Installing a conveyor in a cleanroom can improve productivity radically, but not all models are cheap or suitable. Dynamic Conveyor Corporation looks at the issues.
When analysing a cleanroom conveyor, there are various aspects to consider, including initial cost, total cost of ownership, maintenance needs, noise levels, energy consumption, flexibility and cleanroom classification.
The total cost of ownership is an important step in evaluating the purchase of a cleanroom conveyor system but analysis should go beyond the initial capital investment and installation costs to include: How will energy costs affect the long-term return on investment? What are the preventative maintenance requirements? How often and at what cost will the belt need to be replaced? What is the expected lifespan of the equipment?
Answering these questions will help in evaluating the best conveyor system choice for the long-term. Then, look for a “standard” system that meets your cleanroom environment needs with the least or no additional cost on the conveyor. For example, reconfigurable modular conveyors offer a Federal Standard 209D Class 1 (ISO Class 3) rating at a standard conveyor price.
How flexible is the conveyor system in length, configuration and the addition of accessories? In industries where production needs can suddenly change, or where sudden innovation is common, a conveyor with flexibility – such as the ability to be reconfigured like Lego building blocks – helps manufacturers to meet the demands of new developments and manufacturing changes.
Reconfigurable conveyors offer the flexibility of easily changing length and angle configurations. Modular conveyors also allow for easy adaptation of cleanroom accessories and components such as HEPA filters, tunnel enclosures, ionisers and hermetically sealed entry/exit gates.
Cleanroom classification
The most critical requirement for a cleanroom environment is a conveyor’s cleanroom classification. Those rated to Federal Standard 209D Class 100,000 (ISO 8) are readily available, but for processes requiring true contamination control, Class 100,000 is well out of range. Indeed, a truly sensitive process will require a vastly stricter specification, down to Class 1 (ISO 3) in some cases, while other processes in the same facility require only Class 100 (ISO 5) or Class 1,000 (ISO 6).
Your range of cleanroom requirements should be considered when making your conveyor purchase. Why purchase a Class 1,000 conveyor when you can purchase a Class 1 conveyor for virtually the same price that will meet all of your cleanroom conveying needs?
Another aspect of conveyor specification to consider is technological changes that may require an upgrade in the clean environment rating. It may be advisable to specify a conveyor with a higher cleanliness class, such as reconfigurable modular conveyors with a Class 1 rating.
Noise can be an issue in the cleanroom. Although maximum permissible exposure limit for noise set by OSHA is 90 dBA, a range of 50 to 60 dBA is actually considered comfortable. There are no conveyors that can be run in silence. With all the working and moving parts that most conveyor processes involve, noise is inevitable. But the level of noise produced by conveyors runs the gamut and can exceed 70 dBA. There are, however, quiet conveyors available, such as reconfigurable modular conveyors that operate below 50 dBA.
Another consideration relates to the maintenance and upkeep required by each conveyor system. How often, how easy and what is required to maintain and keep the conveyor clean?
Modular conveyors use an FDA-approved modular plastic link style belting and brushless DC motors. Plastic link-style belting is self-lubricating, requires no maintenance and is easy to clean and repair. Positive sprocket drive and tracking with the plastic link-style belting eliminates slippage and edge damage, doing away with the need for belt replacement. Brushless DC motors include maintenance-free gearboxes that are grease packed, require no lubrication and eliminate the potential of leaking oil.
Energy consumption
In terms of energy use, no matter the requirements of the particular conveyor, most conveyor manufacturers use the same large horsepower motor on all models. Based on each application, reconfigurable modular conveyors utilise energy efficient motors, which range from 1/30 HP to 1 HP.
Lowering the kilowatts used not only saves money, but reduces the carbon emissions. Savings can be seen with electric power consumption. These energy efficient motors are brushless DC motors that meet cleanroom standards by not emitting carbon like comparable brushed motors.
Taking the time to choose the right conveyor for a cleanroom offers numerous advantages for both companies and staff.
