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AIRFLOW VISUALIZATION:
STANDARDS, REGULATIONS
AND COMMON
MISUNDERSTANDINGS
Morgan Polen

Microrite Inc. 5019 New Trier Ave, San Jose, CA 95136 United States of America
[email protected] http://www.microrite.com,
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INTRODUCTION
Abstract:
Cleanrooms are high technology environments that
Airflow visualization studies allow for the visual char-
require appropriately pre-conditioned HEPA filtered air,
supplied in a consistent manner with a sufficient vol-
acterization of the “Contamination Control Effect”
ume and in a direction that provides the desired con- in cleanrooms or clean zones. The movement of
tamination control effect. Airflow Visualization Stud- HEPA filtered air dictates the contamination control
ies (AVS) document this contamination control effect, effectiveness of the overall installation. Factors
allowing the analysis and evaluation of the physical such as cleanroom design, HEPA filter placement, air
(actual) airflow patterns against design and operational
return locations, equipment configuration, furniture
requirements.
locations, personnel movements, manufacturing op-
The International cleanroom standards (ISO 14644 se- erations all can impact air patterns. Because air is
ries) provide guidance and standardization regarding transparent, it is difficult to determine this contam-
classification, testing and monitoring of cleanrooms.
ination control effect and unfavorable (adverse) air
These standards are the basis of contamination con-
patterns may go undetected. Airflow visualization
trol however they are not industry specific.
studies provide the analysis, evaluation and docu-
Pharmaceutical and medical product manufacturing mentation of air movement in cleanrooms and clean
cleanrooms require greater microbial and particulate zones. Pragmatic contamination control requires
control than cleanrooms used in other industries. A that comprehensive airflow visualization studies are
key aspect of this environmental control is the conta- performed under all operating conditions, including
mination control effect of HEPA/ULPA filtered airflow
simulations of operations.
moving in suitable volume and direction to prevent the
settling of contamination on products or product hand-
ling surfaces. Information gathered in airflow visualization stud-
ies can be used in risk assessment, optimization
In non-unidirectional flow cleanrooms, the contaminati- of airflow patterns in cleanrooms and barrier sys-
on control effect is achieved by the over pressurization
tems, adjustment of operator standing positions or
of the cleanroom by continually moving clean (HEPA/
movements, selection of environmental monitoring
ULPA filtered) air through the cleanroom while swee-
ping out contamination via strategically placed exha- locations, operator training and troubleshooting
usts or air returns. This effect prevents an ingress of cleanroom contamination issues.
contamination from external sources, while removing
internal contamination from the cleanroom. Pragmatic The paper will discuss airflow visualization testing
cleanroom design and equipment placement regarding
of cleanrooms including industry standards, regula-
airflow is required to maximize the contamination cont-
tions, and guidelines. Information such as regulator
rol effect of clean air.
expectations, common mistakes and the technology
In areas where lower contamination levels are required required for these studies will be presented.
(≤ISO Class 6) the contamination control effect is en-
hanced by using unidirectional airflow. Airflow is dire-
cted in a single direction providing a sweeping action
over surfaces or through the critical area, displacing
any contamination intrinsic to the manufacturing process out of the critical area. Additionally, this robust flow of
air helps prevent contamination from entering the critical area. The importance of unidirectional airflow cannot be
overstated in pharmaceutical and medical product manufacturing as it is the last defense in protecting exposed
clean or sterile components from contamination.

Many medical product facilities utilize combination flow conditions, where unidirectional flow zones, interface with a
non-unidirectional flow zones. A common example would be a Grade A zone (ISO Class 5 RABS, BSC or flow bench)
located inside a Grade B (ISO Class 7) background cleanroom.

Airflow visualization of both Grade A and B areas as well as the interface between these two zones is exception-
ally important as it provides a physical evaluation of the contamination control effectiveness of the enclosure, the
cleanroom, and the integration of these two systems.
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AIRFLOW VISUALIZATION FOR CONTAMINATION CONTROL

Too often Airflow Visualization Studies are approached only as a regulatory require-
ment and not as a contamination control tool. Airflow visualization studies are an ext-
remely important tool in assessing the physical contamination control effect of air pat-
terns and should be used to identify risk based environmental sampling locations.

It is important that in medical product cleanrooms, dislodged particles should not be

redeposited on products, personnel, or work surfaces. Because human beings are a
constant source of particulate and microbial contamination, a pragmatic and scientific
approach must be deployed to prevent contaminated medical products. Airflow visuali-
zation as applied to the science of contamination control provides valuable information
in terms of assessing contamination risk. Understanding air patterns in cleanrooms inc-
lusive of equipment and personnel movements is a fundamental component of holistic
contamination control.

The necessity of having a broad range of controls such as cleanrooms, barrier systems,
sterilization, sterile gowning, aseptic practices, and risk based environmental moni-
toring is due to the seriousness contamination poses to patients. It is important to
CONDUCTING note the impossibility of maintaining a sterile cleanroom environment that has humans
working in it for any period of time. Even with the most technologically updated facility
AIRFLOW VI-
designs and rigid sterile cleanroom gowning practices, human, and environmental con-
SUALIZATION
tamination is a constant threat to aseptically produced products. It is difficult to fully
STUDIES: eliminate microbial and particulate contamination in the entire operating cleanroom,
METHODS AND however, using all these controls and the use of robust, appropriately clean airflow, con-
TECHNIQUES tamination can be prevented from reaching products and product contact surfaces for
the duration of aseptic operations.

Because no amount of testing and monitoring can guarantee a contamination free ma-
nufacturing environment, airflow visualization should be utilized to optimize and qualify
the contamination control effect of the airflow under all operating conditions.

As regulatory bodies are expected to review airflow visualization videos, it is important

to work out any shortcomings in the system before attempting the documented “in situ
air pattern analysis”.

The actual (or physical) contamination control effect of cleanroom airflow can only be
properly understood when it is visually represented. From this visual representation
and analysis:

f Engineering can optimize the cleanroom, RABS, Isolator, or other barrier system de-
sign and integration of these systems into the cleanroom. Poor equipment place-
ment and integration can lessen a cleanroom’s ability to remove contamination.
Other factors such as equipment exhausts or cooling fans can significantly alter air
patterns and be a possible channel for contamination.

f Manufacturing can optimize operator positions, movements, and sequences to re-

duce the risk of human generated contamination near product or product contact
surfaces. Videos can be used for operator training and SOP development.

f Quality Control and Validation can review changes and create a suitable means of
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documenting static and dynamic in situ air pattern analyses once the optimization
of the cleanroom or clean zone and the operator’s movements have been defined.

WHAT ARE AIRFLOW VISUALIZATION STUDIES (AVS)?

