A Case Study for the Food Industry: Pharma-Grade Starch

Project Overview

• Project: Cleanroom for Starch Extraction
• Industry: Food Processing
• Client: Shivangan Food and Pharma
• Cleanroom Size:23.8 x 7 x 3.5 meters
• Location: Pune, Maharashtra
• ISO Classification: Class 7 (10,000)
• Application: Starch Extraction Process in a Cleanroom Environment

About the Client

Shivangan Food & Pharma Products Pvt. Ltd. is one of India’s top producers of premium corn starch products for diverse industries, including the Food, Pharmaceutical, and Personal Care industries. Focusing on product quality and legal compliance, they operate a modern plant that has, as part of their set-up, a cleanroom environment and automated packing systems. Shivangan is the only EXCiPACT-certified company in India that produces Pharma Grade Starch, which finds application in both national and international markets.

Their Work and Resulting Needs for Cleanrooms

Shivangan Food & Pharma’s starch extraction from maize and corn is brought about by multiple operations, including maize grinding, starch extraction, drying, sieving, blending, and automated packing. Of all these steps, the starch extraction and final packing are the most likely to be contaminated with dust, microbes, and moisture. To take care of these elements, they required a cleanroom specifically at these points so as to ensure purity, maintain low LOD (Loss on Drying) levels, and finally meet pharmaceutical-grade hygiene standards in starch production. The cleanroom environment had an added advantage in these processes. It helped the company prevent cross-contamination during handling, which ensured product quality compliance with international food and pharma regulations. 

Project Objectives and Client Requirements

Kaizen Airtreat was brought in to deliver a turnkey cleanroom solution, covering the enclosure, HVAC, electricals, and automation systems. The client’s expectations included:

• An ISO Class 7 certified cleanroom.
• Smooth integration within the existing RCC infrastructure.
• Precise control of Temperature, humidity, and air quality through customised HVAC.
• Energy-efficient electrical systems with automation and monitoring.
• Zero disruption to ongoing operations during installation.
• Long-term durability and ease of maintenance.

Materials Used

Given the critical nature of food safety and cleanliness in processing, Kaizen Airtreat used materials that offered insulation, durability, and compliance with ISO norms,

PUF Insulated Panels (50 mm): Used on the walls and ceilings to ensure thermal insulation, airtight construction, and smooth, cleanable surfaces.

HVAC System: It included components like AHUs, HEPA filters, and custom-designed HEPA terminal boxes to manage particulate levels, airflows, temperature, and humidity.

Cleanroom Electricals & Automation: These included lighting, smoke detectors, air showers, and boom barriers to restrict personnel entry and thereby reduce particulate levels.

Control Panel: A customised panel to manage the entire cleanroom’s electrical load, equipment, and automation features.

Our Solution

Kaizen Airtreat’s engineering team conducted a detailed site study and developed an initial modular cleanroom designed to fit the client’s existing setup. 

The components included,

Cleanroom Enclosure: 50 mm PUF panels were used on the walls and ceiling for ISO-compliant insulation. The layout was adapted to work with the client’s existing RCC structure, reducing civil modification needs to a minimum.

HVAC System Design: AHUs and outdoor units were installed to regulate temperature and humidity. Custom-fabricated HEPA terminal boxes and precision-aligned ducting were put in place to make sure they complied with ISO Class 7 requirements.

Electrical & Equipment Setup: Cleanroom-specific equipment, including lighting, various sensors, air showers, smoke detectors, and boom barriers, was installed. A control panel was designed and installed for the centralised management of all systems.

Installation Execution: The entire installation process, including delivery, preparation, and execution, was carefully planned and carried out in phases to avoid disruption. Dust and noise control were maintained throughout the project.

Manufacturing, Testing, & Delivery

The cleanroom system was fabricated, installed temporarily, and tested at Kaizen’s facility in Pune. The testing included,

Testing the compatibility of the HVAC and electrical systems.

Physical validation of air quality to meet ISO standards, besides testing the airflow distribution.

Labelling of each part and component for the perfect fit in minimum time and effort, and creation of detailed installation guides for on-site assembly at the intended plant.

Final testing and commissioning were carried out post-installation at Shivangan’s plant site.

Project Results & Client Benefits

Successful commissioning of the ISO Class 7 cleanroom for contaminant-free starch extraction.

A clean, energy-efficient environment that ensures product quality at all times.

Installation of the ISO Class 7 cleanroom within a live facility with zero disruption to other existing activities.

Optimised integration of HVAC and electrical systems for the perfect ISO Class 7 cleanroom that also aligned with existing food safety regulations.

Enhanced operational control, hygiene, and compliance.

Structural System Overview

To ensure long-term performance and safety

PUF panels were used for thermal control.

All ducts and panels were integrated for optimal air balance.

Customised electrical and automation systems were installed for full facility control.

Safety and regulatory checks were conducted at each phase.

Conclusion

The Shivangan Food and Pharma cleanroom project stands as a showcase of Kaizen Airtreat’s capabilities at delivering high-quality turnkey cleanroom solutions tailored specifically to customer needs, which in this case was complex food processing. Despite the challenge of working within the plant of an already existing and operating facility, the project was completed with precision, speed, and minimal disruptions.

From design to commissioning, every aspect of the project was executed with precision to focus on the client’s needs. It has resulted in the creation of an ISO Class 7 cleanroom environment that supports safe and efficient food processing, resulting in the extraction of the highest quality of starch.

This successful installation and functioning of the cleanroom ensured that international hygiene standards were met and helped to improve the client’s operations and product quality, with sales taking place worldwide.