From Concept Design to Final Validation: A Customized GMP Cleanroom Equipment Project in the UAE

How Flair worked with a local cleanroom contractor to design, manufacture, deliver and validate a pharmaceutical cleanroom equipment package

For pharmaceutical cleanroom projects, supplying the equipment is only part of the job.

The more difficult part is often everything around the equipment.

The dimensions have to fit the cleanroom.

The equipment has to work with the HVAC and airflow design.

Maintenance access has to be considered before installation.

Materials and finishes need to be suitable for the pharmaceutical environment.

And, perhaps most importantly, the equipment supplier needs to communicate closely with the cleanroom contractor throughout the project.

That was the case with a recent pharmaceutical project in the UAE.

We supplied and supported a customized equipment package consisting of:

• 6 GMP laminar flow pass boxes
• 3 staff gowning air showers
• 1 sampling booth & 1 dispensing booth
• Ceiling-mounted HEPA filter boxes with diffusers
• Full SUS304 stainless steel construction

The project was completed successfully, from concept design and engineering through manufacturing, delivery, installation coordination and final validation.

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The Project at a Glance

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The Project Was Not About Standard Equipment

On paper, the equipment list looks quite straightforward.

Six pass boxes.

One sampling booth  &one dispensing booth

Three staff gowning air showers.

HEPA filter boxes.

But for a cleanroom contractor, the equipment list is only the beginning.

The actual questions are usually more practical:

Will the equipment fit the room?

Will the maintenance doors still be accessible after installation?

How does the equipment connect with the cleanroom ceiling?

Where do the electrical connections go?

How does the airflow work with the surrounding HVAC system?

Can the contractor install it without creating problems for the other trades?

These are the details that can determine whether a cleanroom project runs smoothly or becomes difficult during installation.

So we started with the project requirements rather than simply selecting standard models.

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Challenge 1: Designing Around the Actual Cleanroom

One of the first priorities was understanding the actual cleanroom layout and site conditions.

For a cleanroom design and construction contractor, equipment cannot be considered independently from the room.

The equipment interfaces with:

• Cleanroom walls and panels
• Ceiling systems
• HVAC
• Electrical services
• Material flow
• Personnel flow
• Maintenance areas
• Other process equipment

This is why we worked through the equipment dimensions and interfaces during the design stage.

The objective was simple:

Make the equipment fit the cleanroom, rather than asking the contractor to modify the cleanroom around a standard product.

This approach is particularly important when the available space is limited or when several systems need to be coordinated within the same area.

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Challenge 2: Maintenance Had to Be Considered Before Manufacturing

One detail that received particular attention was maintenance access.

It is easy to design equipment that works when it is new.

The more important question is:

How will the equipment be maintained after several years of operation?

For cleanroom equipment, components such as HEPA filters, fans, electrical components and control systems will eventually require inspection or replacement.

But the available space around the equipment is not always generous.

For this project, we therefore considered maintenance access during the engineering stage.

Depending on the actual equipment and available space, access could be arranged from the appropriate direction.

In some configurations, internal access was suitable.

In other situations, side access was more practical.

This may seem like a small detail.

On site, it is not.

A component that is technically serviceable but physically inaccessible can become a real maintenance problem.

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Challenge 3: GMP-Oriented Material Selection

All of the equipment supplied for this project used SUS304 stainless steel construction.

This included the pass boxes, air showers ,sampling booth,dispensing booth ,and ceiling HEPA filter box assemblies.

For pharmaceutical cleanroom applications, the focus is not simply on appearance.

Material selection needs to consider:

• Cleanability
• Surface finish
• Corrosion resistance
• Durability
• Routine cleaning
• Long-term maintenance

The equipment was therefore designed around a full SUS304 stainless steel construction suitable for the pharmaceutical cleanroom environment(GMP requirement).

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Challenge 4: The Equipment Had to Work as Part of the Cleanroom

Another important point was that these were not independent pieces of equipment.

The pass boxes, gowning air showers ,sampling booth ,dispensing booth ,and ceiling HEPA filter boxes all formed part of the overall cleanroom system.

That meant the equipment design had to be coordinated with the surrounding environment.

For example:

GMP Laminar Flow Pass Boxes

The pass boxes were designed to provide controlled airflow during material transfer between cleanroom areas.

The configuration considered:

• HEPA filtration
• Airflow
• Interlocking
• Internal cleanability
• Maintenance access
• Material transfer requirements

Staff Gowning Air Showers

The air showers were designed for personnel entering the controlled environment.

The equipment configuration considered:

• Personnel movement
• Door interlocking
• HEPA filtration
• Air jet arrangement
• Control system
• Cleanroom interfaces

Ceiling HEPA Filter Boxes

The HEPA filter boxes with diffusers formed part of the room’s clean-air supply system.

Their dimensions and interfaces had to be coordinated with the ceiling arrangement and the surrounding HVAC system.

This is why equipment drawings were important before manufacturing started.