Airflow visualization is the science of making airflow patterns visible for analysis and is
useful in contamination control. Because air is transparent, airflow patterns are invisi-
ble to the naked eye. The most common method to make air patterns visible is the Trac-
er Particle Method. The tracer particle method utilizes the addition of millions of tracer
particles into the air stream being tested. This smoke-like cloud of tracer particles
makes the air patterns visible, allowing the analysis of the physical (actual) airflow pat-
terns against design and operational requirements. The term “Smoke Study” is often
used synonymously for airflow visualization as originally these studies utilized smoke
sticks, cigarettes, incense, and powders.

The accuracy of these studies and the conclusions obtained, is dependent upon mul-
tiple factors. The methodology, equipment and the material used, can impact the ac-
curacy of the airflow visualization studies. Inaccurate airflow visualization studies have
created incorrect conclusions regarding airflow in medical product cleanrooms. Critical
areas that are reported to have suitable unidirectional airflow, actuality have vortices CONDUCTING
or other adverse airflow patterns. These adverse air patterns can act as a channel or
AIRFLOW VI-
reservoir for contamination. This has led to contaminated products, failed media fills,
SUALIZATION
sterility assurance failures, 483 observations, warning letters, import notifications and
negotiated facility closures. STUDIES:
METHODS AND

TECHNOLOGY FOR AIRFLOW VISUALIZATION STUDIES

TECHNIQUES

The Tracer Particle Injection Method typically used in cleanrooms involves the observa-
tion and recording the behavior of tracer particles that are injected or diffused into the
air stream being tested.

The accuracy of the air pattern analysis is dependent upon:

f Tracer particles faithfully following the air patterns.

f Tracer particles remaining visible long enough to allow for the analysis of the area
being tested.
f Location of the tracer particle injection.
f Method the tracer particles are injected into the air patterns being tested.

Various conditions (e.g., tracer particle size, temperature, composition, vapor pressure,
gravity) may influence the tracer particle behavior and stability. These conditions influ-
ence the behavior of the tracer particles, causing them to deviate from the actual airflow
patterns being tested. Tracer particles that settle or disappear rapidly may not accurate-
ly demonstrate air patterns in critical areas. This has resulted in incorrect conclusions
related to airflow visualization studies. Various systems and equipment are used for
performing airflow visualization and creating the tracer particles with varying levels of
accuracy.

Examples of equipment used for airflow visualization

f Ultrasonic, water based “Cleanroom Foggers”. These systems use an ultrasonic
transducer or series of transducers with WFI, distilled, purified, or deionized water.
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The transducer vibrates at an ultrasonic frequency creating tiny water droplets (trac-
er particles) that are propelled via a fan into the area of interest. These tracer parti-
cles are unstable and expand or coalesce creating larger particles that are heavier
than the air. Tracer particles dispersed from the output hose or manifold of these
systems range between 5-25 μm in size. Because gravity influences the behavior
of these tracer particles, these systems cannot reliably visualize dead air spaces or
other adverse airflow patterns (see figure 1). Condensation on nearby surfaces and
fogging of windows in RABS and Isolators may occur when using these systems.

f CO2 (dry ice) and water based “Cleanroom Fog Generators”. These systems use WFI,
Distilled, purified or DI water and Carbon Dioxide to create tiny water droplets (tracer
particles) that are propelled via a fan into the area of interest. These tracer parti-
cles are unstable and evaporate rapidly. Tracer particles dispersed from the output
hose or manifold of these systems range between 5-10 μm in size. Because gravity
influences the behavior of these tracer particles and they rapidly evaporate, these
systems cannot reliably visualize dead air spaces or other adverse airflow patterns
in critical areas.

f Nitrogen and water “Ultra Clean Cleanroom Fog Generators”. These systems use de-
ionized water and nitrogen to create tracer particles. These tracer particles however
CONDUCTING
are heavier than the air and evaporate rapidly. Tracer particles dispersed from the
AIRFLOW VI- output hose or manifold of these systems are approximately 2 μm in size. Because
SUALIZATION gravity influences the behavior of these tracer particles, these systems cannot re-
STUDIES: liably visualize dead air spaces or other adverse airflow patterns (see figures 2,3).
METHODS AND
TECHNIQUES f Glycol and water based “Tracer Particle Generators”. These systems vaporize a pro-
pylene glycol and water-based solution that when suitably diffused create sub-mi-
cron tracer particles approximately 0.3μm in size. These tracer particles are neutrally
buoyant and stable (see figures 4, 5). Tracer Particles created from these systems,
stay visible long enough to evaluate the area being tested. The glycol and water
technology utilized is the same as artificial smoke generators used in movie, stage,
television, and fire safety training. The main component, propylene glycol, is non-tox-
ic, anti-microbial and is used in pharmaceutical formulations (eye-drops, injectables),
food manufacturing (as a preservative), personal care products (shampoos, condi-
tioners, lotions), and e-cigarettes (creating the smoke like effect).

Tracer Particles used for in Airflow Visualization Studies

For consistent and repeatable results, the tracer particles (smoke cloud) must be neu-
trally buoyant, stable, and suitably diffused or injected into the air stream being tested.

Neutrally Buoyant Tracer Particles

Neutrally Buoyant describes the behavior of Tracer Particles when they are diffused into
an area with no apparent airflow. The cloud of tracer particles should not settle or rise
rapidly after being released into an area with no airflow. This allows for the detection and
recording of adverse airflow such as dead spaces, turbulence, refluxing air or vortices
(eddy currents). Tracer particles that settle rapidly cannot detect if HEPA filters are tur-
ned off (see figure 2), a significant requirement for accurate airflow visualization studies.
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Water based (Ultrasonic, CO2, Nitrogen) “Cleanroom Foggers” produce a fog (of tracer
particles) that is not neutrally buoyant. These systems are sold based upon the clean-
liness of the fog and not the ability to map the actual air patterns. Unfortunately, the CONDUCTING
use of these systems has created problems for pharmaceutical manufacturers as these
AIRFLOW VI-
systems cannot reliably detect dead air spaces, vortices, and air exchanges from door
SUALIZATION
openings in critical areas. These water-based foggers can make non-cleanroom areas
such as meeting rooms appear to have unidirectional airflow (see figure 1). STUDIES:
METHODS AND
Figure 1: Ultrasonic and water “Cleanroom Fogger” in a meeting room without airflow. TECHNIQUES

The smoke sinks, giving the false impression of unidirectional airflow.

Figure 2: Nitrogen and water “Cleanroom Fogger” Beneath HEPA filters. Note: HVAC is
Off

The smoke sinks, giving the false impression of unidirectional airflow.

