Which PUF Panel Is Best for Clean Room? — Pharmaceutical & Industrial Guide 2026
Cleanroom construction in India's pharmaceutical, biotech, semiconductor, and medical device sectors demands insulated panels that go far beyond standard industrial specifications. A single particle on a surface, an improperly sealed joint, or a panel that off-gasses volatile compounds can contaminate an entire batch, trigger regulatory shutdown, and cost crores in lost production. In this comprehensive guide, our cleanroom engineering team — with 100+ validated cleanroom projects — explains exactly how to select the right insulated panel for your ISO class, GMP tier, and industry requirements.
📍 Manufacturer in Ahmedabad, Gujarat | Pan-India Cleanroom Projects
Why Standard Panels Fail in Cleanroom Environments
Every year, pharmaceutical companies across India invest heavily in HVAC systems, HEPA filters, and air handling units for their cleanrooms — only to fail WHO-GMP audits because the wall and ceiling panels themselves are the contamination source. Standard industrial PUF panels, designed for warehouses and factory roofs, introduce failure modes that are invisible until an auditor arrives or a batch fails microbial testing. Understanding these failure modes is the first step toward specifying the right cleanroom panel.
- Particle-Generating Joints: Standard tongue-and-groove PUF panels have exposed fasteners, visible joint lines, and micro-gaps where particles accumulate and become airborne during pressure fluctuations. In an ISO Class 5 cleanroom where the limit is 3,520 particles per cubic metre at 0.5 microns, a single poorly sealed joint can push the entire room out of specification.
- Non-Flush Surfaces: Industrial panels with raised ribs, corrugated profiles, or protruding fastener heads create surfaces that are impossible to clean and sanitize to pharmaceutical standards. Biofilm formation in crevices and around screw heads is a leading cause of environmental monitoring failures in Indian pharma facilities.
- Outgassing from Panel Core: Low-quality PUF foam can release volatile organic compounds (VOCs) over time, especially under the positive pressure conditions of a cleanroom. These VOCs contaminate sensitive products in pharmaceutical, semiconductor, and biotech environments, leading to unexplained batch failures.
- Failed GMP Audits: WHO-GMP, USFDA, and CDSCO auditors evaluate cleanroom panel quality as a critical parameter. Facilities built with standard industrial panels frequently receive observations for non-smooth surfaces, non-cleanable joints, missing documentation, and inadequate fire rating — each observation delaying product approvals by months.
- Incompatible with Cleanroom Accessories: Standard panels lack provisions for flush-mounted HEPA modules, pass-through boxes, viewing windows, and interlocked cleanroom doors. Retrofitting these accessories into industrial panels creates more joints, more gaps, and more contamination risk.
The Solution: Purpose-Built Cleanroom Panels with Flush-Mount Joints
PHOENIXX cleanroom panels are engineered from the ground up for controlled environments. Every aspect — from the PIR/PUF core formulation that minimizes outgassing, to the concealed-fix flush-mount joint system that eliminates particle traps, to the antimicrobial surface coatings that resist biofilm formation — is designed to meet the demands of ISO 14644 classified cleanrooms. Combined with integrated accessories and complete GMP documentation packages, PHOENIXX panels help your facility pass regulatory audits the first time.
Cleanroom Panel Selection: ISO Class Requirements Guide
The ISO 14644-1 cleanroom classification directly determines your panel specifications. Higher cleanliness classes require smoother surfaces, tighter joints, and more stringent material certifications. The table below maps each ISO class to the panel specifications PHOENIXX recommends based on 100+ validated cleanroom installations across pharmaceutical, biotech, electronics, and medical device facilities.
ISO Class × Panel Specification Matrix
| ISO Class | Application | Surface Finish | Joint System |
|---|---|---|---|
| ISO Class 5 | Injectable pharma, semiconductor fab | Stainless Steel 304/316 | Flush-mount + pharma-grade sealant |
| ISO Class 6 | Sterile manufacturing, biotech | SS 304 or food-safe coated steel | Flush-mount concealed-fix |
| ISO Class 7 | Oral dosage, medical devices, API | Food-safe coated PPGI | Flush-mount concealed-fix |
| ISO Class 8 | Packaging, general pharma, cosmetics | Standard PPGI with PE coating | Concealed-fix (standard) |
All recommendations validated against ISO 14644-1:2015 and WHO-GMP Annex 2 requirements
PIR vs PUF for Cleanroom Applications
While both PIR and PUF cores provide excellent thermal insulation, PIR (Polyisocyanurate) is the preferred choice for pharmaceutical cleanrooms due to its superior fire performance, lower smoke generation, and better dimensional stability at elevated temperatures. Standard PUF panels remain suitable for ISO Class 7-8 applications where fire rating requirements are less stringent.
