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Advancing sustainability and productivity in cleanrooms with BioClean™ kits
As cleanroom operations become increasingly essential across industries — from pharmaceuticals to semiconductor manufacturing — balancing sustainability with productivity has never been more critical. BioClean™, part of Ansell’s suite of cleanroom solutions, is at the forefront of addressing this challenge, delivering sustainable, high-performance products that elevate operational efficiency while supporting environmental goals.
A new standard in cleanroom garment packaging
At the heart of BioClean’s commitment to sustainability is its cleanroom garment kit solution. Traditionally, cleanroom garments are individually packaged, leading to excessive packaging waste and inefficiencies in gowning processes. Operators often spend valuable time unwrapping and sorting different garment components, which increases the risk of errors and cross-contamination.
BioClean has reimagined this model by introducing pre-assembled kits that contain all necessary garments — coveralls, hoods, overshoes and more — bundled together in a single, easy-to-handle package. These kits are designed to meet the high standards of contamination control required in cleanroom environments while also aligning with sustainability goals.
This approach has several advantages - reducing packaging waste, the single-bag approach cuts plastic waste by two-thirds, saving 1 ton of plastic annually. This is equivalent to eliminating approximately 2.38 million plastic straws from the waste stream¹.
With streamlined gowning, means operators handle fewer packages during the gowning process, enabling quicker donning and reducing time taken to gown by 66%. This equates to saving 59 hours annually per operator, equivalent to nearly 7.5 full workdays².
Optimised storage and transport - consolidated packaging improves shipping efficiency by 116% per shipper container, resulting in a 53% reduction in the total number of shipments required annually. This means fewer shipments, less handling, and lower transportation emissions, contributing to a smaller overall environmental footprint.
Supporting sustainability goals
The BioClean™ kit-based packaging solution is designed with cleanroom sustainability firmly in mind, offering a more responsible approach to packaging without compromising on performance.
By using recyclable materials throughout, such as LDPE for the inner bags, HDPE for the outer bags, and shipper cases made entirely from recycled content and are recyclable³, it supports cleaner waste management practices within cleanroom environments.
These thoughtful choices don’t just reduce waste; they also help lower carbon emissions, saving an estimated 2.1 tonnes of CO2 each year. To put that into perspective, it’s the equivalent of charging around 262,500 smartphones⁴.
What’s more, the packaging has been specifically developed to simplify recycling, even in highly controlled environments where contamination risks can make waste-segregation a challenge.
The crucial role of plastic
Some may question the reliance on plastic in cleanroom packaging, given the global drive to reduce plastic waste. However, as outlined in the article Why plastic packaging is crucial for cleanrooms, plastic remains essential for maintaining sterility and contamination control, unlike alternative materials, plastic provides a reliable barrier against dust, moisture and microbes during storage, shipping and handling. This is essential for ensuring that cleanroom consumables arrive at the point of use in a pristine condition.
Plastic packaging also plays a vital role in adhesion to gowning protocols, ensuring that each garment or consumable is sterile and properly packaged to maintain cleanroom standards. BioClean™ has embraced this challenge by adopting single-polymer designs that are more easily recyclable, without compromising on sterility or worker safety.
Smart packaging innovations driving sustainability
BioClean™’s approach to smart packaging is a direct response to industry best practices, as highlighted in Sustainable packaging innovation for cleanrooms, and reflects a commitment to driving meaningful environmental change.
By embracing more compact packouts, the total volume of plastic used is significantly reduced — an optimised pack design alone can save up to 20.4 tonnes of plastic every year⁵.
Beyond materials, the strategy also includes stackable configurations for shipper cartons, which not only make better use of warehouse space but also cut down on transport-related emissions.
Adding a digital touch, QR-coded labelling gives operators instant access to critical information — such as gowning instructions — streamlining cleanroom processes while reducing the reliance on printed manuals. It’s a forward-thinking blend of practicality and sustainability.
Efficiency gains that boost productivity
Beyond sustainability, the BioClean™ kit model enhances productivity in cleanroom operations. By providing all required garments in a single pack, operators spend less time preparing for work. This not only saves time but also improves compliance with cleanroom protocols, as gowning becomes a more straightforward and consistent process.
The reduction in gowning steps minimises the risk of errors and cross-contamination, helping maintain the integrity of the cleanroom environment.
Efficiency gains also extend to logistics and storage. With fewer individual packages to handle, warehouse space requirements are reduced, and inventory management becomes easier. This supports overall productivity and cost savings across the supply chain.
A balanced approach
By combining contamination control, ergonomic design and sustainable packaging innovations, BioClean™ empowers cleanroom facilities to advance both their productivity and their sustainability goals. The move towards kit-based packaging reflects a holistic approach to cleanroom management.
This approach acknowledges the essential role of plastic packaging while seeking to minimise its impact through smarter design.
Partnering for a cleaner, greener future
BioClean’s kit-based solutions demonstrate how cleanroom operations can evolve to meet the challenges of today’s demanding regulatory and environmental landscape. By simplifying gowning, reducing packaging waste and supporting recyclability, BioClean™ stands as a reliable partner in building a more efficient and sustainable cleanroom environment.
Sources:
1. Phys.Org - Science Says: Amount of straws, plastic pollution is huge
2. Based on an 8-hour workday
3. Always check your local recyclable status of HDPE & LDPE as this plastic material may not be considered suitable for recycling in your country.
4. Compare the Market - Carbon footprint of phone charging
5. Based on FY22 sales volumes (styles 91-225 & 73-701 only)
For more information, contact your local ERIKS Service Centre, who will be happy to discuss your options.
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