Clean rooms for Beverage & Food Industries
At LCGC LABS, we design and set up your Modular Cleanrooms according to the Beverage & Food Industry standards. Not only do we design and set up your cleanroom, but we also offer maintenance services for its smooth operation. Our office is situated in Hyderabad, India, and our services are offered to all industries across the country!
At LCGC LABS, we offer you clean and hygienic settings ensuring smooth functioning across all procedures. With temperature, humidity, and pressure control, we also ensure particle count control in your beverage and food cleanrooms. We comply with the industry standards and regulations to ensure the topmost conditions in your cleanrooms. We thrive on eradicating contamination and creating a microbe-resistant environment for your Food and Beverage cleanrooms.
Advantages
- Visitor friendly
- Bottle entry and exit flaps
- Airlock system at access areas
- Contamination free
- Aesthetic setup
Included Components
Our modular cleanrooms for the food industry, medicine bottling, and filling beverages are manufactured, keeping cost efficiency and flexibility in mind. We only equip high-quality products and installations in your cleanroom while ensuring high design efficiency. Thus, your operational productivity increases manifolds!
Here are the parts of your Beverage & Food Industry Cleanrooms.
- Enclosure Section
- Supply Section and
- Air Filtration Section
1. Enclosure section:
We manufacture the enclosure section from contamination-resistant steel with a brilliant. The rock wool panel sandwiching between the steel plates provides an A15 fire rating temperature resistance. And our products are eco-friendly while ensuring top-notch hygiene indoors!
a. Structural frame
Filling room construction starts with creating the structural frame. We use a rigid, anti-contamination metal structure that supports your design entirely. The frames can be of 2 types, vertical frames, and horizontal frames.
i. Vertical Frames
Higher-level placement of industrial fillers ensures better contamination resistance. And our vertical frame is perfect for providing you with extra care! We either use stainless steel vertical frame or powder-coated steel for the structure. The structure places the floor higher than the ground level.
Key Features
- Chemical and corrosion-resistant
- High-temperature resistance
- Bacteria and microbe resistance
- Extremely hygienic and clean
ii. Horizontal Frames
Our horizontal frame design complies with the ISO class 9 level cleanliness standards and allows airborne particles to conform with the DIN EN ISO 14644-1 limits!
Key Features
- Rigid and stable structure
- Rigid and stable structure
- Integrated lighting space
- Fan filtration unit attachment
b.Partition
At LCGC LABS, we offer you easily demountable and modifiable partitions for your cleanrooms. They provide you with transparency and rigid support during the operations with designs complying with the ISO class 9 standards!
i. Transparent partition
The highly automated and complicated bottle filling process requires a human interface in swift functioning to reduce malfunctioning. Thus, transparent partitions work miracles in controlling and overseeing the procedures. And we design tempered glass or polycarbonate partitions, making the overseeing convenient by offering maximum transparency.
Key Features:
- Clean and transparent
- Temperature control
- Fog, smoke, and dust resistant
ii. Metal partition
Metal partition vital in protecting contamination between two rooms and maintaining hygiene. And with our specially designed, ISO 7 cleanliness compliant stainless steel metals partitions, you will see your filling system flourish.
Key Features:
- Higher heat resistance
- Hygienic
- Contamination resistant
- Rigid and durable structure
- Customization available
c. Ceiling
Conventional ceilings fail to maintain the cleanliness standards. At Kaizen, we provide a standard ultraclean ceiling system for generating clean environments in industrial filling systems. We offer highly durable fire-safe ceiling panels with antimicrobial coating complying with international standards for cleanliness. Ceilings are composed of the sandwiched panel between two steel plates ensuring appropriate environment. It is built to accommodate the weight and dimensions of the fan filtration unit.