| Property | PIR Panel | Standard PUF Panel |
|---|---|---|
| Fire Classification | B1 (self-extinguishing) | B2 (normally flammable) |
| Smoke Generation | Very low | Moderate |
| Thermal Conductivity | 0.022-0.024 W/mK | 0.024 W/mK |
| Max Service Temp | 120°C | 80°C |
| VOC Outgassing | Minimal (pharma-grade) | Low (standard-grade) |
| WHO-GMP Compliance | Preferred / Required | ISO 7-8 only |
| Cleanroom Suitability | ★★★★★ | ★★★★☆ |
For fire-rating comparisons with other materials: PUF Panel vs Rockwool Panel — Complete Comparison
Cleanroom Surface Finish Options
Stainless Steel 304/316
ISO Class 5 and below
Pharma-grade stainless steel facings with electropolished or #4 brush finish. Fully resistant to aggressive cleaning agents including H₂O₂ VHP decontamination. Required for aseptic and injectable manufacturing areas.
Food-Safe Coated Steel
ISO Class 5-7
Pre-painted galvanized steel with FDA-compatible polyester coating. Smooth, non-porous surface resists most pharmaceutical cleaning agents. Cost-effective alternative to stainless steel for oral dosage and API manufacturing.
Standard PPGI with PE Coating
ISO Class 7-8
Standard polyester-coated pre-painted steel suitable for general pharmaceutical areas, packaging zones, and cosmetics manufacturing. Smooth finish with good chemical resistance at an economical price point.
Benefits of PHOENIXX Cleanroom Panels
When your facility's regulatory approval, product quality, and patient safety depend on the cleanroom envelope, every panel specification matters. PHOENIXX cleanroom panels are purpose-built to deliver the controlled environment your process demands — and the documentation your auditors require.
WHO-GMP Compliance Built In
Every PHOENIXX cleanroom panel is manufactured to meet WHO-GMP Annex 2 and Annex 6 requirements for pharmaceutical manufacturing areas. Flush surfaces, sealed joints, and antimicrobial options ensure your facility satisfies the most stringent regulatory expectations from day one — not as a costly retrofit after a failed inspection.
Audit-Ready Documentation
PHOENIXX provides complete documentation packages including material certificates, fire test reports (B1 for PIR), surface finish specifications, MSDS sheets, and IQ/OQ validation support documents. When CDSCO, WHO, or USFDA auditors request panel documentation, everything is ready — organized and referenced.
Antimicrobial Surface Technology
Optional antimicrobial coatings integrated into the panel surface inhibit bacterial and fungal growth between cleaning cycles. This is particularly critical for pharmaceutical facilities where environmental monitoring for viable organisms is a continuous regulatory requirement.
Energy Efficient Thermal Envelope
PIR/PUF core insulation with λ = 0.022-0.024 W/mK reduces HVAC energy consumption by 20-35% compared to uninsulated or poorly insulated cleanroom partitions. For facilities running 24/7 air handling units, this translates to ₹5-15 lakh in annual energy savings depending on cleanroom size.
Rapid Modular Construction
Prefabricated cleanroom panels reduce construction time by 40-60% compared to conventional plastered drywall cleanrooms. A 500 sq.m cleanroom suite can be enclosed in 12-18 days. Faster construction means earlier revenue generation and reduced facility downtime during expansions.
Fully Modular & Reconfigurable
As product lines change and production scales, PHOENIXX modular cleanroom panels can be disassembled, reconfigured, and relocated without compromising cleanliness classification. This future-proofs your facility investment against changing regulatory requirements and production needs.
Standard Industrial Panel vs PHOENIXX Cleanroom Panel
❌ Standard Industrial PUF Panel in Cleanroom
- • Exposed fasteners and visible joint lines
- • Particle accumulation in ribs and screw heads
- • Biofilm formation in non-smooth crevices
- • VOC outgassing from low-grade foam
- • No provisions for HEPA modules or pass-boxes
- • WHO-GMP audit observations on panel quality
- • Costly retrofit required within 2-3 years
✅ PHOENIXX Cleanroom Panel (Flush-Mount)
- • Concealed-fix flush-mount joints — zero exposed fasteners
- • Smooth, non-porous surfaces validated for particle counts
- • Antimicrobial coating resists biofilm formation
- • Pharma-grade PIR core with minimal outgassing
- • Pre-engineered openings for HEPA, doors, pass-boxes
- • WHO-GMP compliant with full documentation package
- • 25+ year service life with consistent classification
Need cold storage panels alongside your cleanroom? Read our best PUF panel for cold storage guide for temperature-zone specifications and cam-lock joint details.
