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Case Study: Softwall Modular Cleanroom for ISO Class 7 Flexible Packaging Sealing

Created on 01.22

Project Background

A European packaging manufacturer specializing in flexible plastic packaging and spout sealing required a controlled clean environment to support critical sealing operations. To meet international quality and hygiene standards, the customer needed a cleanroom solution that could be rapidly deployed within their existing production facility, without the cost and complexity of a traditional hardwall cleanroom.
GCC Cleanroom was selected to design and supply a Softwall Modular Cleanroom that would provide stable ISO Class 7 performance while maintaining flexibility for future layout changes.

Customer Requirements

The customer defined the following project requirements:
  • Cleanliness Level: Static ISO Class 7
  • Cleanroom Type: Softwall Modular Cleanroom(Clean Booth)
  • Application: Flexible packaging sealing and spout sealing
  • Overall Size: Approximately 6 meters (L) × 3 meters (W)
  • Fast Deployment: Modular structure for quick installation
  • Operational Flexibility: Ability to relocate or expand in the future
The goal was to create a localized clean production zone to improve sealing quality while minimizing disruption to existing operations.

GCC Cleanroom Solution

GCC Cleanroom engineered a customized Softwall Modular Cleanroomcombining a stainless steel modular frame, anti-static softwall curtains, and high-efficiency FFU-based airflow to achieve stable ISO Class 7 cleanliness.

Softwall Modular Cleanroom

1. Modular Stainless Steel Structure

The cleanroom structure was designed for durability, hygiene, and long-term reliability: Support frame constructed of
50 × 50 mm, 1.0 mm thick 304 stainless steel square tubing
  • Anti-static PVC softwall curtains installed on all sides
  • Strip curtain door at the entrance to minimize air disturbance
  • Transparent softwall design for clear visibility and optimized workflow
This modular stainless steel construction allows fast installation, easy cleaning, and future reconfiguration as production requirements evolve.

2. ISO Class 7 Airflow and Filtration System

To ensure consistent ISO Class 7 performance, the Softwall Modular Cleanroom is equipped with a ceiling-mounted FFU system:
  • Four FFUs installed at the top of the cleanroom
  • Each FFU equipped with
H14 non-separator HEPA filters
  • Filtration efficiency: 99.999% @ 0.3 μm
  • Designed to maintain stable airflow and cleanliness under final filter resistance conditions
This configuration delivers uniform vertical airflow across the sealing area, effectively removing airborne particles from critical process zones.

3. FFU Technical Specifications

Each FFU is designed for high performance, low noise, and long service life:
  • External Dimensions: 1175 × 575 × 350 mm
  • HEPA Filter Dimensions: 1170 × 570 × 69 mm
  • Airflow: 1000 m³/h per FFU
  • Noise Level: ≤ 60 dB
  • Power Supply: 220 V, 50 Hz
  • Stepless Speed Control: Ensures stable airflow regulation and constant air volume
  • Maintains airflow stability even at high final filter resistance
  • Centrifugal Fan Design:
Long lifespan, low vibration, low noise, maintenance-free operation
These specifications ensure reliable long-term cleanroom performance with reduced operating and maintenance costs.

4. Lighting and Work Environment

To support production and inspection requirements, the cleanroom is equipped with:
  • Two 40W cleanroom lights
  • Uniform illumination to meet operational and quality inspection needs
Softwall Modular Cleanroom 2

Project Results

Following installation and validation, the Softwall Modular Cleanroom successfully achieved Static ISO Class 7 performance and now supports critical flexible packaging and spout sealing operations. The solution delivered measurable benefits, including:
  • Improved contamination control for sealing processes
  • Enhanced product quality and sealing consistency
  • Reduced particle-related defects
  • Faster deployment compared to traditional cleanroom construction
  • Modular and scalable cleanroom infrastructure for future growth

Conclusion

This project demonstrates GCC Cleanroom’s expertise in delivering Softwall Modular Cleanroomsolutions for packaging and plastics manufacturing environments. By combining modular stainless steel construction with high-efficiency H14 HEPA filtration and advanced FFU airflow control, GCC Cleanroom provided a flexible, cost-effective, and high-performance ISO Class 7 clean environment.
For manufacturers seeking fast-deployment, modular cleanroom solutions for packaging, sealing, and assembly applications, GCC Cleanroomoffers engineered systems tailored to your exact operational and technical requirements.
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