Key Features:
- Customizable configuration
- ISO class5 and ISO class8 cleanliness certification
- Aesthetic design
- FFU accommodation
Technical Specification:
| Variables | Specifications |
|---|---|
| Ceiling grid | T-joists with slide in dividers |
| Ceiling grid material | Powder coated MS/ Stainless steel |
| Material | Polypropylene |
| Fire-safe SS 304 | |
| Powder coated steel | |
| Clear Acrylic | |
| SDPVC | |
| Edge finish | Paint sealed for improved cleanroom performance |
| Coating | Antimicrobial |
| NRC | 0.7 |
| CAC | CAC 41 |
| Temperature range | 0C-49C |
| Humidity | RH 99% |
| Thermal insulation | 0.40 m2k/W |
| Weight | 5.28 kgs/m2 |
| Colour | White |
d. Fan Filtration
Our fan filtration unit (FFU) ensures the microfiltration of outdoor air and ensures clean airflow indoors. These motor-driven fan filtration units work even better with HEPA filters. Along with the HEPA filters, it decontaminates the polluted air to create a hygienic working environment while providing a constant, even microfiltered airflow of class 7 standard. Also, the vibration and sound are low, being around 50dB only.
Key Features:
- Hygienic environment
- Two-step filtration
- Noise-free operation
- Auto filter change indicators
- Easy installation and maintenance
Technical Specification:
| Particle retention at fine filtration | 3 to 5micron |
|---|---|
| Particle retention at HEPA filter | 0.3 micron |
| Ceiling height | 27430mm |
| Noise level | 50dB |
| Cleanliness class | ISO Class 7 |
| Floor area | Standard and Customized |
e. Light fixtures
Contamination-free environments require clean and hygienic lighting. We design and develop the lighting fixture with closure the provide your required visibility. These fixtures are fire and fume-resistant, too. Moreover, the intracellular Reactive Oxygen Species (ROS) helps the lights in targeting and eliminating bacteria.
We provide you with two types of lights.
- Fluorescent Lights Features:
- LED panels performance specifications:
Key Features
- Filler unit
- Durable
- ISO standard compliance cleanliness
- Up to 3150 lumens
- Customizable configurations
- Dust, bacteria, and water protection
- Low heating concerns
- Air pressure balance
- Arcing prevention
- Outgassing resistant
Different types of lights :
- Highly durable fluorescent lights
- Available in panel and tube structures
- Total lumens up to 3150
- Customized dimensions and configuration
- Certified with ISO standards for cleanliness
- Protection against dust, water, and small items
Type2: LED panels performance specifications :
| Variables | Specifications |
|---|---|
| Power | 49-77W |
| Ceiling grid (module length) | 300-600 mm |
| Light source | Replaceable LED |
| Mains voltage | 220V/50-60Hz |
| Ceiling type | Exposed T-bar ceiling |
| Colour | White |
| Color rendering index | >80 |
| Average life | 25,000-70,000 hours |
| Driver failure rate | 1% per 5000hours |
| Ambient temperature | +25 C |
| Operating temperature range | -20C to +35C |
| Connection | Push in connector |
| ISO class | 2-9 Fraunhofer certified |
| Certification | IP65 |
| Housing material | Sheet steel |
| Cover material | Tempered glass |
| Internal optic material | Aluminum |
| Heatsink | Aluminum sheet steel |
| LED type | Square LED | Rectangular LED |
|---|---|---|
| Luminous flux (In l m) | 3600, 3900, 6000, 6300 | 6000, 6300 |
| Color temperature | 3000 or 4000 k | 3000 or 4000 k |
| Initial luminaire efficiency | 109- 120 l m/W | 109- 120 l m/W |
| Luminous flux tolerance | +/- 10% | +/- 10% |
| Dimensions | 596x596 mm | 1196x296 mm |
f. Cable Management System
You require a reliable, diligent cable management system to ensure signal integrity as well as to reduce outgassing. And without a cable management system, getting a contamination-free setting is hard. From EMI shielding, continuous flexing to MTW rating, or resisting electrical shocks, cable management systems are vital. And we design your cable system to ensure lower friction and leakage with a protective covering. Thus, you get nothing but the best!