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Figure 3 Nitrogen and water “Cleanroom Fogger” beneath a florescent light (dead zone)
the smoke sinks, giving the false impression of unidirectional airflow

CONDUCTING
AIRFLOW VI-
SUALIZATION
STUDIES:
METHODS AND
TECHNIQUES Figure 4 Glycol-based Tracer Particle Generator Note: Beneath HEPA filters HVAC is
Off

Figure 5 Glycol-based Tracer Particle Generator testing two HEPA filters in a unidirecti-
onal flow cleanroom. The filter on the left demonstrates unidirectional airflow, the filter
on the right is turned off.

Stable Tracer Particles

The Tracer Particles used for accurate AVS should be Stable (visible long enough to
evaluate the area being tested). In order to accurately observe and record the air pat-
terns by observing tracer particles, these particles must remain visible long enough to
record and document the air patterns being tested. Tracer particles that are unstable
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and evaporate too rapidly cannot accurately characterize the “Contamination Control
Effect” in cleanrooms and controlled environments. These particles simply do not re-
main visible long enough to observe mixing of air in non-unidirectional flow areas.

Figure 6: Tracer Particles for Smoke Studies: Neutral Buoyancy and Stability CONDUCTING
AIRFLOW VI-
SUALIZATION
Tracer particles must be suitably diffused into the air stream
STUDIES:
For accurate airflow visualization it is important that the tracer particles are introduced METHODS AND
without altering, disturbing, or overpowering the air patterns being tested. Per the FDA
TECHNIQUES
guidance “In situ air pattern analysis should be conducted at the critical area to demon-
strate unidirectional airflow and sweeping action over and away from the product under
dynamic conditions.”

Referring to the definition of the word “In situ”: meaning situated in the original, natural,
or existing place or position, undisturbed. In order to deliver the tracer particles into the
critical area the use of; tubing, manifolds, stands, suctions cups, cable ties or tripods may
be necessary. Additional test personnel operating a wand or tube to inject the tracer
particles through a partially opened door, should be avoided if possible.

The use of a tracer particle dispersion manifold should be considered to best deliver the
tracer particles to the critical area being tested. Manifold design and orientation can in-
fluence the accuracy of the airflow visualization.

Manifolds with a slotted or single row of orifices along the length of the manifolds (see
Figure 7.) must be orientated to not overpower the air patterns being tested and give
the false impression of unidirectional airflow when the actual air pattern is something
different.
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Figure 7: Tracer Particle Manifold Orientation in Respect to Airflow

CONDUCTING STANDARDS, REGULATIONS AND GUIDLINES

AIRFLOW VI-
SUALIZATION ISO Technical Committee 209 has published various standards related to cleanrooms.
STUDIES: Important concepts such as cleanroom principals, design, testing, start-up, qualification,
operation, and monitoring are addressed in these standards. Designated “Cleanrooms
METHODS AND
and Associated Controlled Environments” ISO 14644 parts 1-16. Of these standards, ISO
TECHNIQUES
14644 Parts 1-3 apply to all cleanrooms and controlled environments regardless of in-
dustry or function. Although these standards are not industry specific, they provide
the basis for discussions related to cleanroom qualification, testing and operations. In
addition, the FDA, EMA, PIC/S, USP and CETA have commented on the use of airflow
visualization.

International Cleanroom Standard ISO 14644-3:2019

The ISO 14644 series of standards provide the fundamental information related to clean-
rooms and controlled environments. “ISO 14644-3:2019 Part 3 Test Methods” provides
guidance on test methods, recommended test apparatus and procedures to support
testing and qualification of cleanrooms and controlled environments. Guidance for air-
flow visualization testing referred to as “Airflow direction test and visualization” is ad-
dressed in this standard as a means to demonstrate airflow direction and uniformity of
velocity for comparison to the design and performance specifications for the cleanroom
or clean zone being tested.

The standard introduces the Tracer Particle Injection method where the test is carried
out by the observation and recording the behavior of Tracer Particles. In addition, the
standard introduces the apparatus (Tracer Particle Generator) and methods from which
the tracer particles may be generated. Additional caution is provided related to the trac-
er particle size and the effects of gravity. Tracer particles should of a suitable size to be
observed and recorded, but not so large that gravity or other effects will result in their
behavior diverging from that of the airflow patterns.
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FDA regulations and guidance
The US FDA requires and reviews airflow visualization studies for cleanrooms and crit-
ical areas. Examples of the FDA’s scrutiny related to smoke studies is found in warning
letters and inspectors’ 483 observations. From a US Regulatory perspective, perhaps
the most important guidance on Smoke Studies (Air Pattern Analysis) is found in “Guid-
ance for Industry Sterile Drug Products Produced by Aseptic Processing Current Good
Manufacturing Practice” 2004: The expectation is the studies are meant to demon-
strate and document that HEPA-filtered air is supplied at a velocity sufficient to sweep
particles away from the critical area and maintain unidirectional airflow during opera-
tions. As airflow patterns are influenced by air movement, air velocity measurements
should correlate with smoke studies. The goal is to document and demonstrate (video
recording) that the installation can maintain unidirectional airflow and air quality under
all operational conditions. “After the relevant parameters are established, it is crucial
that airflow patterns be evaluated for turbulence or eddy currents that can act as a
channel or reservoir for air contaminants (e.g., from an adjoining lower classified area).
In situ air pattern analysis should be conducted at the critical area to demonstrate uni-
directional airflow and sweeping action over and away from the product under dynamic
conditions.”

The studies should be well documented with written conclusions and include evaluation
of the impact of aseptic interventions and equipment design. Inspectors commonly re- CONDUCTING
view videos of airflow visualization studies and expect that these studies are repeated AIRFLOW VI-
at a defined frequency as that even successfully qualified systems can be compromised SUALIZATION
by poor operational, maintenance, or personnel practices.
STUDIES:
METHODS AND
Clean Area Separation
TECHNIQUES
Airflow Visualization Studies should include the testing of cleanroom and barrier sys-
tem doors (including pass-throughs) to document proper airflow from areas of higher
cleanliness to adjacent less clean areas. It is vital for rooms of higher air cleanliness to
have a substantial positive pressure differential and airflow relative to adjacent rooms of
lower air cleanliness (with doors closed). Airflow Visualization Studies should document
and demonstrate when doors are open, outward airflow should be sufficient to minimize
ingress of contamination. This information can be used in risk analysis, environmental
monitoring site selection and to determine the time a door can remain ajar before alarm-
ing.

