Cronax Industries - #1 Largest Air Shower Manufacturers In India

What is an Air Shower? Working Principle, Types & Technical Specifications

What Is An Air Shower?

An air shower is a small enclosed chamber installed at the entrance of a cleanroom or controlled environment. When a person or material passes through it, high-velocity jets of filtered air blow loose dust, fibres and particles off the surface before they can enter the clean area. It acts as the last checkpoint against contamination carried in on clothing, tools and trolleys.

Air showers are used in pharmaceutical, biotech, electronics, food processing and laboratory facilities. If you are ready to buy, see our range of air showers manufactured in India.

Importance of Air Showers in Cleanrooms

Most contamination in a cleanroom is brought in by people and materials, not generated inside. Even a clean gown picks up fibres and dust on the way to the entrance. An air shower reduces this by removing loose particles from surfaces just before entry, which helps protect product quality in pharmaceutical, biotech, electronics and food processing facilities.

Three points are worth knowing:

An air shower does not sterilize. It removes loose particulate. It does not kill microorganisms and does not replace proper gowning.
It is one layer of protection. It works together with gowning rooms, sole cleaning, pass boxes and trained staff.
It is a design decision, not a universal rule. Standards such as ISO 14644 define cleanroom classes, but whether an air shower is needed depends on your process, risk assessment, and industry guidelines such as GMP.

How Does an Air Shower Work? (Working Principle)

The working of an air shower involves several steps to effectively remove contaminants from personnel or equipment before they enter a cleanroom or controlled environment. Here’s a detailed explanation of how an air shower chamber works:

Entry: The person or load enters through the first door, which then closes.
Interlock and start: The doors are interlocked, so both can never be open at once. The cycle starts automatically through a sensor or manually through a push button, depending on the model.
Pre-filtration: Air is drawn through a pre-filter that captures coarse dust and protects the main filter.
HEPA filtration: A blower pushes the air through a HEPA filter (typically H13 or H14), which captures at least 99.95% of particles at the most penetrating particle size.
Nozzle discharge: Clean air leaves through nozzles on the side walls (and sometimes the ceiling) at high speed, striking the surface from several angles.
Particle removal: The turbulent airflow dislodges loose particles from clothing and objects. In most designs the air is pulled back through return grilles, filtered again and reused.
Cycle end and exit: After a preset time, usually around 15 to 30 seconds (adjustable by model), the air jets stop and the inner door unlocks. The person can enter the cleanroom with a much lower risk of carrying in particles.

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Cronax – India’s Largest Air Showers Original Equipment Manufacturer (OEM)

1. Construction and Design:

Material: Stainless steel (304/316), powder-coated steel, or other durable materials.
Dimensions:
- External: (customizable based on requirements)
- Internal: (customizable based on requirements)
Doors:
- Type: Interlocking, manual, or automatic sliding/swing doors.
- Material: Stainless steel, tempered glass.
- Operation: Pneumatic or electric control.

2. Airflow and Filtration:

Air Velocity: 20-25 m/s (meters per second) at nozzle exit.
Airflow Volume:
- Supply: 1000-2000 CFM (cubic feet per minute) depending on size and model.
- Exhaust: Matching supply volume to ensure balanced pressure.
Filtration:
- Pre-filters: G4 (EN779) or MERV 10-13.
- HEPA filters: H13/H14 (EN1822) or equivalent, with 99.97% efficiency at 0.3 microns.

3. Air Shower Room Cycle:

Cycle Time: Adjustable, typically 15-60 seconds.
Air Jets:
- Number: 10-30 adjustable nozzles (varies based on model and size).
- Configuration: Multi-directional, strategically placed for optimal coverage.
Noise Level: Below 70 dB(A).

4. Control System:

User Interface: Touchscreen control panel or PLC-based system.
Control Features:
- Cycle start/stop.
- Adjustable cycle time.
- Door interlock status.
- Filter status indicators.
Interlock System: Ensures one door remains closed while the other is open to maintain cleanroom integrity.

5. Electrical and Power:

Power Supply: 220-240V, 50/60 Hz, single-phase or three-phase.
Power Consumption: 1-2 kW (varies based on model and features).
Emergency Stop: Accessible emergency stop button.

