There are many different industries that require clean room die cutting processes. Finding a manufacturer that can bear the cost of developing clean production without passing on higher prices to you can be the problem. There are some well-known companies that have developed an economical clean room system that meets or exceeds standards, while also providing some of the best costs in the business. Here are the basics of why making sure your supplier has clean room die cutting and processes available that are also affordable for your business.
What it takes to meet the standards
All clean rooms must be validated and certified ISO 14644 Class 7 clean room with an environmental viable bio burden monitoring program in accordance with ISO 14698. The best clean rooms will also have dedicated machines with terminal uses for clean and ultra-clean environments including fully automated process and manual procedures too. All of this means that the technicians employed are also highly specialized. This can be expensive to put in place in a manufacturing business if certain other steps aren't also given priority. In-house controls is something you should be looking for to determine if a supplier can support a clean room without having to pass costs to you.
In-house quality controls
In addition to meeting the federal and industry standards for clean room production, companies also have to reduce their risk of loss through the use of stringent in-house quality controls. For example, BarilCorp.com has a clean room facility is climate and moisture controlled and is subject to multiple verification testing that exceeds the schedule determined by ISO regulations. This is considered a best practice not just in providing you with quality clean room manufacturing, but also in reducing the potential of loss to the company. In-house quality controls mean that production is delivering at higher rates of usable product than a line that uses no additional controls. What you want to see is an offer from the company to see any and all of their certifications and verifications upon request. This is really the only way to guarantee standards are met. This type of double quality check should be offered on all the different forms of die cutting under clean and sterile standards such as flatbed (steel cut) and rotary die casting.
Flatbed die cutting
Not enough can be said about the importance of in-house flatbed die cutting. In a clean room system this allows for the following standards for steel cut dies:
- Capable of cutting large format and thick parts
- Excellent tolerancing
- Clean room flat-bed die cutting available
- In-line material laminating with multi-web capabilities
- Kiss cutting
- Servo-controlled presses for ultra-fine control
- Handfed clamshell presses
- Hydraulic presses for fast set-up prototypes and small runs
- State-of-the-art in-house tool making
- Custom engineered production lines
By having dedicated machinery in-house and in a clean room facility, you don't have to worry about your end product meeting standards. You also won't encounter a high cost to cover a temporary certification of a flatbed process if the machines are dedicated to clean room operations. By making them terminal use machines in a clean environment both you and the manufacturer are saving money by reducing risk and delivering quality.
Rotary die cutting
Another of the clean room processes that is popular is the rotary die cutting. These should be done on terminal clean machines that are certified for clean, ultra-clean and sterile procedure. Some of the features of this process include:
- Capable of cutting intricate parts with multiple layers
- Progressive die cutting: capable of registering multiple die cuts
- Up to 8 webs in a single pass
- Excellent tolerances
- In-line laminating, slitting, and adhesive application available
- In-line machine vision inspection
- Custom engineered production lines available based on project requirements
There are some companies that offer rotary die cutting process that is managed under a guardianship program. This means that the manufacturer works with your engineers and designers to create the product and standards to be met and then assumes guardianship during the manufacturing process to safeguard your order. This assures you that the highest quality standards are met throughout each stage.
Multi-layer laminating is used in the production and packaging of the products. Clean room laminating allows for the integrity of the layered product to be ensured, and it also allows sterile field protection designs to be used in packaging without risking contamination or creating a package that is difficult to open in the field.
Ultrasonic part cleaning
The last step in the clean room die cutting production is ultrasonic part cleaning. This takes the product from the clean environment and creates an ultra-clean product. Ultrasonic methods are capable of eradicating contamination to a fine degree so you are sure of a clean and sterile product before it enters the assembly and packing stage. This guarantees product verification to standards needed in multiple industries.
Assembly teams in the clean room facilities are also an important part of the process. They use a mix of manual sterile procedures and assisted assembly procedures to make sure that our ratings remain verifiable for clean room production. The standards set in-house have to beat the regulations required in order to really ensure you have quality materials and equipment processing. Nowhere else is this more important than with a sterile packaging process.
Sterile packaging can be achieved in numerous ways to protect the ultra-clean products that you have requested. Whether your industry is medical or homeland security the packaging is the key to successful applications. You can also select label customization for multi-layer laminate and standard packaging to improve your quality control and inventory tracking too.
Delivering product that can improve efficiency
Your top choice for a company to provide you with clean room processes is that all the products should be reliable and verified. That means that you don't have to worry about the quality of materials that you are using. Packaging standards should make using any die cut or laminated materials and packaging easy. In certain applications, the most sterile and clean product can't withstand complicated packaging that risks exposure through breaks in use protocol.
Working with you to achieve the best
Clean room die cutting can be done with custom and specialty designs, as well as with ISO approved standard products and appliances. From the manufacturing to the labeling, you need to make sure that your choice in manufacturers is capable of providing you with a product that is optimized to give you the best resources. Each part of a sterile process needs perfection, but that perfection has to be taken up a notch to really meet the needs of today's industries. Take the time to make sure your supplier can make the grade to make sure that you can exceed the standards you need to meet.