How Are Air Showers Produced?

Several main components make up air shower systems:

Enclosure Structure

The outer shell or body houses the internal components. Usually constructed from stainless steel or aluminum.

Filtration Systems

Multi-stage filtration cleans and recirculates air, removing incoming particles.

Fans and Motors

Powerful fan motors generate the required high velocity airflows.

Air Nozzles

Strategically placed nozzles direct focused air jets over personnel and items.

Control Panel

Houses controls, timers, indicators, and integration interfaces.

A combination of fabrication, integration, assembly, and testing methods produce air showers:

Metal Fabrication of Enclosure

The outer structure is cut, formed, welded, and finished from sheet metal using machining tools.

Integration of Filtration System

The filters and housings are installed and connected to the air ducting.

Installation of Air Nozzles

Nozzles are strategically positioned and secured at precise angles to optimize airflow coverage.

Electronics Assembly

Control panels are populated with timers, indicators, buttons, wiring and interfaces.

Final Assembly and Testing

All components integrate together, followed by thorough multi-point testing to verify performance.

Typical materials used include:

Stainless Steel and Aluminum

Corrosion-resistant metals used for the structure withstand daily washdowns.

HEPA/ULPA Filters

High-efficiency particulate air filters remove contaminants from recirculated air.

Industrial Control Systems

Programmable automation controls allow customization of cycles.

Quality Control and Assurance

Rigorous quality checks are conducted:

Materials Testing

Raw metals and components are verified to meet specifications.

Inspection of Critical Components

HEPA filters, nozzles, motors, etc. are inspected for defects before integration.

Performance Verification

Finished air showers go through comprehensive testing to confirm airflow, filtration efficiency and functionality.

Air showers are manufactured by assembling specialized enclosures, filtration systems, air nozzles and programmable automation controls, using metals and other cleanroom-compatible materials. Following rigorous quality control ensures the finished air showers meet stringent performance specifications to effectively remove contaminants in critical environments.

Q: What standards do air showers conform to?

A: They are designed to meet ISO 14644 cleanroom standards, IEST guidelines, and applicable electrical safety standards.

Q: How long does it take to manufacture an air shower?

A: Under normal circumstances, the complete manufacturing process takes 4-6 weeks from raw materials to finished product testing.

Q: What tolerances are critical?

A: Nozzle positioning and orientation tolerances are tight to optimize laminar airflows HEPA filter sealing is also critical.

Q: Can used or refurbished components be utilized?

A: New components are recommended for maximum reliability, but certified refurbished fans and controls can potentially be used.

Q: Are production lines dedicated for air showers?

A: Larger manufacturers will dedicate production lines and cells optimized specifically for air shower assembly.