6. Safety Features:

Emergency Interlock Release: Allows manual override of door interlock in case of emergency.
Alarm System: Visual and audible alarms for system faults, door status, and emergency conditions.
Door Sensors: Proximity or magnetic sensors to detect door status.

7. Compliance and Standards:

Cleanroom Standards: ISO 14644-1, ISO 14698.
Electrical Safety: CE, UL, or equivalent certifications.
Air Quality Standards: Compliance with industry-specific air cleanliness standards.

8. Optional Features:

UV-C Sterilization: For additional microbial decontamination.
Ionization System: For enhanced particle removal.
Custom Size and Design: Tailored to specific application needs.
Remote Monitoring and Control: Integration with building management systems (BMS).

Air showers, also known as cleanroom air showers, are specialized enclosures designed to decontaminate personnel and equipment before they enter a controlled environment, such as a cleanroom or laboratory. Here are the different types of air showers based on their design and usage:

Single-Person Air Shower

A compact chamber that cleans one person at a time, with a single entry and exit door and nozzles that blow filtered air onto clothing. It suits small cleanrooms, labs and low-traffic entrances.

Multi-Person Air Shower

A larger chamber where several people pass through in one cycle, with more nozzles to cover everyone inside. It reduces queues at busy entrances and during shift changes.

Three-Door Air Shower

Adds a third door, so people or materials can enter or leave from a different direction. It helps in cleanroom layouts where traffic flow is more complex.

Roller Door Air Shower

Uses roller doors that move up and down instead of swinging open. They open and close quickly and work well where carts, trolleys or equipment pass through.

Sliding Door Air Shower

Uses doors that slide sideways, so no floor space is needed for a door swing. It suits tight layouts and high-traffic entrances.

Standard Air Showers

Designed for general use, these air showers feature high-velocity nozzles that blow air to remove contaminants from personnel or materials. They are typically compact and efficient for routine cleanroom or industrial applications.

Pass-Through Air Shower (In-Feed and Out-Feed)

Has an entry on one side and an exit on the other, so people or materials are cleaned on the way in and the clean side stays sealed. It suits processes where separate in-feed and out-feed points are required.

Custom Air Showers

Tailored to specific requirements, custom air showers are designed based on unique needs such as size, airflow patterns, and additional features. They are suitable for specialized industries or environments.

Modular Air Showers

These are flexible and can be assembled in various configurations to fit different spaces or requirements. Modular air showers are often used in environments where adaptability is needed.

Vertical and Horizontal Air Showers

Vertical air showers blow air from top to bottom, while horizontal air showers direct airflow from the sides. The choice between vertical and horizontal depends on the layout and specific needs of the cleanroom or facility.

Heavy-Duty Air Showers

Built to withstand harsh conditions, these air showers are used in environments with high contamination risks or where durability is a critical factor. They are constructed with robust materials and advanced features to handle demanding applications.

Each type of air shower is designed to meet specific operational needs, helping remove loose particles from personnel and equipment before they enter controlled environments. The right air shower depends on traffic volume, available space, what moves through the entrance and your cleanroom class. Cronax manufactures all of these types in-house, with custom sizes and materials. Share your requirement and our team will recommend the right configuration, or see our air shower range.

The Key Benefits of Air Showers

Air showers offer several key benefits, especially in environments where maintaining cleanliness and reducing contamination is critical. Here are the primary advantages of using air showers:

1. Enhanced Contamination Control:

Particle Removal: Air showers effectively remove dust, dirt, and other particulate matter from personnel and equipment, significantly reducing the risk of contaminating cleanroom environments.
HEPA Filtration: The high-efficiency particulate air (HEPA) filters used in air showers capture 99.97% of particles as small as 0.3 microns, ensuring that only clean air is recirculated.

2. Improved Cleanroom Performance:

Maintaining Cleanliness Standards: By preventing contaminants from entering cleanrooms, air showers help maintain the strict cleanliness standards required in industries such as pharmaceuticals, biotechnology, and semiconductor manufacturing.
Air Quality Preservation: Continuous removal of contaminants helps preserve the high air quality within cleanrooms, essential for sensitive processes and products.

