Complete Air Filtration Solutions for Clean Rooms in Zimbabwe

Introduction to Cleanroom Air Filtration

Primal Air, Zimbabwe’s leading air filtration specialist, provides comprehensive cleanroom filtration solutions for industries requiring controlled environments across Harare and nationwide. Our expertise in Air Handling Unit (AHU) filtration systems ensures that your cleanroom operations meet international standards while maintaining operational efficiency and cost-effectiveness. In today’s increasingly regulated industrial landscape, proper air filtration has become critical for sectors ranging from pharmaceutical manufacturing to medical facilities, electronics assembly, and food processing – all of which Primal Air serves with customized solutions .

At Primal Air, we understand that cleanrooms are meticulously controlled environments where airborne particulate levels are maintained within strict limits. These specialized environments require sophisticated multi-stage filtration systems to remove contaminants that could compromise sensitive processes, products, or research. Based in Harare, our team of certified technicians designs, supplies, installs, and maintains complete air filtration systems tailored to Zimbabwe’s unique environmental conditions and industry requirements .

Understanding Air Handling Units (AHUs) in Cleanroom Environments

Air Handling Units (AHUs) are the cornerstone of any cleanroom ventilation system, responsible for conditioning air (regulating temperature, humidity, and cleanliness) and circulating purified air throughout the controlled environment. The effectiveness of an AHU fundamentally depends on its filtration stages, which typically include primary, secondary, and final HEPA filters working in sequence to achieve the required air purity levels .

Properly designed AHU systems for cleanrooms must address several critical factors:

• Air change rates (ranging from 20-480 changes per hour depending on cleanroom classification)
• Pressure differentials between adjacent areas to prevent cross-contamination
• Temperature and humidity control for process consistency and personnel comfort
• Energy efficiency to minimize operational costs while maintaining performance
• Compliance with international standards (ISO classifications) and industry-specific regulations.

Primal Air’s engineering team specializes in designing and optimizing AHU systems for all cleanroom classifications, from ISO 8 (Class 100,000) to ISO 5 (Class 100) environments, ensuring that each system delivers reliable performance while considering the specific challenges of Zimbabwe’s climate and infrastructure.

Primary Filtration: The First Line of Defense

Primary filters serve as the essential first stage in cleanroom AHU systems, capturing larger particulate matter (typically 5μm and larger) that would otherwise prematurely clog and reduce the effectiveness of more expensive downstream filters. These filters protect the entire system from large particle load, extending the lifespan of secondary and HEPA filters while improving overall energy efficiency .

Types of Primary Filters We Supply:

• Panel Filters: Cost-effective, disposable filters with synthetic media, ideal for capturing large dust and dirt particles
• Pleated Filters: Featuring expanded surface area for higher dust-holding capacity and longer service life
• Washable Metal Filters: Reusable aluminum mesh filters that can be cleaned and reinstalled, offering economic advantages for environments with high particulate loads

Primal Air supplies and installs high-quality primary filters from leading international manufacturers, all available with various frame materials (galvanized steel, aluminum, or durable paper frames) and filter media (non-woven synthetic, metal mesh, or activated carbon composites) to suit your specific application requirements .

Primary Filter Applications and Specifications

Panel Filters G4 (65% ASHRAE) Pre-filtration for HVAC systems, industrial cleanrooms 1-3 months

Pleated Filters M5-M6 (40-60% ASHRAE) Pharmaceutical facilities, manufacturing cleanrooms 3-6 months

Washable Metal G3-G4 (50-65% ASHRAE) High-dust environments, industrial applications Clean quarterly, replace annually

Maintenance Guidelines:

Primary filters typically require replacement every 1-3 months depending on environmental conditions and operational hours. Regular inspection and timely replacement of primary filters significantly reduce pressure drop across the AHU system, lowering energy consumption and protecting more expensive downstream filters .

Secondary Filtration: Intermediate Protection for Enhanced Air Quality

Secondary filters (also called medium filters) provide the critical intermediate filtration stage in cleanroom AHU systems, capturing medium-sized particles between 1-5μm that pass through the primary filters. These filters serve as an essential protective barrier for the final HEPA filters, significantly extending their service life and overall system efficiency .

Primal Air supplies and installs two main types of secondary filters:

1. Bag Filters

These filters feature synthetic filter media arranged in bag configurations that provide extensive surface area for particle capture. Bag filters offer excellent dust-holding capacity and are available in various efficiency ratings from M5 to F9 according to EN 779 standards .

2. Plate/Box Filters

Constructed with rigid frames (galvanized steel, aluminum, or stainless steel) and pleated filter media, these filters provide high efficiency with minimal depth. They are ideal for installations with space constraints and are available in efficiencies from M5 to F9 .

