In-house manufacturing
In-House Cleanroom Manufacturing
When you order a cleanroom, one question decides how the whole job will feel. Who is responsible when something does not fit on site.
Fabtech Cleanrooms answers that with one name. The clean shell and the equipment that conditions it are made on our own floor, checked before they leave it, and installed by the company that built them.
- Material in
- Pre-coated steel coil
- Cores made here
- PUF and Rockwool
- Material out
- Wrapped panel, addressed to one wall run
Goods-in. Every modular wall panel on every Fabtech room starts as a coil, and the first quality gate is on the coil, not on the panel.
2,000+
Cleanroom projects since 2004
Eight
Product families made on our own floor
ISO 9001
One quality system, goods-in to dispatch
The core of every room, built in our own facility
On most projects that answer gets tangled. The panels came from one supplier. The air handling came from another. The doors came from a third. Each supplier checked its own part and signed it off. Nobody checked the joint between them. When a seal will not close, every one of them can honestly say the fault sits somewhere else.
The cost of that tangle rarely shows up as a bill. It shows up as time. A week spent proving whose tolerance was wrong is a week the room is not running.
Fabtech Cleanrooms answers that question with one name. We design and make our own cleanroom panels and equipment in our own facility. One team owns the quality of your room, from the first design to the day it ships. If a panel and a door do not line up, there is no argument about whose fault it is. It is ours, and we fix it.
That ownership is why our rooms go together predictably on site. The people who engineer a panel, an air handling unit or a laminar flow unit also answer for it once it is installed. If the finished room does not hold its air cleanliness class, that sits with them too. There is nobody else to hand it to.
In practice that means two things. The room holds ISO 14644 conditions once it is running. It also stands up to inspection under EU-GMP when a regulator walks the floor.
Fabtech's track record runs to more than 2,000 cleanroom projects since 2004, across every industry that needs controlled air. That work is made in three plants of our own, in Umbergaon, Hyderabad and Thane. The Umbergaon floor alone covers roughly 6,500 square metres. Every piece of equipment is checked before it leaves us. Where it applies, it is Factory Acceptance Tested first. What arrives on your site is what was proven on ours.
A Fabtech room therefore tends to fit first time. It does not turn into a week of cutting, shimming and improvised rework while somebody makes a part work. Fewer surprises on site means a shorter and steadier path to a room your qualification team can start on.
| Who answers for your room | Detail |
|---|---|
| The company | Fabtech Cleanrooms |
| The engineering | One engineering team behind the panels, the doors, the filter housings and the air handling |
| The quality system | One ISO 9001 system over the whole build, from goods-in to dispatch |
FIG. 01One name on the design, the build and the result.
Inside our cleanroom manufacturing facility
We manufacture in three plants of our own. Umbergaon in Gujarat, Hyderabad in Telangana and Thane in Maharashtra. Each is a dedicated cleanroom production facility, not a general workshop with a cleanroom line in one corner. They run to one set of drawings under one ISO 9001 system, so a panel made on one line meets a door made on another and the two fit.
Walk it end to end and the sequence is easy to follow. Panel cores are made first. Sheet metal work for air handling and filter housings runs alongside them. Enclosures such as laminar flow units and pass boxes are assembled, then tested, then crated. Finishes set the pace on every line, because a classified room will not tolerate a surface that cannot be cleaned.
None of that layout is accidental. The lines were built for cleanroom work rather than adapted to it afterwards.
Three plants and one quality system also means one set of eyes on a part from cut to crate. A panel core and the door that will meet it are made to the same tolerance, checked against the same drawing, and signed off by the same system, wherever on our floor they were cut.
Goods-in
Panel line
PUF and Rockwool wall and ceiling panels
Sheet metal
AHU casings, HEPA housings, terminal boxes, FFU bodies
Enclosure assembly
Laminar flow units, pass boxes, air showers, biosafety cabinets
Door and finish
Cleanroom door leaves, frames, final finishing
Test and crate
Factory Acceptance Testing, protection, crating
Dispatch, to site
FIG. 02The manufacturing unit in plan. Five bays between one goods-in door and one dispatch door, so a panel core and the door that will meet it are made a few steps apart, under one quality system.
- Manufacturing locations
- Umbergaon, Dist. Valsad, Gujarat · Hyderabad, Telangana · Thane, Maharashtra
- Floor area, Umbergaon
- Roughly 6,500 square metres (70,196 sq ft)
- Postal addresses, Hyderabad and Thane
- Shared on request during technical review
- Under one roof
- Panel cores, sheet metal work for air handling and filter housings, and the assembly and testing of enclosures such as laminar flow units and pass boxes
- Production lines
- Built for the finishes a classified room demands
- Quality system
- ISO 9001, applied from goods-in to dispatch
- Testing on the floor
- Factory Acceptance Testing before dispatch, where it applies
- Capacity and line configuration
- Shared on request during technical review
The principle
Whatever the floor area reads on the day you visit, and whichever of the three you walk, the principle behind it does not change. The clean shell and the equipment that conditions it are made on our own floors, to our own specifications, under our own quality system. They are not bought in and rebadged.