GMP Annex 1:

The 2022 updated of GMP annex 1 expands regulatory scrutiny of airflow visualization
studies and addresses gaps related to this testing.

f Airflow patterns within cleanrooms and clean zones should be visualized.

f Airflow Visualization should be performed in the at-rest (static) condition and in oper-
ational (dynamic) condition while simulating operations.
f Airflow Visualization should demonstrate the absence of ingress from lower grade
areas to higher grade areas via doors, mouseholes, isolator and RABS openings.
f Airflow Visualization should demonstrate that air does not travel from less clean
areas (such as the floor) or over operators or equipment that may transfer contami-
nation to the higher-grade areas.
f Where unidirectional airflow is required, airflow visualisation studies should be per-
formed in cleanrooms, RABS and isolators.
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USP 797 USP General Chapter <797> Pharmaceutical Compounding Sterile
Preparations

For sterile compounding facilities USP 797 provides additional requirements and guidance
for airflow visualization studies, referred to in the regulation as smoke pattern testing.

f Dynamic airflow smoke pattern test: A Primary Engineering Control (RABS, Isolator,
BSC, Flow Bench) test in using a visible source of smoke, which is neutrally buoyant,
is used to observe air patterns within the unidirectional space under dynamic condi-
tions. Operating personnel are present and simulating or performing compounding.
The conditions should reflect the largest number of personnel and highest com-
plexity of compounding expected during routine operations as determined by the
designated person(s). This test is not appropriate for ISO Class 7 or ISO Class 8 clean-
rooms that do not have unidirectional airflow (see Visual smoke study).
f Visual smoke study: A test, used in ISO Class 7 and ISO Class 8 rooms that do not
have unidirectional airflow, in which a visible source of smoke, which is neutrally
buoyant, is used to verify an absence of stagnant airflow where particulates can
accumulate. This test does not need to be performed under dynamic operating con-
ditions and is not appropriate for PECs (see Dynamic airflow smoke pattern test).

Controlled Environment Testing Association (CETA) Guidance

CONDUCTING
AIRFLOW VI-
The Controlled Environment Testing Association (CETA) made up of experienced clean-
SUALIZATION
room testing professionals in the United States, provides important considerations and
STUDIES: procedures related to airflow visualization testing for sterile compounding facilities.
METHODS AND
TECHNIQUES “CETA Application Guide CAG-014 Airflow Visualization Study Revised March 2022”. Im-
portant points made in this guide:

f The visible medium (tracer particle) should be as close to neutrally buoyant as pos-
sible.
f Water based generators such as ultrasonic and water, CO2 and liquid nitrogen cre-
ate a fog that is heavier than air and do not always provide for an accurate represen-
tation of the actual air patterns. These smoke sources also diffuse rapidly in ambient
air, making identification of stagnant air, or delayed re-entrainment to the critical
zones difficult to accurately identify.

USP 1116: USP General Information <USP 1116> Microbial Control and Monitoring of Aseptic
Processing Environments

Though not considered compulsory, USP 1116 provides important noteworthy guidance;
“Studying airflow visually is probably more useful than measuring air velocity or air ex-
change rates. Additionally, USP 1116 introduces the L-R (Ljundqvist & Reinmüller) method
using a tracer particle generator for cleanroom airflow visualization to identify any vor-
tices or turbulent zones. This can be done to fine tune cleanroom airflow and for risk
assessment. After the visual optimization of cleanroom airflow, smoke studies are done
in the critical zone during simulation of production conditions with equipment and per-
sonnel in place. By using a tracer particle generator and an airborne particle counter a
physical risk assessment can be conducted to evaluate the ability of RABS and Isolator
system to resist contamination.

COMMON MISTAKES AND MISUNDERSTANDINGS RELATED TO AVS

Because the performance of airflow visualization studies is not universally understood,

the following is a list of common mistakes associated with airflow visualization studies.
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1. Smoke Studies were not comprehensive and did not include simulations of all ac-
tivities such as automatic filling and closing operations, corrective & inherent inter-
ventions (including set-up and environmental monitoring).
2. Smoke Studies did not have the correct number of people per media fills.
3. Smoke Studies were not used as part of the risk assessment or operator training.
4. Smoke Studies not used for establishing CCPs for Environmental Monitoring.
5. Video documentation omitted important information, location, time, and date.
6. Smoke was too dense or not dense enough.
7. The camera was obstructed by too dense of smoke or the operator.
8. The AVS Protocol, Procedure, or Training was either incomplete or missing.
9. AVS Video shows GMP violations (dirt, residue, rust, water damage…).
10. AVS Video shows poor aseptic behavior.
11. There was no test report, or the report was missing conclusions.
12. QA and Validation did not participate in the smoke study.
13. The smoke injection method influences the local air patterns (the jetting effect)
14. AVS test results show smoke refluxing back into critical areas that were not noted
on the test report.
15. AVS test conditions are deliberately altered to present more favorable results.
(Knowingly using fog that isn’t neutrally buoyant, injecting particles with high veloc-
ity, altering manifold positions, turning of HEPAs to obscure actual air patterns and
obtain more favorable results)
CONDUCTING
16. AVS videos are not retained or are not available for review.
AIRFLOW VI-
17. AVS Videos are retained on outdated format: CD, DVD, VHS…
18. AVS Videos are in low resolution (e-mail purposes). SUALIZATION
19. Unedited (raw) Videos are not retained, suitably stored, indexed or available. STUDIES:
20. Untrained personnel are utilized for simulating aseptic interventions. METHODS AND
21. Smoke (tracer particles) are ejected into the air stream, overpowering the local air TECHNIQUES
patterns.
22. Smoke Studies were conducted using heavier than air fogging systems which do
not faithfully (accurately) follow the actual airflow patterns.
f Smoke Studies did not Identify Dead Spaces
f Smoke Studies did not identify Vortices (Eddy Currents)
f Smoke Studies did not identify upwards movement of air

ADDITIONAL CONSIDERATIONS FOR AIRFLOW VISUALIZATION

A variety of factors can impact the quality of the airflow visualization testing, and docu-
mentation. Factors such as camera angles, video storage, smoke density and method of
delivery can all influence the results of what is recorded.

Preparation for Airflow Visualization

Well executed and documented airflow visualization studies require preparation. A clear
understanding of what areas are to be tested, what activities are to be simulated, the
testing methodology to be used. Factors such as acceptance criteria and the recording
methods should be defined before the testing commences. Airflow visualization studies
that are intended for regulatory or customer review should utilize a protocol that ad-
dresses these considerations. If the studies are for engineering purposes or investiga-
tive in nature, a less formal approach can be taken.

f In preparation for the studies, make sure all cleanrooms adjacent to the area being
tested and on the same air handling system are not in use.
f The cleanrooms and clean zones including RABS, Flow benches BSCs and Isolators
should already be qualified and operational.
f Gowning requirements for test personnel need not be the same as production op-
erators as the areas being tested will be extensively cleaned after the smoke study.
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f Smoke detection systems should be in stand-by mode and local fire authorities alert-
ed prior to conducting smoke studies.

Cameras

Suitably placed video cameras are critical to AVS. The correct camera angle, focus and
recording method play an important part in the clarity of the smoke study video and can
influence the conclusions related to the airflow studies. Technological advances in cam-
era technology and data storage have enhanced AVS. There are a wide variety of cam-
era options available. The small size and portability of smart phones and sport cameras
allow for cameras to be placed inside critical zones, allowing for more comprehensive
understanding of air patterns.