Key Features:
- Efficient design
- Effective maintenance
- Less heavy
- Particles free cables
- Outgassing prevention
- Better flexing
| Variables | Specifications |
|---|---|
| Materials | Steel and Aluminium |
| Guides | Plastic T guides |
| Finishes | Black/ White powder coat paint |
| Cable capacity | 12 bundle swivels |
| Accessory rods | 2021-04-02 00:00:00 |
| Assembly | Centre track assembly |
| Spools | 4 half spools (Not included in 150 and 200mm) |
| Size | Customized |
| Cable Management | Single sided/ Double sided |
| Hinges | Duel hinge for front and rear panel |
| Cable Management | Single sided/ Double Sided |
|---|---|
| Hinges | Dual hinge for front and rear door |
| Materials | Steel/ Aluminium with plastic guides |
| Colour | Black/ White |
| Size | Standard and customized |
| Accessory rods | 2/4 rods |
g. Intelligent Doors
Security of your cleanroom is critical for uninterrupted functioning. And biometric doors are best in preventing unauthorized people from entering the premises.
At LCGC LABS, we design and install highly secure, durable automated doors, ensuring your cleanroom integrity. Not only do they prevent unauthorized entries, but they also control the flow of contaminants from outside. And the disinfect blower helps in sanitizing a person while they are entering the cleanroom.
Key Features
- All-around security with integrated locks
- Biometric scanners to unlock doors
- Smart access
- Auto alarming system
| Door type | Manual door | |
|---|---|---|
| Door | Sliding door | Swing door |
| Panels | Acrylic/PVC | Acrylic/PVC |
| Panel type | Puff panel | Puff panel |
| Frame | Aluminium | Aluminium/Stainless steel |
| Dimensions (In mm) | 1016x2083 | 914x2057 (Single swing) |
| 1829x2057 (Double swing) | ||
| Door type | Automatic door | |
| Door | Sliding door | Double slide door |
| Dimensions | 2438.4x2336.8 | 3754.75x2336.8 |
| Panels | Glass/PVC/Customized | Glass/PVC/Customized |
| Panel type | Puff panel | Puff panel |
| Frame | Aluminum | Aluminum |
| Compliance | UL, NFPA | UL, NFPA |
| Finish | Clear/Dark bronze | Clear/Dark bronze |
| Door interlocking | Electromagnetic door locks |
|---|---|
| Resistance | Up to 225 kg force |
| Access type | Iris scanner |
| Fingerprint scanner | |
| Prox Pad card scanner | |
| Keycard reader | |
| Notification alarms | Smart door alarm |
| (Audible and visible) | |
| LED display bar | |
| Smart message panel | |
| Surveillance | CCTV |
h. Wall Panel:
LCGC LABS designs and installs easily cleanable and germ-free wall panels giving you the enclosure you need. The center mountable, highly flexible design complies with international standards while customizing its configurations according to your requirements.
Technical specifications:
| Variables | Specifications |
|---|---|
| Standard Size (WxH) | 1200x3000 mm |
| Thickness | 25 to 150 mm |
| MOC | Powder coated/Precoated galvanized steel/ Stainless steel |
| Infill | PUF (Polyurethane Foam) |
| PIR (Poly Iso Rinate) | |
| Mineral Wool/Glass wool/Rockwool | |
| FRP | |
| CPVC | |
| Profile | Aluminum/GI |
| Fire resistance class | F130 under EN 13501-2 |
| Compliance | ISO 5 |
i. Windows:
Our transparent, premium quality windows allow you to view the internal operations of the cleanroom from the outside. We design easy to clean, and sturdy windows customized per your requirements and offer your complete satisfaction. Our windows are available in framed and frameless with a single or double-sided view.
Technical specifications:
| Single sided window | Double sided window | ||||
|---|---|---|---|---|---|
| Construction | Nominal dimensions | Window material | Construction | Nominal dimensions | Window material |
| (In mm) | (In mm) | ||||
| Framed window | 14325.6x10972.8 | Tempered glass | Framed window | 14325.6x10972.8 | Tempered glass |
| 10972.8x14630.4 | 10972.8x14630.4 | ||||
| Fire-rated glass | Fire-rated glass | ||||
| SDPVC | SDPVC | ||||
| Polycarbonate | Polycarbonate | ||||
| Acrylic | Acrylic | ||||
| Frameless windows | 14325.6x10972.8 | Tempered glass | Frameless window | 14325.6x10972.8 | Tempered glass |
| 10972.8x14630.4 | 10972.8x14630.4 | ||||
| Fire-rated glass | Fire-rated glass | ||||
| SDPVC | SDPVC | ||||
| Polycarbonate | Polycarbonate | ||||
| Acrylic | Acrylic |
j. Flooring:
At LCGC LABS, we customized the height of your flooring according to your requirements and thrived on providing you with international standard cleanliness. We customize the configurations for your durable, high-tech matrix floor panels!
