BAUSCH Advanced Technology Group has over 60 years in engineering and manufacturing. Bausch has divisions located here in the USA, Germany, Brazil, and Switzerland. They offering table top units for small batches up to high speed fully automatic production lines for Syringes, Cartridges, Vials, Bottles, Ampoules, Bags and various other containers. Cleanrooms are used in industries and manufacturing processes where small particles can adversely affect the outcome. Cleanrooms can vary in size and complexity based on an individual companies’ needs. A cleanroom is a contained space where there is reduced particulate contamination and extensive control other environmental parameters such as temperature, humidity and pressure. One of the main components is the High Efficiency Particulate Air (HEPA) filter that is used to trap particles that are 0.3 micron and larger in size.

The clean room installed at Bausch Advanced Technology was manufactured by PortaFab. The PortaFab cleanroom is a series 300 fire and sound proof modular cleanroom. The Series 300 wall system is often used for creating standalone units like this ISO 7 cleanroom for medical device manufacturing. The load-bearing roof supports HVAC equipment, provides easy maintenance access, and is anti-static which is ideal in manufacturing situations. You can read more them here.

Furthermore, Controlled Air Inc. designed, and installed the complete HVAC system. The installation included an AAON air handling unit with modulating hot gas reheat, digital compressors with 2 lead stages and variable speed compressor fan head pressure control. We also designed and installed a custom duct air distribution system to supply the fan powered HEPA supply terminals along with the air return system. Controlled Air Inc. engineered and installed a Johnson Controls system with a FX-80 Supervisory controller, Web based user interface, room pressure sensors for the cleanroom, AHU control, 8 VAV boxes.

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In the first two phases of work, Controlled Air, Inc. installed two Carrier high efficiency gas electric roof top units on standard 14” insulated curbs with slope, to match their existing roof pitch. The RTUs have multi stage cooling with barometric relief and MERV 7 filters. Units are equipped with factory controls along with BacNet interface that tie into a new Johnson Controls FX system.  In addition to installing the RTUs we manufactured and installed the supply and return duct distribution system.

In the second phase, Controlled Air, Inc. installed a Carrier heat recovery VRF system for the new surgery recovery rooms, which consisted of eight ceiling mounted recessed evaporators and one outdoor condensing unit with a single and central controller. For additional energy efficiency, an Energy Recovery Unit (ERV) with a supply and return duct distribution system was added.

In the third phase Controlled Air, Inc. furnished and installed three AAON roof top units with filter curbs and HEPA filters, serving the new operating rooms and clean room. These units include high gas heat and multi stage cooling. Additionally Controlled Air, Inc. manufactured and installed the necessary supply and return-duct distribution system with Nortec steam humidifiers and HEPA grills. Each operating room was equipped with thermostats, humidistats and room pressure monitoring sensors. Multiple fresh air and exhaust fans with hood systems were installed for the oxygen storage rooms and clean rooms.

To accommodate the new system our controls department upgraded the existing FX-30 web based supervisory controller to a new FX-80. All the new equipment was tied into the new system by our in-house controls department.

When making renovations to an existing medical center it is important for us not to interrupt any daily activities. All work in critical areas was performed at specific shut down periods dictated by the vacation schedule of the facility, during holidays or after hours.

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