Time and Date

An important consideration for AVS is documenting and recording the study. It is import-
ant the video start with a marquee or sign displaying testing information, so the viewer is
introduced to the test and is aware of testing details. Important information on this mar-
quee or sign is the time and date of the AVS. The internal clock of any computer, cam-
era, smart phone or sport camera used for the AVS, should be synced to the local time
and date. This is important as original unedited video files will have metainformation
including the timestamp of when the video was recorded. If the clock of the camera is not
CONDUCTING correct, the timestamp of the video will not match the documentation. In order to avoid
AIRFLOW VI- any confusion in the audit trail, make sure all relevant clocks are synced. It is not neces-
SUALIZATION sary to have the camera automatically overlay the time stamp (camcorder effect) on the
recorded raw video as this information is retained in the original video’s metainformation.
STUDIES:
METHODS AND
The use of multiple cameras or camera networks
TECHNIQUES
The use of multiple cameras allows the recording multiple angles of the same test. This
is helpful as sometimes in tight spaces, operator movements may obstruct one camera,
having additional cameras at alternate angles and locations allows the documentation
of the air patterns to continue. The use of multiple cameras may require the use of ed-
iting software to splice the videos from the different cameras into a more manageable
and viewable single summary or report video. The original videos remain unaltered and
available for review or comparison.

VIDEO STORAGE AND INDEXING

For videos that will be available for regulatory scrutiny, it is imperative that all videos
be suitably indexed and available for review. It is not necessary or advisable to utilize
the original camera media card as the primary storage. A secure location on a network
server or a dedicated hard drive suitably indexed, labeled, and backed up are commonly
acceptable methods. Older technology such as video tape, DVD, CD are not widely used,
making review difficult.

DOCUMENTATION WITH CONCLUSIONS

Appropriately trained airflow visualization test personnel and end user representatives
should document the airflow tests with conclusions on a test report. The conclusions
should be made at the time of the testing. It is important to consider that first-hand ex-
perience provides much more detail than anything captured on video. If adverse air is
observed, it may be necessary to repeat the testing to best document the phenomena
for management or engineering.
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POST AIRFLOW VISUALIZATION STUDY CLEANING

There is nothing clean about a “Smoke Study”. Because the number of tracer particles
required for suitable testing exceeds the cleanroom’s particle concentration limits, clean-
ing the cleanroom after the smoke study is required. Additionally, the type of Airflow
Visualization that is required by the FDA and other international regulatory bodies re-
quires smoke studies to be performed in conjunction with the simulation of processing
tasks, filling and closing of containers, loading, and unloading of freeze dryers, inherent
and corrective interventions including aseptic connections. As these simulations mimic
actual operations with additional testing personnel, equipment (cameras, Tracer Particle
Generator, tripods etc.) inside or in close proximity of the critical area, a deep cleaning
inclusive of sanitization, disinfection and sterilization must be undertaken.

REFERENCES

¸ ISO 14644-3: 2019 Cleanrooms and Associated Controlled Environments: Part 3 Test
Methods.

¸ Guidance for Industry Sterile Drug Products Produced by Aseptic Processing Current
Good Manufacturing Practice” 2004. US FDA

¸ The Rules Governing Medicinal Products in the European Union Volume 4 EU Guide-
CONDUCTING
lines for Good Manufacturing Practice for Medicinal Products for Human and Veteri-
nary Use: Annex 1 Manufacture of Sterile Medicinal Products AIRFLOW VI-
SUALIZATION
¸ USP General Chapter <797> Pharmaceutical Compounding Sterile Preparations
STUDIES:
¸ USP General Information <USP 1116> Microbial Control and Monitoring of Aseptic Pro- METHODS AND
cessing Environments. TECHNIQUES

¸ CETA Application Guide CAG-014 Airflow Visualization Study Revised March 2022
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CONDUCTING AIRFLOW
VISUALIZATION STUDIES:
METHODS AND TECHNIQUES
Bill Shade

Consultant, Microrite, Inc., [email protected], http://www.microrite.com

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INTRODUCTION
Abstract:
For medical product cleanrooms, Airflow Visualization
Airflow Visualization Studies provide a visual rep-
Studies (AKA Smoke Studies) should be considered as
resentation of the contamination control effect of
more than a definitive pass/fail test. The criticality of
these areas demands additional scrutiny that goes cleanrooms and clean zones. This information is
beyond the testing outlined in international cleanroom important for unidirectional, non-unidirectional and
standard ISO 14644-3:2019 Cleanrooms and associated mixed flow conditions. These studies can be used
controlled environments Part 3: Test methods. As the to identify adverse airflow and optimize the contam-
ISO 14644 series of standards apply to all industries, ination control effect that is critical to cleanrooms
additional considerations are required for the control
and clean zones of all classes and grades. Airflow
of particulate and microbiological contamination in
Visualization Studies are more than a single set of
medical product cleanrooms. Air pattern analysis (air-
flow visualization with conclusions) is an expectation by pass/fail tests that are part of the cleanroom or clean
regulatory bodies worldwide and an important tool for zone qualification, they provide information that
contamination control. can be used to optimize and improve the contami-
nation control effect, assist in risk analysis, identify
Suitably conducted, analyzed and utilized, airflow visu-
alization studies allow for: environmental monitoring locations (for viable and
non-viable), and provide operator training. This paper
f Characterization and documentation of airflow will discuss the various methods and techniques of
patterns in cleanrooms, barrier systems and
airflow visualization as well as provide examples such
controlled environments.
as: Investigative or engineering studies for trouble-
f Evaluation of actual airflow direction and air
velocity uniformity against design and perfor- shooting contamination problems, evaluating the
mance specifications. (ISO 14644-3:2019) cleanroom design, equipment layout and standing
f Identification of any undesirable air patterns or work positions for personnel prior to implementing
that can act as a channel or reservoir for con- the environmental monitoring program; static stud-
tamination.
ies to evaluate the manufacturing environment after
f Elimination of undesirable air patterns via op-
optimization (prior to in situ dynamic studies); in situ
timization of cleanroom and barrier system air
patterns or adjustments in operational behav- dynamic studies to evaluate airflow patterns during
ior, prior to conducting environmental monitor- simulations of manufacturing operations.
ing location selection.
f Minimization (when elimination is not possible)
of undesirable air patterns via optimization of
cleanroom and barrier system air patterns or adjustments in operational behavior, prior to conducting envi-
ronmental monitoring location selection.
f Identification of adequate locations for testing during cleanroom classification, (in the at rest and operation-
al state) as part of risk assessment with attention on areas where the complete elimination of undesirable
air patterns is not possible.
f Identification of adequate locations for monitoring the risk of viable and non-viable particles with attention
on areas where the complete elimination of undesirable air patterns is not possible.