Technical specifications:
| Variables | Specifications |
|---|---|
| Coating | Vinyl powder coated |
| Roll Dimensions (WxL) | 2x20 m |
| Tile format | 608x608 mm |
| Colour | Blue/Grey/Customized |
| Thermal conductivity | 0.25 W/(m.k) |
| Fire rating | Bf1-s1 |
| Slip resistance | R9 |
| Heat resistance | 0° to 50°C |
| Air cleanliness class | ISO 4 |
| Load resistance | 40 kg/sq. cm |
| Static electrical propensity | <2000V |
| Electrical resistance | >1011 Ω |
| Particulate cleanability | 85.66% reduction in particle contamination |
| The action of micro-organism on the flooring | Inert and resistant |
| Chemical resistant | Excellent |
| Resistance to gaseous H2O2 | No damage |
| Compliance | CE Marking |
k. Smart Access Control:
Our smart security access system gives you complete control over your cleanrooms. While lessening any cross-contamination, you can also control the filling machine speed for operational maintenances and others. And our customized approach makes the control even smoother than ever!
2.Supplies Section
a. Pass-Through Chambers:
We design our pass-through chambers for comfortable and complication-free material transfer. Alongside controlling the extent of cross-contamination, they provide better ease of transportation within the cleanroom that can be customized accordingly.
Technical specifications:
| Variables | Accessories |
|---|---|
| Chamber material | Stainless steel |
| Construction | Double wall design |
| Mounting | Floor/Wall |
| Dimensions | Customized |
| Latch | All steel |
| Viewing window | Tempered glass |
| Accessories | Automatic doors |
| Alert alarms | |
| ULPA filtered air shower | |
| LED lights | |
| Smart access control |
b. Air Shower
We equip or air showers with high-velocity air jets to ensure minimal contamination within the cleanroom. The configuration is highly customizable according to your requirements!
Technical specifications:
| Variables | Specifications |
|---|---|
| Air change | Up to 743/hr |
| Initial airflow velocity | 20-22 m/s |
| Number of nozzles | 1936-06-01 00:00:00 |
| Air shower duration | 12 seconds |
| Persons/min | 2023-04-01 00:00:00 |
| Person per cycle | 2021-06-01 00:00:00 |
| Pre-filter | 85% Arrestance, 20% efficiency |
| HEPA filter | 99.99% efficient @ 0.3micron |
| Frame | Electro galvanized steel |
| Coating | White oven baked epoxy powder coated |
| Electrical | 220-240V/50-60 Hz |
| 110-130V/50-60 Hz | |
| Dimensions | Customized |
| Included accessories | Photophilic pressure gauge |
| Control panel | |
| LED lights | |
| Ionizing bars | |
| Fan filtration unit | |
| Compliance | UL listed |
3. Air Treatment Section
a. Air Conditioning:
Proper air conditioning is crucial in performing complicated and sensitive operations. That is why we abide by the NABH guidelines in setting up customized, tailored air conditioning solutions in your cleanrooms.