3. Increased Product Quality and Safety:

Reduced Contamination Risk: Lower contamination levels lead to higher product quality and safety, minimizing defects and ensuring compliance with industry regulations.
Consistency and Reliability: Air showers contribute to consistent production conditions, reducing variability and enhancing the reliability of manufacturing processes.

4. Cost-Effectiveness:

Minimized Cleanroom Maintenance: By controlling contaminants at the entry point, air showers reduce the frequency and intensity of cleanroom maintenance and cleaning activities, leading to cost savings.
Longevity of Equipment: Reduced contamination can extend the lifespan of sensitive equipment and tools used in cleanrooms, lowering replacement and repair costs.

5. Operational Efficiency:

Quick and Effective: Air shower cycles typically last only 20 to 60 seconds, providing a quick and effective method for decontaminating personnel and equipment without significant delays in workflow.
Automated Operation: Modern air showers are equipped with sensors and control systems that automate the decontamination process, enhancing operational efficiency and ease of use.

6. Employee Safety and Comfort:

Health Protection: By reducing the spread of contaminants, air showers help protect the health of employees working in cleanrooms, particularly in industries dealing with hazardous substances.
Ease of Use: Designed for user comfort, air showers provide an intuitive and user-friendly experience, ensuring compliance with decontamination protocols.

7. Regulatory Compliance:

Meeting Standards: Air showers help facilities comply with stringent industry standards and regulations regarding cleanliness and contamination control, such as ISO standards for cleanrooms.
Audit Readiness: Effective contamination control measures, including air showers, ensure that facilities are always ready for inspections and audits, reducing the risk of non-compliance penalties.

In summary, air showers play a vital role in maintaining the cleanliness, safety, and efficiency of cleanroom environments. They provide a robust solution for controlling contaminants, enhancing product quality, and ensuring regulatory compliance, all while contributing to cost savings and operational efficiency.

Applications of an Air Shower

1. Pharmaceuticals and Biotechnology

Cleanroom entry: Air showers sit at the entrance of cleanrooms where medicines and biotech products are made. They remove loose dust and fibres from personnel and equipment before they go in.
Product protection: An air shower is one layer of a GMP contamination control strategy. It works alongside gowning, cleaning and validated procedures to reduce the particles that reach the production area.

2. Semiconductor and Electronics Manufacturing

Microchip Production: In semiconductor fabrication, even very small particles can cause defects in microchips. An air shower at the entrance helps reduce the particles carried into the fab area.
Precision Manufacturing: Dust and fibres can affect small, high-precision electronic components. Cleaning people and materials at the entry point lowers that particle load.

3. Food and Beverage Industry

Hygiene Control: Air showers help prevent contamination in food processing areas, ensuring that products meet health and safety standards.
Compliance: They assist in complying with stringent hygiene regulations and maintaining high levels of cleanliness.

4. Aerospace and Defense

Component assembly: Sensitive aerospace and defense components are assembled in controlled areas, where particles can affect performance. Air showers reduce what enters those areas.
Quality Assurance: Ensuring a contaminant-free environment is critical for the reliability and safety of aerospace and defense products.

5. Healthcare and Medical Device Manufacturing

Device production: In medical device assembly and packing cleanrooms, air showers reduce the particles carried in by staff and materials.
Hospital Cleanrooms: Used in hospital cleanrooms to maintain a sterile environment for critical procedures and manufacturing of medical supplies.

6. Laboratories and Research Facilities

Controlled lab entry: Cleanroom laboratories use air showers at the entrance to reduce particles that could interfere with experiments and sample handling.
Chemical and analytical labs: Dust and fibres can disturb sensitive measurements and sample preparation. An air shower helps keep that particle load down at the entry point.

7. Cosmetics and Personal Care Products

Product Integrity: In the cosmetics industry, air showers help maintain clean environments for the production of personal care products, ensuring product quality and safety.
Regulatory Compliance: They assist in meeting industry regulations and standards for cleanliness and hygiene.

8. Automotive Industry

Paint and coating: Dust on a wet surface leads to finish defects. Air showers at paint shop entrances remove loose particles from workers’ clothing before they enter.
Clean assembly areas: They help control particles in areas where critical components are assembled and small particles can cause failures.