Secondary Filter Efficiency Standards and Applications

M5 40-50% Industrial cleanrooms, commercial buildings 60-80

M6 60-70% Healthcare facilities, manufacturing 60-80

F7 80-90% Pharmaceutical production, hospital surgery rooms 100-120

F8 90-95% Electronics manufacturing, higher class cleanrooms 120-140

F9 95%+ Pre-filter for HEPA systems, critical environments 140-160

Secondary filters typically have a service life of 6-9 months, though this can vary significantly based on environmental conditions and how well the primary filters are maintained. Regular monitoring of pressure differential across the filter bank is the most accurate method for determining replacement timing, with most secondary filters requiring replacement when the pressure drop reaches approximately 450 Pa .

HEPA Filtration: Ultimate Protection for Critical Environments

HEPA (High Efficiency Particulate Air) filters represent the final and most critical stage of cleanroom air filtration, capable of capturing at least 99.97% of particles 0.3 micrometers in diameter. These filters are essential for maintaining ISO Class 5 (Class 100) environments or cleaner, where even microscopic particles could compromise product quality or research integrity .

Primal Air’s HEPA Filter Solutions:

• Standard HEPA Filters: With efficiency ratings of 99.97% on 0.3μm particles, these filters are suitable for most pharmaceutical, medical, and electronics cleanrooms
• Mini-pleat HEPA Filters: Featuring compact designs with hot melt separator technology, these filters offer space-saving advantages and are ideal for installations with height restrictions
• Gel-Seal HEPA Filters: Utilizing specialty sealing compounds for superior gasketing performance, these filters provide maximum protection against bypass and are recommended for critical applications
• High-Temperature HEPA Filters: Designed to withstand temperatures up to 300°C, these specialty filters are essential for applications involving heated air streams or sterilization processes

HEPA filter maintenance requires specialized expertise and equipment. Primal Air’s certified technicians perform integrity testing (using photometric or particle counter methods) and installation services to ensure your HEPA filters perform to specification. With proper upstream filtration protection, HEPA filters typically have a service life of 2-3 years, though regular testing is essential to confirm continued performance .

Primal Air’s Comprehensive Service Approach

1. Consultation and Assessment

Our process begins with a detailed evaluation of your cleanroom requirements, including:

• Cleanroom classification needs (ISO class)
• Industry-specific regulations and compliance requirements
• Operational parameters (temperature, humidity, pressure differentials)
• Existing infrastructure limitations and opportunities
• Budget considerations and total cost of ownership analysis

2. System Design and Filter Selection

Based on our assessment, we design a comprehensive filtration strategy that includes:

• Proper filter matching across stages for optimal performance and economy
• Custom-sized filters for non-standard AHU configurations
• Energy efficiency optimization to reduce operational costs
• Maintenance planning to minimize downtime and operational disruptions

3. Professional Installation

Our certified installation technicians follow strict protocols to ensure:

• Proper sealing of filter banks to prevent bypass
• Correct airflow direction and orientation
• Integrity testing of HEPA installations
• Documentation of all installation parameters for future reference

4. Ongoing Maintenance and Support

Primal Air offers comprehensive maintenance programs including:

• Scheduled filter inspections and replacement based on actual condition
• Pressure differential monitoring across filter banks
• Airflow velocity testing and balancing
• Emergency support for critical filtration issues
• Record keeping for compliance and auditing purposes

Industry-Specific Applications Across Zimbabwe

Pharmaceutical and Medical Device Manufacturing

Stringent compliance requirements for pharmaceutical manufacturing demand robust filtration systems. Primal Air provides filtration solutions that meet WHO GMP standards and Zimbabwe Medicines Control Authority requirements, with validated systems for documentation and auditing purposes.

Healthcare Facilities and Hospital Surgical Suites

Infection control is paramount in healthcare environments. Our surgical suite filtration systems maintain ISO Class 5 environments during procedures, reducing surgical site infections and protecting vulnerable patients.

Electronics and Microtechnology Manufacturing

Particulate control is essential for manufacturing yield and product reliability in electronics. Our cleanroom solutions maintain the ultra-low particulate environments required for semiconductor production, micro-assembly, and research facilities.

Food Processing and Packaging

Hygienic manufacturing conditions extend product shelf life and meet food safety standards. Our filtration systems help Zimbabwean food processors meet international export standards while maintaining product quality and safety.

Why Choose Primal Air for Your Cleanroom Filtration Needs?

• Local Expertise: As a Harare-based company, we understand Zimbabwe’s unique environmental challenges and industrial requirements
• Technical Excellence: Our team includes certified filtration specialists with extensive cleanroom experience
• Quality Products: We supply filters from internationally recognized manufacturers that meet ISO, EN, and ASHRAE standards
• Comprehensive Service: From design through installation and maintenance, we provide end-to-end solutions
• Validation and Regulatory Compliance: Our systems help you meet local and international cleanroom standards and certification requirements
• Cost Optimization: We focus on total cost of ownership, not just initial price, to deliver long-term value