Services: Packaging clean room decoration and construction, including design, construction, commissioning, acceptance and other services.
Project Result: OUDELONG project team combined with the enterprise budget, production process and future development space, to provide ‘economic, practical, safe’ overall solutions. The project includes changing rooms, packaging workshop, injection moulding workshop, warehouse and other functional areas, and integrates intelligent process management system, meets the standard of 100,000 class dust-free workshop (ISO 14644-1 Class 8), and pays attention to energy saving and environmental protection at the same time.
Details
1. Design proposal
overall layout：
People/materials flow lines： Adopting the principle of one-way flow, personnel enter from the changing room, through the air shower room into the clean area, the material enters through the independent material channel to avoid cross-contamination.
Clear functional zoning：
Changing room： Divided into the first change area (storage of coats, shoes, etc.) and clean area (change of clean clothes, shoes), equipped with lockers, shoe lockers, full-body mirrors, hand-washing sinks, hand dryers, etc.
Air shower ： §Use automatic induction fast rolling door, equipped with high efficiency filter, wind speed ≥ 25m / s, blowing time adjustable.
Packaging workshop： Arrange the equipment according to the product packaging process, reserving enough space for operator activities and material turnover.
Injection moulding workshop： It is independently set up and connected with the packing workshop through buffer room, effectively isolating noise and heat. Independent exhaust system is set up to discharge the waste gas and heat generated during the injection moulding process in time.
Warehouse： It is divided into raw material area, semi-finished product area and finished product area, and different storage conditions are set according to the material characteristics, such as temperature and humidity control.
Fire safety： Designed in accordance with the local Malaysian fire code with smoke detectors, sprinkler system, emergency lighting and evacuation routes.
Intelligent Process Management System：
monitoring system： Real-time monitoring of temperature and humidity, differential pressure, cleanliness and other parameters in the workshop, and recording of data for easy analysis and traceability.
equipment management： Monitor the operating status and manage the maintenance of key equipment such as injection moulding machines and packaging machines to improve equipment utilisation.
Production management： Achieve production planning, material management, quality traceability and other functions to improve production efficiency and management level.
Environmental design：
Energy saving measures： Energy-saving equipment such as inverter air-conditioning, LED lighting and high-efficiency motors are used to reduce energy consumption.
Exhaust gas treatment： The waste gas generated in the injection moulding workshop is treated and discharged in accordance with local environmental protection standards.
Noise control： Low-noise equipment is used and soundproofing measures are taken to reduce the noise level in the workshop.
2. Material used
Envelope：
Wall and ceiling panels： Adopting 50mm thick rock wool sandwich colour steel plate, the fireproof grade reaches A level, and the surface coating adopts anti-bacterial paint to prevent bacteria from breeding.The plate connection adopts special aluminium profile to ensure airtightness.
Door windows： Adopt steel purification doors and aluminium alloy purification windows with good airtightness, and sealant is used to seal the connection between door and window frames and walls.
Floor：
Packaging and injection moulding workshop： Using 2mm thick epoxy self-levelling flooring, which is wear-resistant, impact-resistant, dust-proof, easy to clean, anti-static and so on. Colour can be customized according to customer’s demand.
Pipelines：
Supply and return air ducts： It is made of hot-dip galvanised steel sheet, cleaned internally and pasted with flame-retardant insulation material. Pipe connections are flanged and sealed with sealing gaskets.
Other pipelines： Such as water pipes, gas pipes, etc., according to the characteristics of the medium to choose the appropriate material, and thermal insulation or anti-corrosion treatment.
3. Main equipment
Air purification system：
AHU： A combined air-conditioning unit is used, containing components such as primary, intermediate and high efficiency filters, surface coolers, heaters, humidifiers, etc., which can be combined and configured according to the needs.
High Efficiency Filter： A HEPA high efficiency filter is used with a filtration efficiency of 99.99%@0.3μm.
Air shower ： Stainless steel, two-person, double-blow air shower room.
FFU： Low noise FFU with adjustable airflow.
Injection moulding equipment： Choose the right injection moulding machine according to the product type and output, such as vertical injection moulding machine, horizontal injection moulding machine, etc.
Packaging equipment： According to the packaging form to choose the appropriate packaging machine, such as automatic packaging machine, vacuum packaging machine.
Testing equipment： Such as dust particle counters, anemometers, differential pressure meters, etc., are used to detect cleanliness, wind speed, differential pressure and other parameters in the workshop.
4. Challenges and solutions
Challenge 1: Malaysia’s high temperature and high humidity climate has a significant impact on energy consumption in cleanrooms.
Solution： Adopting high-efficiency heat preservation materials to reduce cold loss; adopting dehumidification unit to control the humidity of workshop; optimising the design of air-conditioning system to improve the efficiency of energy use.
Challenge 2: The injection moulding process generates harmful gases such as VOCs.
Solution： Installation of waste gas treatment equipment such as activated carbon adsorption device or RTO (Regenerative Thermal Oxidiser) to treat harmful gases such as VOCs to the standard and then discharge.
Challenge 3: How to control costs while maintaining quality.
Solution： Adopt modular design to shorten the construction cycle; select cost-effective materials and equipment; and optimise the construction programme to reduce waste.
5. Project Highlights
Customised design： Customised design to meet the specific needs of our customers and their individual requirements.
Full Service： Provide the whole process of service from design, construction, commissioning to acceptance, to provide customers with one-stop solutions.
Intelligent Management： Adopt intelligent management system to improve production efficiency and management level.
Sustainable development： Focusing on energy saving and environmental protection, we create green factories for our customers.