How a cleanroom wall panel is made, and where the line stops
The panel line is the clearest place to see what in-house actually means. A modular wall panel starts as a coil of pre-coated steel at goods-in and leaves as a wrapped, numbered panel addressed to one wall run on one job. Everything between those two points happens on our own floor.
The drawing below runs the line in elevation, left to right, in the order the work happens. Station names, the order of operations and the position of the hold points describe how our panel line is set out. Panel cores are PUF or Rockwool, and both are made here. The stations are only half of the drawing. The other half is the four gates, because a factory is judged less by what it makes than by where it agrees to stop.
Goods-in at the top, dispatch at the foot
HOLD POINT H1Material
At goods-in, before station 01
- Checked
- Steel grade, coating and thickness, and the core material, verified against the purchase specification before anything enters production.
- If it fails
- The delivery is held at goods-in and does not reach the line. No panel is ever built on material that has not been read against its specification.
STATION 01Skin
Decoil, level, cut, fold
The coil is decoiled, levelled and cut to length, then the edges are folded to make the two skins that will face into and out of your room.
STATION 02Core
PUF injected or Rockwool laid
PUF is injected between the skins, or a Rockwool slab is laid in, depending on what the compartment needs. Fire duty decides this before insulation or cost does.
STATION 03Bond
Press and cure
The sandwich is pressed and cured so the skins and the core behave as one structural panel rather than three layers held together by hope.
HOLD POINT H2Bond
After station 03, press and cure
- Checked
- The bond between skin and core, and the core itself, read across the whole panel rather than at one convenient corner.
- If it fails
- The panel comes off the line and is scrapped. A failed bond is not reworked, because there is no honest way to repair a cured sandwich.
STATION 04Edge and lock
Edge profile and cam lock
The edge profile is formed and the cam lock hardware is set. This is the station that decides whether two panels pull up tight against each other on site.
STATION 05Cut and finish
Cut to drawing, openings, finish
The panel is cut to the dimensions on the job drawing, openings are made for view windows, doors and services, and the surface is finished so it can be cleaned.
HOLD POINT H3Dimension
After station 05, cut and finish
- Checked
- Edge profile, cam lock engagement, squareness and finished dimensions, read against the job drawing for that specific wall run.
- If it fails
- The panel goes back to the edge station and is presented at the same gate again. It does not skip forward on somebody's judgement.
STATION 06Wrap
Protect, label to the wall run
Protective film and edge protection go on, and the panel is labelled to the room and the wall run it belongs to, so nothing has to be worked out on site.
HOLD POINT H4Dispatch
After station 06, before loading
- Checked
- Surface finish and cleanability, the protection, and the label that ties the panel to its room and its wall run.
- If it fails
- The panel is held in the finish bay and the rest of the set waits with it. A wall run is dispatched complete or it is not dispatched.
STATION 07Load
Stage in fit order, load
Panels are staged in the dispatch bay in the order the site crew will fit them, then loaded as part of one coordinated package.
- Station, work happens here
- Hold point, the line stops
FIG. 03The panel line in elevation, goods-in on the left, dispatch on the right. Seven stations, four quality hold points. Panels run the line continuously, and each one stops at every gate until the check is signed.
A hold point is not a form. It is a place where the panel physically stops and somebody signs. The panel behind it stops too, which is what makes a gate expensive and why a factory that means it puts them where the damage would be worst: on the material before it is used, on the bond that cannot be repaired, on the dimensions your site crew will have to live with, and on the finish an auditor will see.
The same idea runs through the other lines in the building. Sheet metal for air handling units, HEPA housings and terminal boxes, and the assembly of laminar flow units, pass boxes, air showers and biosafety cabinets, are held at their own gates and proven before they are crated.
From our factory to your site
A Fabtech installation runs to plan because most of the risk is taken out before anything reaches your site. The path is deliberate, and it is the same on every job.
Each stage hands the next one a known quantity. The crew that fits your room is not meeting the parts for the first time. They work with the same panels and the same enclosures on every job, so they know where a fixing goes and how a joint is meant to close.
Our facility
Built on our floor
Equipment is made and, where it applies, Factory Acceptance Tested before dispatch.
One package
Delivered
Sent as one coordinated package, staged in the order the site crew will fit it.
Your site
Installed
Fitted by teams who know the parts, because their own company made them.
Into IQ
Handed over
Given into Installation Qualification as a documented, ready-to-verify room.
FIG. 04Factory to site, four stages. Each stage hands the next one a known quantity rather than a surprise.
When one company designs the room, makes the equipment and installs it, the seams largely disappear. Seams are where cleanroom projects usually lose time. The same accountability runs up into Fabtech's leadership and governance.
If you want to see rooms that were built this way and handed over, our completed projects are the place to start. Same panels, same enclosures, same quality system, running in somebody else's building.
Quality control on the manufacturing floor
Quality on a cleanroom does not wait for handover. It starts at the workbench. Our manufacturing runs under an ISO 9001 quality management system, which means the checks are written down and repeatable. They are not a matter of who happened to inspect the part that day.
