Modular manufacturing is the process of production of individual sections or modules in an off-site location and assembling at the final site. These prefabricated modular buildings have recently gained momentum in the pharmaceuticals due to ease of construction and customization. The increasing demand for drugs worldwide and regulatory requirements have put a burden on the pharmaceutical industries to streamline operational units and develop more drugs. Pharmaceutical companies not only have to accelerate the production of the drugs but also need to follow safety regulations for successful approval of drugs from regulatory authorities. The construction complexities, additional space requirement, and requirement of cutting-edge technology is a high-price process and require time.
However, the introduction of modular cleanrooms allows pharmaceutical companies to create a safe and contamination-free environment for drug development—facilitating fast production, improving effectiveness, and ensuring great precision. The trends of personalized medicine have also increased the demand for modular manufacturing as it reduces cost pressure and provides flexibility for drug development in one place without additional construction. Driven by the increasing demand for modular buildings, the modular construction market is likely to boost in the future and deliver promising solutions to meet the current demand for drug development.
An Overview of Modular Cleanrooms
Cleanrooms provide a secure environment that filters contaminants such as airborne microbes, dust particles, and aerosol particles that degrade the drug. The cleanroom contains filters such as HEPA (High-Efficiency Particulate Air) that help to flush out contaminants and facilitate drug testing in a clean environment. Modular cleanrooms enable researchers to perform operations involving drug isolation and testing in a dirt-free environment. The most significant benefit of a modular cleanroom is it can easily be customized according to the size, type of rooms, and applications a pharmaceutical company requires for drug development. Modular cleanrooms have been used in critical research and drug development processes, including:
▪ Research facilities
▪ Medical laboratories
▪ Pharmaceutical industry
▪ Lens manufacturing companies
▪ Cell therapy production units
Modular Cleanroom Systems Components
Modular manufacturing focuses on the development of a different type of cleanroom systems component that offers a controlled environment. The main components of the modular cleanroom systems include:
▪ Wall Panels
The wall panels of the modular cleanrooms ensure firm joint lines for a smooth finish and customized structure. The customized wall panels designed by modular manufacturing companies ensure that the structure remains firm and supports other systems of the cleanrooms, creating a safe environment for research and development.
The prefabricated cleanrooms have ceilings that offer resistance from dust particles. Generally, the ceilings have been designed with prefabricated material and modular blocks that block the entry of dust particles and create a secure environment for researchers. The modular cleanroom manufacturers design customized a ceiling that fits the requirements of the pharmaceutical companies.
Doors play an essential role in modular cleanrooms as they are made with modules or blocks that ensure a safe environment by blocking the entry of dust particles.
Types of Modular Cleanrooms for Pharmaceutical Companies
Modular cleanrooms are a sophisticated approach to modern pharmaceutical companies as they help to meet regulatory compliance. Different types of modular cleanrooms have been developed for pharmaceutical companies, including:
▪ Commercial Growing Rooms
The leading modular manufacturing companies design cGMP (Controlled Goods and Manufacturing Practices) cleanrooms that are useful for the development of hybrid drug manufacturing. The commercial grow rooms offer humidity-controlled incubation and temperature control, which is essential for the cultivation of microbes used in the process of drug development.
▪ E-Liquid Modular Cleanrooms
These types of modular cleanrooms have been designed for the batch processing, packaging, and loading of the drug. It provides a secure environment by eliminating the contamination. The E-liquid modular cleanrooms have HEPA filtration that regulates the flow of air and provides an ideal temperature for the batch culturing of the microbes.
▪ Nanotechnology Cleanrooms
The nanotechnology-based modular cleanrooms have been designed by linking multiple cleanrooms to provide different testing, cultural, and manufacturing rooms in one place. The nanoparticle-based modular cleanrooms feature high-efficiency filters that help to eradicate microscopic airborne particles through the ventilation system.
▪ Modular Drug Test Cleanrooms
Modular cleanrooms have been designed with pre-fabricated components containing components such as ceilings and wall panels. The controlled chambers provide an insulated environment for drug testing and allow researchers to avoid potential contaminants, including dust particles and microbes.
Benefits of Modular Cleanrooms
Modular manufacturing brings a dramatic change in the construction of tailored cleanrooms for research and development purposes. The modular cleanrooms are prefabricated offsite with subsequently integrated facilities and skid-mounted platforms that facilitate research in a safe environment. Some other benefits of having a modular cleanrooms include:
▪ Ease of Installation
The modular cleanroom manufacturers use fabricated material for the construction that is interconnected with aluminum. This allows up-gradation expansion and minimal downtime. Moreover, it allows easy maintenance and offers sturdiness.
▪ Complete Insulation
Modular panels offer complete insulation and also possess fire retardness properties, which researchers cannot leverage in aditional construction. The complete insulations also help to avoid contaminants and allow the optimum temperature required for the research and development of drugs.
▪ Air-Flushing Doors For Integrity
Modular cleanrooms offer high resistance and air-tight sealing to achieve different pressures. The air-flushing doors can act as a barrier between outside environments, thereby protecting the integrity of the modular cleanroom, making it a safe alternative for research.
▪ Cost Effective
Traditional cleanroom construction is expensive and time-consuming. On the other hand, modular cleanrooms are cost-effective and ensure quick production. The modular panels provide usable space and eliminate the requirement of renovation costs.
Modular Cleanrooms: Advanced Facilities of the Future
Modular manufacturing is the future of pharmaceutical companies as it offers flexibility, convenience, and ease of construction. Moreover, modular facilities help to save the cost and space required for different research and development processes. Driven by the significance and rising interest in modular manufacturing, the market is expected to expand in the future. In addition, modular manufacturing companies also look for innovative solutions where personalized medicines and targeted therapies can be developed and controlled.
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