Cleanroom Projects Delivered by PHOENIXX
From oral dosage facilities to injectable manufacturing suites, PHOENIXX has delivered 100+ validated cleanroom projects across India. Here are four representative installations showcasing our pharmaceutical cleanroom expertise.
Pharma Cleanroom — Pune
Pune, Maharashtra
Industry: Pharmaceutical Manufacturing (Oral Dosage)
Scope: 2,800 sq.m ISO Class 7 cleanroom suite — 12 rooms
Products: PIR 60mm walls + 50mm ceiling panels, food-safe coating, flush-mount joints
✓ WHO-GMP certified on first inspection. Zero audit observations on panel quality. Environmental monitoring consistently within specification across all 12 rooms.
Edkem Pharma — Ahmedabad
Ahmedabad, Gujarat
Industry: API Manufacturing & Processing
Scope: 1,500 sq.m ISO Class 7-8 production area with controlled corridors
Products: PIR 80mm panels with chemical-resistant coating, integrated pass-boxes
✓ CDSCO approval secured within timeline. Modular design allowed Phase 2 expansion without disrupting existing production. 30% HVAC energy savings.
Makson Pharma — Surendranagar
Surendranagar, Gujarat
Industry: Sterile Manufacturing (Injectable)
Scope: 900 sq.m ISO Class 5-6 aseptic processing suite
Products: PIR 60mm with SS 304 interior facing, pharma-grade sealed joints, HEPA integration
✓ USFDA-ready facility. Particle count validation passed on first attempt. Stainless steel panels withstand daily VHP decontamination cycles without degradation.
Fuji Silvertech — Ahmedabad
Ahmedabad, Gujarat
Industry: Electronics & Semiconductor Cleanroom
Scope: 2,200 sq.m ISO Class 6-7 electronics manufacturing cleanroom
Products: PIR 50mm panels with anti-static coating, flush-mount joints, integrated lighting
✓ Achieved ISO Class 6 at rest and Class 7 operational — both targets met. Anti-static panel surfaces eliminated ESD concerns. Completed in 16 working days.
Engineered by PHOENIXX Cleanroom Division | 100+ Validated Cleanroom Projects Nationwide
Explore our cleanroom and pharma solutions: Cleanroom Panel Solutions | Pharma & Chemical Industry Solutions
Cleanroom Panel Technical Specifications
PHOENIXX cleanroom panels are manufactured to meet the stringent requirements of pharmaceutical, biotech, and electronics controlled environments. Below are the detailed specifications for our cleanroom panel range.
| Specification | Value / Range |
|---|---|
| Panel Thickness | 50mm, 60mm, 80mm, 100mm |
| Core Material | PIR (B1 rated) or PUF (B2 rated) |
| Foam Core Density | 40-45 kg/m³ (high-density rigid) |
| Thermal Conductivity (λ) | 0.022-0.024 W/mK |
| R-Value (at 50mm) | 2.27 m²K/W |
| R-Value (at 80mm) | 3.64 m²K/W |
| Joint System | Flush-mount concealed-fix (no exposed fasteners) |
| Fire Classification | B1 self-extinguishing (PIR) / B2 (PUF) |
| Exterior Facing | 0.50mm PPGI / SS 304 / SS 316 options |
| Interior Facing | Food-safe coated steel / SS 304 / SS 316 (by ISO class) |
| Surface Finish | Smooth, non-porous, Ra ≤ 0.8μm (SS option) |
| Antimicrobial Coating | Optional — silver-ion or copper-based |
| VOC Emission | Low outgassing certified (pharma-grade PIR) |
| Cleanroom Compatibility | ISO Class 5 to ISO Class 8 (ISO 14644-1) |
| Panel Width | 1000mm / 1150mm (effective coverage) |
| Panel Length | Custom — up to 12 metres |
| Integrated Accessories | HEPA modules, pass-boxes, doors, viewing windows, returns |
| Service Life | 25+ years (with proper maintenance) |
Cleanroom Compliance & Certifications
Pharmaceutical manufacturing compliance
Cleanroom classification standard
Indian Standard for sandwich panels
Quality Management System
Self-extinguishing fire classification
Surface coatings compatible with FDA requirements
Documentation for Indian drug authority audits
Environmental Management System
Explore our dedicated PIR panel range for fire-rated applications: PIR Insulated Sandwich Panels
Cleanroom Panel Pricing Guide — By ISO Class
Cleanroom panel pricing varies significantly based on ISO classification, which drives surface finish requirements and joint system complexity. Higher ISO classes require stainless steel facings, pharma-grade sealants, and more precise manufacturing tolerances. Below are indicative price ranges for 2026 across common cleanroom classifications. For exact pricing tailored to your facility layout and specifications, request a formal quotation from our cleanroom engineering team.