Sampling booth/dispensing booth 

• HEPA-filtered unidirectional airflow
• Designed for pharmaceutical GMP environments
• Suitable for powder sampling, dispensing and weighing
• Reduced risk of cross-contamination
• Customized dimensions and airflow configuration
• Front / side / internal maintenance access options
• Front / side / internal maintenance access options
• Differential pressure monitoring

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Working With the Local UAE Contractor

One of the positive aspects of this project was the communication between our engineering team and the local contractor.

There were regular discussions about:

• Equipment dimensions
• Cleanroom layout
• Installation interfaces
• Maintenance access
• Airflow
• Electrical requirements
• Site conditions
• Installation sequence

Some details were adjusted during the engineering stage.

That is normal for a customized cleanroom project.

In fact, we prefer to have these discussions before production.

A few extra discussions during the design stage are usually much easier than solving an interface problem after the equipment has arrived at the site.

For us, this is an important part of working with cleanroom contractors.

The equipment supplier should be part of the engineering coordination, not simply the company that delivers the equipment.

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From Concept Design to Final Validation

The project followed a complete engineering and delivery process:

01 — Concept Design

We reviewed the project requirements, equipment applications and cleanroom layout.

02 — CAD / Engineering

Detailed equipment drawings were developed around the actual project requirements.

03 — Technical Coordination

The drawings and interfaces were discussed with the local contractor and adjusted where necessary.

04 — Manufacturing

After the design was confirmed, the equipment was manufactured using the approved configuration.

05 — Quality Control

The equipment was inspected and checked before shipment.

06 — Export Packing

The equipment was professionally packed for international transportation to the UAE.

07 — UAE Delivery

The equipment was delivered to the project site.

08 — Installation Coordination

Flair supported coordination with the local contractor during installation.

09 — Testing & Final Validation

The installed equipment was checked and validated as part of the completed cleanroom project.

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What Made This Project Different?

It was not the number of units.

It was not a particularly unusual product.

The important part was the engineering coordination behind the equipment.

Six pass boxes, three air showers ，sampling booth &dispensing booth ,and HEPA filter boxes may look like a simple equipment list.

Behind that list were:

• Layout discussions
• Engineering drawings
• Equipment revisions
• Maintenance considerations
• Material selection
• Contractor coordination
• Manufacturing inspections
• Export packing
• Installation coordination
• Final testing and validation

That is the part of customized cleanroom equipment that is often difficult to see from a catalogue.

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What We Mean by Customized Cleanroom Equipment

For us, customization does not simply mean changing the width or height of a standard machine.

It means considering how the equipment will actually be used within the project.

For example:

Where will the operator stand?

How will materials move through the equipment?

Where will the HEPA filter be serviced?

Can the maintenance door be opened after installation?

How will the equipment interface with the ceiling?

Where will the electrical connection be located?

How will the equipment fit into the contractor’s installation sequence?

These questions are part of the design.

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OEM & ODM Engineering Support

This project also reflects the type of support Flair can provide to cleanroom contractors and EPC companies.

We can work from:

• Customer specifications
• Cleanroom layouts
• Equipment schedules
• CAD drawings
• Site dimensions
• Process requirements
• Photos and basic project information

From there, Flair can support:

Concept Design → CAD → 3D Proposal → Engineering → Manufacturing → QC → Delivery → Installation Support

This allows the contractor to involve the equipment manufacturer earlier in the project instead of waiting until the final procurement stage.

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Our Scope

Concept Design

Understanding the application, layout and project constraints.

CAD / Engineering

Developing equipment drawings and technical interfaces.

Manufacturing

Producing the customized equipment according to the approved design.

QC

Inspection and testing before shipment.

Export Packing

Preparing the equipment for international transportation.

UAE Delivery

Coordinating delivery to the project site.

Installation Coordination

Working with the local contractor during installation.

Final Validation

Supporting the final testing and validation process.

Concept Design → CAD/Engineering → Manufacturing → QC → Export Packing → UAE Delivery → Installation Coordination → Final Validation

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A Practical Approach to Cleanroom Projects

We don’t believe every cleanroom project needs a complicated customized solution.

Sometimes a standard product is exactly what the project requires.

But when the site conditions, process, layout or maintenance requirements do not fit a standard configuration, the equipment needs to be adapted.

That is where our OEM/ODM capability becomes useful.

We can work with the contractor’s engineering team to develop the equipment around the project rather than forcing the project to fit the equipment.

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Looking for a Cleanroom Equipment Partner?

If you are a:

• Cleanroom Design & Build Contractor
• EPC / Engineering Company
• Pharmaceutical Facility Contractor
• Cleanroom System Integrator
• Pharmaceutical Manufacturer

and your next project requires customized equipment, Flair can support your engineering and procurement team from the early design stage.

Send us a cleanroom layout, equipment schedule, drawing or even basic project requirements.

We can start from there.

Design it around the project. Build it around the requirements. Deliver it ready for the site.