AIRFLOW VISUALIZATION APPLICATIONS

In addition to regulatory expectations, airflow visualization is a useful engineering and validation tool that can be
used for the following applications:

Cleanroom Qualification (for unidirectional and non-unidirectional flow cleanrooms)

In the qualification of cleanrooms, mapping of Airflow patterns is used for confirming design and performance
specifications. Additional benefits include risk assessment purposes, environmental monitoring site selection and
operator training.
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Equally important is the identification of areas where airflow patterns have a
lessor contamination control effect. (e.g., doors, pass-throughs, spaces between HEPA
filters and areas with equipment exhaust fans).

f In unidirectional airflow zones, air should create a sweeping action over critical areas
across the entire Grade A (ISO Class 5) clean zone. Any adverse air patterns such
as excessive turbulence, eddy currents, vortices or refluxing should be identified
and addressed in the Risk Assessment and evaluated in the Contamination Control
Strategy. When possible, optimization/modification of the cleanroom should occur. If
a physical modification is not possible, additional environmental monitoring scrutiny
of these areas must be undertaken.

f For non-unidirectional airflow cleanrooms, it should be demonstrated that HEPA fil-

tered air entering the cleanroom effectively mixes with room air and exhausts via
suitably placed (low wall air returns). When ceiling mounted air returns or exhausts
are present, airflow visualization studies must demonstrate that HEPA filtered air
does not “short circuit” into air returns or equipment air inlets and suitable mixing
of HEPA filtered air occurs. Important for medical product cleanrooms is the iden-
tification of any areas of concern (such as equipment cooling fans, heat sources,
pneumatics, product handling robotics or areas with poor mixing or no air move-
CONDUCTING ment). These areas once identified, must be addressed in the Risk Assessment and
AIRFLOW VI- evaluated in the Contamination Control Strategy.
SUALIZATION
STUDIES: f For non-unidirectional airflow areas that support critical operations, it is important
METHODS AND that Airflow patterns from equipment cooling fans, heat sources, pneumatics, prod-
uct handling robotics do not pose a contamination risk, as a particle source or by
TECHNIQUES
washing over operators or components that may enter critical areas or are in close
proximity to critical areas.

Barrier System FAT/SAT Qualification

In the qualification of Barrier Systems (e.g., RABS, Isolators) it is important that unidirec-
tional airflow is specified and demonstrated as part for the FAT/SAT qualification, prior to
performing official in situ air pattern analysis. It is important to consider airflow patterns
in the planning and specification stage of a project. RABS and Isolators already integrat-
ed into a production cleanroom have been unable to provide a suitable environment for
aseptic processing due to excessive turbulence and eddy currents caused by design
and integration flaws.

f FAT: The demonstration of unidirectional flow and a contamination control effect for
all use-case conditions must be performed prior to equipment acceptance. Especial-
ly important is the demonstration of open-door conditions for RABS and isolators.
The question that must be answered: Is there a suitable outward flow of air to pre-
vent outside air from entering the Grade A zone when the doors are open?

f SAT: The ability of the Barrier system to prevent outside air from entering is critical
to establishing a suitable environment for aseptic or sterile operations. Large prod-
uct contact components such as stopper Bowls and hoppers must be appropriately
sterilized and transferred into the filling or processing equipment. As these items are
too large to be transferred via product transport ports, it is imperative that during
equipment set-up, outside air (Grade B for RABS, Grade C for Isolators) cannot enter
the Grade A barrier system’s environment.
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Pass-through and Air Lock Qualification

Pass-throughs and Air Locks should be designed and used to provide physical separa-
tion and to minimize the transfer of microbial and particulate contamination between
different areas.

The qualification of pass-throughs and airlocks should utilize airflow visualization as a tool
to evaluate these devices ability to act as an air lock. Tracer particles (smoke) should not
leak from the pass-through or air lock into the surrounding rooms. Often pass-through
gaskets are not integral, damaged or missing. The use of Airflow Visualization Studies
provides a useful Pass-Through Leak test that effectively tests the “Air Lock” principle.

Active or Dynamic Pass-Throughs (with Fan Powered HEPA filter modules) can be evalu-
ated for the effectiveness of the air exchange, or how quickly the pass-through flushes
itself with clean air. Evaluation of pass-through Airflow patterns should be performed
simulating transfer operations with timing and sequence matching normal use-case sce-
narios.

Optimization of cleanroom and barrier systems integration

Often the overall contamination control effect of sterile or aseptic processing areas is
compromised by poor integration of Barrier Systems into cleanrooms. After the Clean- CONDUCTING
room and Barrier systems have demonstrated suitable air patterns as part of their indi- AIRFLOW VI-
vidual qualifications, Airflow visualization should be conducted in order to evaluate the SUALIZATION
Airflow patterns related to the integration of the barrier system within the cleanroom.
STUDIES:
METHODS AND
f Air patterns inside of barrier systems must not be influenced by external activities
such as the opening and closing of cleanroom doors, or the movement of personnel TECHNIQUES
in the surrounding environment.

f Air patterns inside of barrier systems must not be influenced by the connection of
mobile HEPA transfer carts, transfer RABS or transfer Isolators.

f The evaluation of Air Patterns and the interface between the cleanroom and bar-
rier system must be evaluated in all possible scenarios, including the opening and
closing of doors and during simulations of all inherent and corrective interventions.
Important consideration related to the placement HEPA locations, air returns, equip-
ment intake and exhaust impact on air patterns should be evaluated in relationship
to contamination risk.

Optimization of operator movements and positions

As operator movements and positions can influence air patterns, characterization of

these moments as well as standing positions can be assessed in terms of air pattern
analysis. Airflow visualization testing as an engineering tool can help optimize operator
movements as well as positions to achieve improved airflow and increased contamina-
tion control. These tests may need to be performed multiple times in order to optimize
air patterns to provide the best possible overall contamination control effect during sim-
ulations of inherent and corrective interventions.

Training Tool

Additionally, videos from air pattern analysis can providing training material as a meth-
od of critiquing operator behavior in relationship to airflow patterns, particularly while
performing aseptic techniques, inherent and corrective interventions and environmen-
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tal monitoring. Care related to operator gowning, movement and attitude during AVS
recording is important. It may take several different tests to suitably capture the ideal
operator movement for training purposes.

Establishing Risk Based Environmental Monitoring (EM) locations

When establishing environmental monitoring locations and methods, the review of Airf-
low Visualization studies should assist in the selection of risk based environmental mo-
nitoring locations for conducting viable and non-viable particle monitoring. Additionally,
this information should be considered when selecting locations for cleanroom classificati-
on testing, utilizing the sample selection per ISO 14644-1:2015. From the AVS, air patterns
are reviewed and identification of areas where the greatest risk of contamination could
occur (from an airflow perspective).