9. Optics and Lens Manufacturing

Precision Manufacturing: Air showers are essential in the manufacturing of optical components and lenses, where even minor contaminants can affect product quality.
Cleanroom Maintenance: Ensuring a contaminant-free environment is critical for the production of high-quality optical products.

10. Printing and Packaging

Clean production: In controlled printing and packaging areas, air showers reduce the dust that can mark printed surfaces or contaminate packaging materials.
Dust control: Fewer particles entering the area means fewer print defects and less rework.

Cronax Industries: India's Largest Air Shower Original Equipment Manufacturer (OEM)

Cronax Air Showers,featuring HEPA filtration, adjustable air velocity, customizable sizes, with a 3-year warranty.

1. What is the purpose of an air shower?

An air shower removes loose dust and particles from people and materials before they enter a cleanroom, reducing the contamination brought in from outside.

2. How does an air shower work?

An air shower works by directing high-velocity air jets at the person or object entering the chamber. These air jets dislodge and blow off contaminants, which are then captured by the chamber’s filtration system. The air is recirculated through HEPA filters to ensure only clean air is used.

3. Do I need an air shower?

Not always. It depends on your cleanroom class, process risk and industry guidelines such as GMP. An air shower reduces the particles carried in on clothing and materials, but it does not replace gowning, cleaning or other required controls.

4. Where are air showers used?

Air showers are commonly used in industries such as pharmaceuticals, biotechnology, semiconductor manufacturing, food processing, aerospace, defense, healthcare, laboratories, and more. Industrial air showers ensure contamination control by decontaminating personnel and equipment entering sensitive environments like manufacturing facilities.

5. How much space is required to install an air shower?

The space required depends on the size and design of the air shower. Air showers come in various sizes, so it’s important to measure the available space and consult with the manufacturer to determine the appropriate model for your needs.

6. How long should a person stay in an air shower?

Most cycles run about 15 to 30 seconds. The exact time is adjustable and set according to your process and cleanroom requirements.

7. Can the air shower be customized to fit our needs?

Yes, air showers can be customized in terms of size, material, and features to meet the specific requirements of your facility and application.

8. What kind of maintenance is required for an air shower tunnel?

Regular maintenance includes cleaning or replacing pre-filters and HEPA filters, checking the operation of air jets, and ensuring that the control systems and door interlocks are functioning correctly. It’s recommended to follow the manufacturer’s maintenance guidelines.

9. How noisy is an air shower tunnel?

The noise level of an air shower is generally below 70 dB(A), which is comparable to the sound of a normal conversation.

10. What power supply is needed for an air shower?

Air showers typically require a power supply of 220-240V, 50/60 Hz, single-phase or three-phase, depending on the model.

11. What safety features are included in an air shower?

Safety features of air showers include interlocking doors to prevent both doors from being open simultaneously, emergency stop buttons, visual and audible alarms for system faults, and emergency interlock release mechanisms.

12. What is the price of an air shower in India?

The price of an air shower unit varies based on the size, features, and customization options. It’s best to request a quote from the manufacturer based on your specific needs.

13. What is the difference between an air shower and a pass box?

An air shower cleans people and larger loads as they enter a cleanroom. A pass box transfers small items between two zones through interlocked doors. A dynamic pass box adds HEPA-filtered airflow to clean those items as they pass. See our cleanroom pass boxes.

14. What factors influence the air shower price in India?

The air shower price in India is influenced by several factors including the type and size of the air shower, customization requirements, and additional features like advanced filtration systems or energy-efficient components. The cost can also vary based on the manufacturer and the level of support and service provided. For accurate pricing, it’s best to contact manufacturers like Cronax Industries and provide details about your specific needs and preferences.

15. Is stainless steel better for an air shower?

Stainless steel (SS 304 or SS 316) offers better durability, corrosion resistance and a smooth surface that is easy to clean, so it is preferred in pharma and food processing. Powder-coated MS is a lower-cost option for less critical areas.

Cronax Industries manufactures single-person, multi-person, three-door, sliding-door and roller-door air showers in India, with custom sizes and materials, direct factory pricing and pan-India installation support. Share your requirement and our team will recommend the right configuration.