| ISO Class | Surface Finish | Price (per sq.m) |
|---|---|---|
| ISO Class 8 (Packaging / General) | PPGI with PE coating | ₹1,500 – ₹2,000 |
| ISO Class 7 (Oral Dosage / API) | Food-safe coated PPGI | ₹2,000 – ₹2,800 |
| ISO Class 6 (Sterile / Biotech) | SS 304 or food-safe steel | ₹2,800 – ₹3,500 |
| ISO Class 5 (Injectable / Semiconductor) | SS 304/316 electropolished | ₹3,500 – ₹4,000 |
Prices include flush-mount joint system. HEPA modules, cleanroom doors, pass-boxes, and HVAC integration quoted separately.
Turnkey Cleanroom Cost Breakdown (500 sq.m Facility)
Cleanroom Panels (Flush-Mount)
₹12-25 lakh
Varies by ISO class and surface finish
HVAC & Air Handling Units
₹20-45 lakh
AHU, ducting, HEPA filters, controls
Cleanroom Doors & Pass-Boxes
₹5-12 lakh
Interlocked doors, air showers, pass-through
Flooring (Epoxy / PU / Vinyl)
₹4-10 lakh
Self-levelling epoxy or pharma-grade vinyl
Electrical & BMS
₹5-15 lakh
Lighting, controls, environmental monitoring
Validation & Documentation
₹3-8 lakh
IQ/OQ protocols, particle counts, certification
Total Turnkey Range: ₹50 lakh – ₹1.5 crore (depending on ISO class, size, and HVAC complexity)
Typical response time: within 4 working hours
Cleanroom PUF Panel — Frequently Asked Questions
Which panel type is best for pharmaceutical cleanrooms?+
PIR (Polyisocyanurate) panels are the preferred choice for pharmaceutical cleanrooms due to superior fire resistance (B1 rating) and smooth, flush surfaces that prevent particle accumulation. For ISO Class 5-7 cleanrooms, PIR panels with food-safe or antimicrobial coatings meet WHO-GMP requirements.
What thickness is needed for cleanroom panels?+
Standard cleanroom walls use 50-60mm PIR/PUF panels. For temperature-controlled cleanrooms (pharma manufacturing), 80-100mm provides both thermal insulation and structural rigidity. Ceiling panels are typically 50mm with flush joints.
What surface finish is required for cleanroom panels?+
Cleanroom panels require smooth, non-porous surfaces that are easy to clean and sanitize. Options include standard PPGI with PE coating (ISO 7-8), food-safe coated steel (ISO 5-7), and stainless steel 304/316 facings (ISO 5 and below). All joints must be flush-mounted and sealed.
Can PUF panels achieve ISO Class 5 cleanroom standards?+
Yes, when combined with proper HEPA filtration, pressure cascade design, and sealed panel joints. The panel surface finish, joint sealing quality, and room pressure management are the key factors. PHOENIXX cleanroom panels are designed for ISO 14644 compliance.
How do cleanroom panels differ from standard PUF panels?+
Cleanroom panels have flush joints (no exposed fasteners), antimicrobial or food-safe coatings, tighter dimensional tolerances, integrated corner and cove solutions for easy cleaning, and compatibility with cleanroom doors, pass-boxes, and HEPA modules.
What certifications are required for pharmaceutical cleanroom panels?+
WHO-GMP compliance, IS 14644 (cleanroom classification), fire safety certificates (B1 for PIR), material safety data sheets, and FDA-compatible surface certifications. PHOENIXX provides complete documentation packages for regulatory audits.
Ready to Build Your Cleanroom with India's Trusted Panel Manufacturer?
From ISO classification consulting to turnkey cleanroom installation, PHOENIXX SMARTBUILD delivers validated cleanroom projects that pass regulatory audits the first time. 100+ cleanrooms built. Pharmaceutical, biotech, semiconductor, medical devices. Get expert guidance today.