Frequency of Airflow Visualization Testing and Cleanroom Re-Qualification

The frequency of performing airflow visualization studies is dependent upon the type of
facility as well as the operations carried out.

Airflow Visualization studies should be repeated during routine certification/re-qualifica-

tion of the cleanroom or advanced aseptic processing system and whenever significant
CONDUCTING changes are made to the operation, such as changes to; personnel flow, equipment op-
AIRFLOW VI- eration, material flow, air handling systems or equipment layout. It is important to note
SUALIZATION that even successfully qualified systems can be compromised by poor operational, main-
tenance, or personnel practices.
STUDIES:
In the Re-qualification of cleanrooms, it is important to compare studies historically to
METHODS AND
assess any differences from the original airflow visualization study.
TECHNIQUES
Pharmaceutical Manufacturing Airflow Visualization Testing Frequency

The maximum interval for repeating airflow visualization studies for pharmaceutical
manufacturing is not defined in regulatory documents however, the first edition of ISO
14644-2: (2000) indicated repeating this test at a maximum interval of 24 months. This
was changed in the second edition (ISO 14644-2: 2015) to be based upon risk assessment
however many manufacturers are repeating the test between 12 and 24 months.

Pharmaceutical Compounding Airflow Visualization Testing Frequency

The maximum interval for repeating airflow visualization studies for Sterile Pharmaceuti-
cal Compounding facilities (per USP 797) is 6 months. The increased frequency is meant
to address the high degree of human activity, the fluid nature of compounding as well as
the transportable nature of equipment, tables and chairs often utilized in pharmaceutical
compounding facilities.

Types of airflow visualization:

Cleanroom Airflow Visualization can be undertaken to characterize airflow patterns with

several different objectives.

Investigative Airflow Visualization

Investigative Airflow Visualization studies are used for identifying specific contaminati-
on control issues or as part of a cleanroom audit. This type of testing is a useful tool in
troubleshooting contamination and cross contamination problems. Investigative smoke
studies can detect airflow patterns that could act as a transport mechanism or as a re-
servoir for contamination. To avoid problems prior to media fills, these studies should be
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done prior to conducting formal and documented “Dynamic In situ Air Pattern Analysis”
in order to detect and address problems before qualification testing starts.

Engineering Airflow Visualizations

Engineering Airflow Visualization Studies are used as an engineering tool in order to cha-
racterize the cleanroom airflows and barrier system integration. Of particular importance
is the interface between different clean zones such as between Grade A and Grade B zo-
nes in aseptic manufacturing. Additionally Engineering Airflow Visualization is useful as
part of a physical risk assessment of the contamination control effectiveness and should
be used for establishing environmental monitoring locations within the Contamination
Control Strategy. These types of studies should be specified in equipment specifications
(URS) and required as part of FAT and SAT testing of any barrier system (Isolators, RABS).
Particular attention should be focused on the interface between barrier systems and
the external environment. To avoid problems prior to media fills, these studies should be
done prior to conducting formal and documented “Dynamic In situ Air Pattern Analysis”
to detect and address problems before qualification testing begins.

Static Airflow Visualization Studies

Static Airflow Visualization studies are conducted in the at rest occupational state.
These studies are used to characterize the airflow patterns of the entire cleanroom and CONDUCTING
any associated clean air device, barrier system (RABS, Isolators or HEPA Carts). All doors, AIRFLOW VI-
pass-throughs, conveyer belts and equipment that can impact air patterns must be eval- SUALIZATION
uated. The spatial relationship of HEPA filter diffusers and air returns must be evaluated
STUDIES:
in terms of overall contamination control effect of the area being tested. These studies
METHODS AND
are a pre-requisite of “Dynamic In situ Air Pattern Analysis”. Poor airflow under static
conditions is a cleanroom design or integration issue and should be addressed prior to TECHNIQUES
attempting Dynamic Airflow Visualization studies simulating operations.

“Dynamic In situ Air Pattern Analysis” (AKA Dynamic Smoke Studies)

Dynamic In situ Air Pattern Analysis is used to characterize airflow patterns during simu-
lations of operations. Because these studies are focused on the movements of people
and equipment, the overall contamination control effect of the cleanroom cannot be eva-
luated only with dynamic airflow visualization studies. Prior to conducting a “Dynamic In
situ Air Pattern Analysis”, a static airflow study must be performed that evaluates the
entire area. The FDA’s expectations are “Dynamic In situ Air-Pattern Analysis” is used to
demonstrate unidirectional airflow and a sweeping action over and away from the pro-
duct under dynamic conditions”. Multiple cameras may be used to best reflect and docu-
ment the airflow. This type of study is often used as evidence of suitable air patterns as
recommended by regulatory authorities.

What is “Dynamic In situ Air Pattern Analysis”? As the word in situ implies “in the origi-
nal, natural position; undisturbed” This is an important consideration when performing
airflow visualization studies. Having an additional test person holding a smoke tube over
the operator performing an intervention does not represent the natural airflow situation.
Manifolds and fixtures should be utilized as much as possible to better provide a more
realistic simulation of activities performed during “Dynamic In situ Air Pattern Analysis”.

Simulations of Activities During Airflow Visualization:

The most commonly accepted cleanroom norm is the even appropriately attired human
beings are the greatest source of microbial and particulate contamination in the cleanro-
om. This is why the simulation of activities during dynamic airflow visualization is required
in order to demonstrate that air patterns do not act as a channel or reservoir for conta-
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mination (adverse airflow).

Regulatory expectations include airflow visualization during simulations of: the transfer
of materials into the critical area, equipment set-up, assembly, environmental monitoring
in addition to all the inherent Interventions (part of the process) and corrective Interven-
tions (problem resolution) that could occur during operations.

Prior to conducting dynamic AVS a list of interventions and activities should be created
and attached to the associated protocol and report. Examples of activities are shown in
Table 1 below.

Inherent Interventions Corrective Interventions

Line set-up and Assembly Stopper jams

Replenishment of components Fallen vials

Weight / volume checks &

Broken vials
adjustments

Environmental monitoring Defective seals on containers

Removing waste Liquid leaks and spills

CONDUCTING
Non-assisted automated operation
AIRFLOW VI- Other mechanical failures requiring manual
of equipment (smoke studies while
SUALIZATION filling and closing operations)
correction

STUDIES:
METHODS AND Table 1 – Examples of Interventions
TECHNIQUES
Preparation for Dynamic Smoke Studies

The importance of understanding how to perform these tests as well as the nature of the
dynamic testing in the critical environment cannot be understated. Cleanroom testing
professionals may or may not understand the suitable methods for performing a dynam-
ic smoke study for a specific cleanroom and the operations carried out. This is because
they may not have a clearly defined list of all personnel movement for all aseptic opera-
tions.