The value of a written check is that it survives people. A supervisor moves on and the check stays. An auditor asking how a joint was inspected in March gets the same answer as one asking about November. Nothing leaves the floor that we would not want an auditor to see installed. Here is where the work is checked.
| Checkpoint | What happens |
|---|---|
| Materials on receipt | Verified against specification before they enter production |
| In process | Joints and finishes inspected on the line |
| Before dispatch | Each unit signed off against its specification |
| Factory Acceptance Testing | Performance demonstrated on our own floor, for air handling units, laminar flow units, pass boxes and biosafety cabinets |
| DQ, IQ, OQ and PQ validation | Documentation, datum readings and acceptance criteria are ready before the room starts its sequence on site |
FIG. 05Checks run under one ISO 9001 quality management system, from goods-in to dispatch.
The point of testing here is simple. Performance is proven before dispatch, not discovered on your site. A problem found on our floor costs us a day. The same problem found on yours costs a site team that is already standing by.
The same discipline is what makes the equipment validation-ready. The documents, the datum readings and the acceptance criteria are in place before the room starts its sequence on site. Your team inherits a file rather than a blank page.
- Quality management system
- ISO 9001
- Proven before dispatch, where it applies
- FAT
- Documentation ready before site
- DQ IQ OQ PQ
- Built to withstand inspection
- EU-GMP
In-house manufacturing, common questions
Yes. We design and make our cleanroom panels and equipment in our own facility, rather than buying finished units and rebadging them. One engineering team owns the quality of each part, from design through to dispatch. That is what gives our projects single-point accountability.
The clean shell and the equipment that conditions it. PUF and Rockwool modular panels with matching cleanroom doors. Air handling units, HEPA filter housings and fan filter units. Laminar airflow units, pass boxes, air showers and biosafety cabinets. All made on our own floor, to our own specifications.
It is a dedicated cleanroom production facility. It builds the full clean shell and its equipment under one roof, from panel cores to finished enclosures. The current area and line configuration are shared on request during technical review, because capacity is matched to the project mix.
Yes. Our manufacturing runs under an ISO 9001 quality management system. Checks are written down and repeatable. Materials are verified on receipt. Work is inspected in process. Each unit is signed off against its specification before dispatch.
Factory Acceptance Testing, or FAT, is a check run on equipment in the manufacturer's facility before it ships. It shows that a unit meets its specification. Fabtech runs it before dispatch on air handling units, laminar flow units, pass boxes and biosafety cabinets.
It concentrates responsibility. One team designs, makes and stands behind each part. So tolerances are held to one standard, and finishes match across panels, doors and equipment. Parts made to meet each other tend to fit first time. That means less rework and an easier room to qualify.
It makes the schedule easier to control. Panels, doors, air handling and enclosures come from one floor, not several suppliers. So delivery is coordinated as one package. Nothing waits on the slowest outside vendor. Timelines are confirmed against your scope during technical review.
Yes. We build cleanrooms and equipment to withstand inspection under EU-GMP, US-FDA, WHO-GMP and cGMP. Regulators inspect a facility rather than certify a room. So the equipment is made to be documented, testable and validation-ready. That is what lets the installed room stand up to inspection.
What we manufacture in-house
Everything below is made on our own floor: the shell that holds the air, and the equipment that conditions it. Together they make up the whole of our cleanroom equipment manufacturing.
Modular cleanroom panels
PUF and Rockwool cores, with matching flush doors, view windows and walk-on ceiling grid, sealed into one cleanable monolithic shell
Air handling units (AHUs)
Engineered for the pressure cascade and air change rates a classified room needs
HEPA filter housings and fan filter units (FFUs)
Carry the terminal HEPA filtration to the point of use
Laminar airflow units
Horizontal and vertical configurations, for product and sample protection
Pass boxes
Move material between classified zones without breaking the pressure regime
Air showers
Personnel and material entry decontamination at the cleanroom boundary
Cleanroom doors
Flush, gasketed and finished to sit inside the same monolithic wall line as the panels
Biosafety cabinets
Built in-house for containment work, where the operator, the product and the environment all need protecting
FIG. 06The eight families that come off one floor, drawn in elevation. Static, dynamic and VHP pass boxes, and horizontal and vertical laminar flow units, are each made here in every configuration shown on their own pages.
Because these come off one floor, they are made to the same tolerances and finished to the same standard. A door leaf meets a panel it was measured against. A filter housing sits in a ceiling grid that was made for it. On site, they go together cleanly.
Read the list as one system rather than eight products. A pass box only earns its keep if the pressure regime around it holds. An air shower only works if the wall it sits in is sealed. Making both removes the guesswork at the boundary between them.
Each item is engineered for the room it is going into, rather than picked off a shelf and made to suit. Making them ourselves is what buys that freedom.
Related reading: turnkey cleanroom services, the industries we build for, and about Fabtech Cleanrooms.
Next step
Tell us the class, the area and the sector. We will map how your room would be built and proven.
Tell us what the room has to do
Share the ISO class, the floor area and the sector. Our engineers come back with how your room would be built on our floor and proven before it leaves it.