Technical specifications (Air cooled DX unit):
| (23.9°C DB, 16.1°C WB, 11.1°C DP) 44.6% RH | ||
|---|---|---|
| Total | BTU/hr | 54000 to 220000 |
| kW | 15.9 to 64.4 | |
| Sensible | BTU/hr | 54000 to 220000 |
| kW | 15.9 to 64.4 | |
| (26.7°C DB, 17.1°C WB, 11.1°C DP) 37.8% RH | ||
| Total | BTU/hr | 57000 to 231000 |
| kW | 16.7 to 67.7 | |
| Sensible | BTU/hr | 57000 to 231000 |
| kW | 16.7 to 67.7 | |
| (26.7°C DB, 18°C WB, 11.1°C DP) 32.2% RH | ||
| Total | BTU/hr | 60000 to 242000 |
| kW | 17.5 to 71.0 | |
| Sensible | BTU/hr | 60000 to 242000 |
| kW | 17.5 to 71.0 | |
| Electric Reheat | ||
| Housing | Stage aluminum | |
| Capacity (kW) | 6 to 18 | |
| Number of elements | 2 to 6 | |
| Number of stages | 1 to 3 | |
| Supply | 230V/50-60 Hz | |
| Hot Gas Reheat (24°C) | ||
| Capacity (kW) | 9.5 to 13.5 | |
| Humidification | ||
| Capacity (kg/hr) | 5 to 8 | |
| Power input (kW) | 3.7 to 6 | |
| Flush cycle | Auto | |
| Evaporator Blower | ||
| Blades | Backward curved | |
| Motor | Direct drive EC motor | |
| Nominal horsepower | 3.8 to 4 | |
| CFM @ 50Pa | 3500 to 12600 |
| (23.9°C DB, 16.1°C WB, 11.1°C DP) 44.6% RH | ||
|---|---|---|
| Total | BTU/hr | 55000 to 254000 |
| kW | 16.0 to 74.4 | |
| Sensible | BTU/hr | 55000 to 254000 |
| kW | 16.0 to 74.4 | |
| (26.7°C DB, 17.1°C WB, 11.1°C DP) 37.8% RH | ||
| Total | BTU/hr | 57000 to 269000 |
| kW | 16.8 to 78.8 | |
| Sensible | BTU/hr | 57000 to 269000 |
| kW | 16.8 to 78.8 | |
| (26.7°C DB, 18°C WB, 11.1°C DP) 32.2% RH | ||
| Total | BTU/hr | 60000 to 284000 |
| kW | 17.7 to 83.2 | |
| Sensible | BTU/hr | 60000 to 284000 |
| kW | 17.7 to 83.2 | |
| Electric Reheat | ||
| Housing | Stage aluminum | |
| Capacity (kW) | 6 to 18 | |
| Number of elements | 2 to 6 | |
| Number of stages | 1 to 3 | |
| Supply | 230V/50-60 Hz | |
| Hot Gas Reheat (24°C) | ||
| Capacity (kW) | 9.1 to 12.7 | |
| Humidification | ||
| Capacity (kg/hr) | 5 to 8 | |
| Power input (kW) | 3.7 to 6 | |
| Flush cycle | Auto | |
| Evaporator Blower | ||
| Blades | Backward curved | |
| Motor | Direct drive EC motor | |
| Nominal horsepower | 3.8 to 4 | |
| CFM @ 50Pa | 12600 |
b. Dehumidification Module:
Uncontrolled humidity can cause unfaltering damage to any research and production in the food and beverage industry. That is why LCGC LABS provides smart, well-tailored, standard dehumidification units to stabilize the indoor humidity to an acceptable level!
Technical specifications:
| Variables | Specifications | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| Housing | Stainless steel | ||||||||
| Coating | Zinc coat | ||||||||
| Desiccant material | Silica gel | ||||||||
| Material size | 2-5 mm | ||||||||
| Humidity @21°C temperature | Adsorption rate | ||||||||
| 50% RH | 498.9 to 2994 g/hr | ||||||||
| 30% RH | 362.9 to 2268 g/hr | ||||||||
| 10% RH | 136.1 to 816.5 g/hr | ||||||||
| Nominal Dimensions | Process Airflow | Reactivation Airflow | Weight | Full Load AMP | Reactivation Heat | Power | Voltage | ||
| (mm)(WDH) | (CFM`) | (CFM) | (kg) | (BTUH) | (Watts) | ||||
| 756x311x559 | 50 | 15 | 39 | 12 | 3240 | 1400 | 120V/60Hz | ||
| 924x622x692 | 150 | 45 | 86 | 18 | 9725 | 3850 | 240V/60Hz | ||
| 1130x845x819 | 300 | 90 | 136 | 32.9 | 19448 | 6900 | 240V/60Hz |