Dynamic smoke studies require the simulation of production activates. In order to cor-
rectly visualize airflow under dynamic conditions, the cleanroom must be configured to
simulate actual operations. The equipment, product containers, vessels and transfer
materials must be in place. This also requires the actual personnel ready to perform their
operations. This may include support personnel that assist operators working in the crit-
ical environment, as they may (due to their proximity to the critical environment) influence
air patterns as they support operators in the critical environment.

Setting up a dynamic smoke study with video evidence requires the same complexity
as setting up the filming of a small video or movie production. Lighting, camera angles,
(multiple camera angles) as well as directing the operating personnel are all important in
performing a well-documented AFV/Smoke study.

Prior to performing any dynamic AFV/Smoke study, it is imperative to perform a static

AFV/Smoke study. The logic is: if a static AFV/Smoke study reveals turbulence or eddy
currents or air moving from a less critical area to a critical area under static conditions
then we do not meet the requirements of proper cleanroom airflow. Poor airflow under
static conditions equates to poor airflow under dynamic conditions.
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Fire and Smoke Detection Systems

It is important to notify security and if required any external fire monitoring agency that
AFV/Smoke Studies are being conducted in advance and just prior to commencing the
testing. Not all Fire/Smoke Detection Technologies are the same. Different technologies
used, have different sensitivities to smoke/fog particle sizes.

Tracer Particle Manifold Position

The position of the smoke manifold is extremely important. Figure 1 shows the correct po-
sition of the tracer particles manifold: Just below the HEPA Diffuser. In Figure 1 we have
Unidirectional Airflow with First Air Sweeping over the Product Contact Surfaces.

CONDUCTING
AIRFLOW VI-
SUALIZATION
STUDIES:
METHODS AND
TECHNIQUES

Figure 1 – Illustrates Correct Manifold Position Inside RABS

Figure 2 shows the correct position of the tracer particle manifold: Just below the HEPA
Diffuser. In Figure 2 when the RABS door is open, we no longer have unidirectional flow
inside the RABS. This is due to the poor integration of the RABS into the cleanroom. This
is problematic as there is no longer unidirectional flow inside the RABS and first air is NOT
getting to product contact surfaces.

Figure 2 - Illustrates Door Opening Effects On RABS

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Figure 3 shows the incorrect position of the tracer particle manifold: The manifold is
placed here to hide the effect of the door opening on the RABS internal airflow. Unidire-
ctional airflow is not maintained, and first air is NOT getting to product contact surfaces.

CONDUCTING Figure 3 - Illustrates Incorrect Position of Tracer Particle Manifold

AIRFLOW VI-
Figure 4 shows the position of the tracer particles manifold for testing a Grade B Room.
SUALIZATION
Because the RABS inlet is very close to the RABS inlet a “Short Circuit” is created. This is
STUDIES: detrimental to the overall contamination control effect of the facility.
METHODS AND
TECHNIQUES

Figure 4 - Illustrates Short Circuit

Common Airflow Visualization Tests and Methods

In newly commissioned facilities it is common to perform extensive engineering inves-

tigative smoke studies for reasons outlined previously. In general, any air source or
movement that can affect airflow including individual room HEPA filters, air returns, do-
ors, pass throughs, downflow booths and equipment exhausts should be considered for
testing during airflow visualization study. The following is a list of tests that are typically
performed in a clean room.
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1. Static Door Tests. Door pressure differentials are confirmed by generating smoke
along the perimeter of the door to confirm pressure differential across the door.

2. Dynamic Door Tests. Typically, a Pillar of Smoke is generated adjacent to the door
opening and the door is opened, and an operator walks through the opened door
then closes it. Depending on the movement of the door and the operator transfer
of air from the low-pressure side to the high-pressure side may occur. Figure 5 is an
example of a system for generating a pillar of smoke adjacent to a door.

CONDUCTING
AIRFLOW VI-
SUALIZATION
STUDIES:
METHODS AND
TECHNIQUES

Figure 5 - System For Generating A Pillar of Smoke Adjacent To A Door

3. Individual HEPA filter Tests. Smoke is generated just below each HEPA filter and
the airflow from the HEPA is observed. Individual HEPA filter tests can identify in-
adequate mixing of the air in non-unidirectional rooms possibly due to inadequate
air volume, unstable airflows due to fluctuations in the air handling, HEPA filters that
are off, etc. These results can be factored into the development of the EM plan for
the facility.

4. Air Return Tests. Ceiling and Wall Air Returns are tested by generating smoke
adjacent to the returns and confirming the airflows are adequate.
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5. Pass-through Tests. Both Passive and Active Pass-throughs are tested by plac-
ing a smoke source inside the Pass-through with the door closed and filling the
Pass-through with smoke. Any leaks in the Pass-through are readily identified by
observing the door perimeters immediately after filling the pass through with smoke.
If the Pass-through is an Active Pass-through the environment should clear in an
adequate amount of time. At the end of the test the door on the high-pressure side
can be opened to observe any transfer of smoke from the Pass-through to the room.
Figure 6 is an example of a system that can be used for testing Pass-throughs.

Figure 6 – System for Testing Pass-throughs

6. Equipment Exhausts. Many machines including incubators, freezers, cell process-

ing equipment, etc., contain fan exhausts and air-cooling inlets that can have a sig-
CONDUCTING
nificant impact on airflow. The airflow of these sources should be characterized by
AIRFLOW VI-
generating smoke adjacent to them and observing the air movement. If an unfil-
SUALIZATION tered fan exhaust is located adjacent to an open incubator this can be problematic
STUDIES: and may warrant changing the layout of the equipment in the room.
METHODS AND
TECHNIQUES 7. BSC Exhausts. These tend to move a large volume of air and if they are located
at the top of the machine near a ceiling and adjacent HEPA filter they can have a
substantial impact on the airflow in the room and first air coming from the adjacent
HEPA filter. In extreme situations substantial turbulence is created and since this
is adjacent to operator location at the front of the BSC it can result in air traveling
upward over the operator thereby violating the requirement of sweeping downward
first air to protect critical operations.

8. BSC Inlets. BSC Inlets can move a large amount of air and can affect mixing in
non-unidirectional cleanrooms. When testing individual HEPA filters adjacent to
BSC Inlets the airflow effects of the BSC inlets should be fully characterized and
accounted for.

9. Downflow Booths. Downflow booths are used locally for powder operations and
contain HEPA filtration spanning a large area. These booths should be tested to
ensure airflow is sufficiently unidirectional and any gaps between HEPA air inlets do
not create excessive turbulence. In addition, consideration should be given to the
interaction of these airflows with the airflows created by adjacent door operations to
ensure the possibility of cross contamination is minimized.
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CONDUCTING
AIRFLOW VI-
SUALIZATION
STUDIES:
METHODS AND
TECHNIQUES