Case Study: Differential Pressure Monitoring in Pharmaceutical Clean rooms

Industry: Pharmaceuticals / R&D

Engagement Type: Cleanroom Air Pressure Monitoring and Compliance Auditing

🧩 Challenge

A leading pharmaceutical R&D facility operates multiple cleanrooms, each designed to maintain positive air pressure relative to adjacent buffer and peripheral zones. This differential pressure ensures that airborne contaminants do not enter critical production or research environments.

The client required a real-time, auditable monitoring solution to continuously track differential air pressure between cleanrooms and surrounding areas. The system needed to log trend data for regulatory audits and internal quality assurance, ensuring that environmental integrity was maintained 24×7.

💡 Ai-DEA Labs’ Solution

Ai-DEA Labs engineered a customized Indoor Air Quality (IAQ) solution integrated with high-precision differential pressure sensors.

This smart monitoring system continuously measures and records pressure differences, alerts users when readings fall outside prescribed limits, and provides historical data for audit trail and compliance reporting.

Solution Highlights:

• Custom IAQ devices with integrated differential pressure sensors

• Real-time monitoring and data visualization via Ai-DEA Labs’ EMS platform

• Configurable alert thresholds and reporting frequency

• Scalable system design suitable for multi-cleanroom facilities

  
  

⚙️ Implementation

• 4 person-days of detailed system study and customization

• Solution design finalized and ready for deployment

• Integration with existing facility monitoring infrastructure planned for seamless rollout

🚀 Results & Impact

• Enables real-time tracking of cleanroom differential pressures

• Ensures regulatory compliance and readiness for audits

• Supports proactive maintenance and rapid anomaly detection

• Provides historical trend data to validate cleanroom performance and process integrity

📊 Key Takeaway

Ai-DEA Labs’ customized differential pressure monitoring solution equips pharmaceutical facilities with a data-driven compliance framework—protecting product quality, maintaining cleanroom integrity, and supporting a culture of operational excellence.