When plastic fabricators consider replacing an inefficient facility with a state-of-the art operation, two  initial  pitfalls  must  be avoided: they can overestimate  difficulties or underestimate them, with results ranging from expensive too disastrous. These problems can be avoided by assembling a qualified team that includes an architect, a contractor, and if needed a consulting engineer who have experience with plastics manufacturing plants (288,341).

            Choosing the correct site is often the most critical decision in the process. This decision depends on various criteria such as adequate access to power and water. Consider what combination of highway and rail access will work best for receiving  raw materials  and shipping products. Check local zoning laws with regard to the permissibility of  silos or oling towers. Determine if the local labor supply is adequate. Select a site that permits future expansion. Design buildings so that expansion can be accomplished without interrupting production. Wiring and piping systemms should also be designed with expansion in mind. More loading dock space should be blanned. The parking area must be easy to enrge. New venting and air-conditioning technology can help reduce operating costs significantly. 

             The design of  a clean-room facility calls for a wide range of  talents. Aside from a  working  knowledge  of  the machinery  layout, architecture, and industrial or plant engineering, a strong background is needed in advanced air-conditioning and air-handling techniques, construction materials and equipment, lighting apparatus, air and liquid filtration technology, sterilization procedures, manufacturing methods, personnel controls, packaging engineering, maintenance and sanitation methods, and a host of other specialized disciplines.

            The multiplicity of talents required to assemble a clean room reflects the multiplicity of problems that can occur in clean rooms. There are system errors, such as work zones that add rather than reduce contamination, suply  air  systems that  do not effectively wash the sterile-fill zone, storage areas for strile materials that collect rather than eliminate contaminants, panel facings and exposed metal trim that degrade when cleaned and sanitized, room-temperature gradients with hot and cold zones, radical swings in room humidity resulting in static buildup or product caking, floor facings or coverings that crack, blister, or tear, excessive leakage in exhaust systems that prevents positive and stable room pressurization, and rigid-wall construction that cracks as the building settles, to name a few.

              Most clean-room problems arise because the clean room was adapted to the manufacturer’s rather than the room’s own needs.rer’s rather than the room’s own needs. Many clean-room contracting and engineering Machines firms employ one or two basic construction systems as an answer to all customer requirements. Whether  the room is for a sterile-solution filling line or assembly of a spacee telescope, the wall panels, filter modules airflow, lighting, structural supports, airconditioning  system, etc. are identical.  No matter what the manufacturing, personnel, plant requirements, the same basic clean-room shell is offered with the advice that the manufacturer adapt it to the production line (Table 2-5)

              The better approach is to begin with a thorough design review. A complete assessment of all the factors that will affect how the clean room operates must be reviewed in depth and firmly established before work begins on a final facility design. The clean-room engineering firm should have a broad range of component systems available so that the facility can then be tailored to the manufacturer’s requirements. The basic categories below require a complete review by a committee compoed of management, facilities engineering, quality control, manufacturing, purchasing, and
regulatory affairs personnel.

             The clean-room production system is an example of  how production of high quality Injection Molding parts can be set up with slihtly modified  standard  injection  molding machines using a well-thought-out clean-room design. It is of the utmost importance that the clean-room conditions for all the important production steps, as well as all the equipment and devices used in manufacture, should be satisfied. Clean-room manufacture of Injection Molding parts has been and will continue to be achievable, at the very least, beause of the possibilities of automation.