Cleanrooms experts regularly help facility managers evaluate their needs and determine the best cleanroom solution based on industry standards, compliance, and the long-term goals of their operations.
Modular Cleanrooms Made for Modern Demands
Flexibility and efficiency are becoming non-negotiables in cleanroom design. Encompass Cleanrooms specializes in designing, building, and maintaining modular cleanrooms that meet your exact specifications while offering the adaptability needed for future growth. Whether you're constructing a new cleanroom or upgrading an existing one, our team is ready to help you create a contamination-controlled environment tailored to your needs. Contact us to get started.
