A Case study for the Automobile industry

Project Overview

• Project: Cleanroom for Precision Component Assembly
• Industry: Automotive
• Client: TACO (Tata AutoComp Systems)
• Cleanroom Size: 20 x 16 x 4 meters
• Location: Chakan, Pune
• ISO Classification: Class 8 (100,000)
• Application: Automobile Component Assembly & Testing

About the Client

 Tata AutoComp Systems (TACO) is a leading name in the Indian automotive supply chain, delivering innovative solutions to OEMs and Tier-I manufacturers. Known for precision engineering and large-scale production, TACO provides cutting-edge automotive components. They focus on maintaining high-quality standards and operational efficiency across their diverse manufacturing processes.

Their work and where the cleanroom was needed

Tata AutoComp Systems (TACO) specialises in manufacturing precision automotive components, involving complex operations like component assembly, electronics integration, and high-temperature ageing. These processes require a contamination-free environment to ensure product performance and quality. A cleanroom was needed for the assembly and testing of sensitive electronic components, while a high-temperature ageing room was installed to maintain a consistent 80°C for testing parts under extreme conditions. TACO required an ISO Class 8 cleanroom to maintain environmental control and meet strict industry standards.

Project Objectives and Client Requirements

Kaizen Airtreat was assigned complete turnkey responsibility, which included enclosure, HVAC system, structural supports, electrical integration, and cleanroom-specific automation. The key client requirements included:

• ISO Class 8 certified cleanroom enclosure.
• Structural support for both the enclosure and HVAC due to the lack of existing ceiling infrastructure.
• Temperature control for a special high-temperature ageing room.
• Modular design with scope for last-minute design changes.
• Minimal disturbance to existing operations during execution.
• Energy-efficient HVAC and centralised control panel.

Our Solution

Kaizen’s engineering and execution team developed a comprehensive and modular cleanroom system that allowed flexibility and precision.

• Cleanroom Enclosure Design: The enclosure was built using 50 mm-thick PUF panels, designed to fit the plant layout and accommodate four internal partitions, including a high-heat ageing room.
• Structural Framework: Two large trusses and multiple support tubes were fabricated to hold the entire enclosure and HVAC system, as no existing support structure was available.
• HVAC Design & Integration: A 26,000 CFM Air Handling Unit was installed to regulate airflow, temperature, and humidity. HEPA terminal boxes were designed in-house for precise air distribution.
• Electrical & Automation Setup: The control panel was designed for centralised load management, including lights, AHU, air showers, and other cleanroom devices.
• Installation Execution: Site preparation, material supply, and execution were done in steps to avoid disruption. The installation allowed for real-time modifications based on evolving client needs.