Ever Pharma
A cleanroom solution crafted for the top-tier pharmaceutical companies, the 'Champions League' of the industry.
Founded in 1967, Kemmler is a leading processor of High Pressure Laminate (HPL) panels, specialising in installing cleanrooms, personnel airlocks, and changing rooms in Germany and abroad. Recently, they equipped Ever Pharma in Jena with changing rooms and pass-through cabinets that meet cleanroom Class B standards under GMP regulations.
Ralf Stahl, Head of the Cleanroom Division, notes that "Class B is the highest level with personnel access; above this is Class A, which must be operated entirely without personnel." This standard is essential for Ever Pharma, which specialises in cytostatics and neurological medications that require the highest hygiene conditions for production.
A material alternative that better meets the specifications.
Ralf Stahl explains, "This situation necessitates the establishment of a complex airlock system. The changing process itself occurs in five stages. After that, each employee must pass through two additional locks before entering the Class B area. In total, we have equipped the facility with no fewer than 25 personnel airlocks."
"Of course, strict hygiene standards must be maintained in this part of the premises. Initially, we specified stainless steel for the entire facility. However, we quickly discovered that Trespa® TopLab® BASE and Trespa® TopLab® VERTICAL panels were a better alternative."
Ralf Stahl elaborates, "Let's discuss the touch and feel of the materials. Starting the workday sitting on a stainless steel bench in your underwear at 6:00 A.M. is not very appealing! A more contact-friendly surface is certainly preferred. Additionally, the visual appearance offers entirely different possibilities. Although Ever Pharma has chosen a continuous white design, it gives the furnishings a particularly elegant effect."
Even traditionalists are acknowledging Trespa® panels as a viable alternative to stainless steel.
Available in various colours, Trespa® TopLab® panels allow bold accents like red and green, unlike stainless steel, which often feels clinical. Cleaning stainless steel is labour-intensive, and it can corrode when exposed to disinfectants like chlorine and hydrogen peroxide. While more resistant V4A stainless steel exists, it is costly and still requires significant maintenance.
Conversely, Trespa® TopLab® VERTICAL panels are highly resistant to chemicals and cleaning agents, thanks to their material properties and Trespa's proprietary EBC (Electron Beam Curing) process.
Ralf Stahl observes, "In the last 5 to 6 years, the market has transformed significantly, with Trespa becoming a key player in the laboratory and cleanroom sectors due to its product quality."
Ever Pharma's cleanroom features custom-built pass-through cabinets, initially project-specific but now part of the Kemmlit range. Ralf Stahl highlights the unique aspects of these cabinets:
"These are unusually complex components of the furnishings. In this environment, Trespa® TopLab® was not only far more suitable than stainless steel, but also extremely attractive in terms of price/performance ratio. Stainless steel could certainly have been used for these cabinets – but it would have been very complicated and therefore sinfully expensive."
"The decisive factor here is the scope and complexity of the technical equipment that had to be accommodated. Added to this was the flexibility and precision in processing, which we achieved with Trespa® TopLab® panels. The pass-through cabinets are equipped with a supply and exhaust air system because it is important to prevent the ingress of dust on the one hand, and on the other hand to protect employees from coming into contact with active substances - such as hormones - which are sometimes used in production."
He continues, "Not only did we need to house the technology itself, but we also had to accommodate and maintain complete cable harnesses. By using Trespa® TopLab® panels, we integrated the technical components seamlessly and with relative ease. This also applies to the necessary inspection panels, which are secured with a practical clip system. Consequently, accessing the electronics and air filter systems requires just a few simple steps."
"Using TopLab® panels from Trespa allowed us to address the technical challenges with elegant, function-optimised solutions for these pass-through cabinets. Additionally, we avoided many issues we would have encountered with stainless steel. Finally, the cabinets could be integrated harmoniously into the wall construction."
"In terms of practicality and cleanliness, the facility has met all requirements, and it also looks outstanding, which is certainly a bonus."
The Final Conclusion: A Complete Success from Start to Finish
The project was completed in 2021, and according to Ralf Stahl, the overall solution has proven itself in every aspect. "The customer is happy," he confirms. "In terms of practicality and cleaning, the facility has met all the requirements, and it also looks outstanding, which certainly helps." The cleanroom area at Ever Pharma has positively impacted Kemmlit beyond this project.
Recently, Kemmlit expanded its machinery for HPL processing. This expansion provided an opportunity to develop new application areas for the TopLab® panels and demonstrate their technical potential in a highly impressive manner.
Integrating the initial project-specific pass-through cabinets into the general product line illustrates that the versatile possibilities of the TopLab® panel from Trespa are far from being fully explored.
