About the Client
The client is a leading materials manufacturer in Western Europe, recognized for its strong focus on sustainability and operational excellence. They specialize in producing a broad portfolio of advanced performance materials serving various industries—including automotive, construction, plastics, electronics goods, consumer goods, and medical devices. Their product range encompasses high-performance polymers, coatings and materials frequently found in multiple industrial applications.
Challenge
The client encountered product contamination issues in their manufacturing process, particularly around the extrusion and die (nozzle) areas. These areas generate significant heat, which contributes to spreading contaminants within the clean environment. The presence of these contaminants resulted in defects affecting product quality, leading to higher risk of batch rejections through defect and therefore decreased yield. Maintaining precise air handling was essential to sustain a contamination-free production setting.
Goals:
- Enhance product quality
- Prevent cross-contamination
- Support the client’s objectives regarding operational excellence and sustainability
Approach
Pre-engineering study:
JOA conducted a comprehensive on-site evaluation, collecting data on air flows and contamination risks around the heated die area. Air technical modeling and simulations were then used to pinpoint how contaminants dispersed throughout the production space.
Design & Engineering:
Armed with the study findings, JOA created a tailored solution featuring secondary extraction hoods and HEPA-filtered air supply units that seamlessly integrated with the existing HVAC system. Air distribution plates and balancing restrictors were implemented to maintain uniform airflow and minimize potential contamination sources. Dead zones were localized and prevented by design with CFD-modelling.
System Realization:
The installation included specialized extraction hoods, HEPA-filtered air units, and connecting piping. All components were integrated carefully with the existing HVAC setup, resulting in a dedicated MicroClimate™ (cleanroom) around the die area. The project was delivered on time and within budget, underscoring the constructive partnership between JOA and the client.
Validation:
Thorough validation measures, including smoke testing, confirmed that the die area was effectively isolated and that airflow design elements worked as intended to prevent contamination.
Outcome
By deploying JOA’s MicroClimate™ Technology to extract heated air from the die area and replace it with cooled, HEPA-filtered air, the client achieved:
- Reduced Defects: Contaminant spread from the melt process was significantly minimized, leading to fewer product defects.
- Improved Product Quality: Cleaner air contributed to more consistent and reliable product output.
- Efficient Air Handling: Balanced extraction and supply ensured optimal performance without disrupting existing production processes.
- Significant ISO Classification Improvement: Overall air quality improved substantially, elevating the production environment’s ISO classification.
- Lower Batch Rejection Rate: A 55% reduction in batch rejections was observed, boosting yield and reducing waste.
- Cost Savings & ROI: Significant operational cost savings were realized, with a return on investment achieved within 3–4 years.
Conclusion
Through JOA’s detailed engineering approach and specialized MicroClimate solution (sometimes also referred to as Cleanrooms), the client successfully addressed contamination challenges, improved product quality, and enhanced overall production reliability. The project was executed within the agreed timeline and budget, reflecting the fruitful collaboration between JOA and the client. This initiative further advanced the client’s sustainability and operational excellence goals, proving that a thorough, data-driven design can deliver both immediate and long-term benefits.
