Case Study: Cleanroom Intercom System in a Pharmaceutical Manufacturing Facility

Background of cleanroom intercom system project

A leading pharmaceutical company operating under GMP and ISO 14644 standards faced a common challenge: ensuring reliable, traceable communication within controlled cleanroom environments. Staff working in Grade A/B sterile areas often needed to coordinate with supervisors, request materials, or report emergencies. However, leaving the cleanroom to use conventional telephones created contamination risks, wasted time, and violated gowning protocols.

The client required a cleanroom intercom system that:

• Maintains compliance with cleanroom design standards.

• Supports emergency communication.

• Offers SIP/VoIP integration with existing IT infrastructure.

• Provides call recording and traceability for audits.

• Ensures high audio quality despite noisy HVAC and equipment.

Challenges

1. Hygiene and Cleanroom Compliance

   • Equipment needed to withstand aggressive disinfectants and frequent cleaning cycles.

   • Devices had to be flush-mounted to avoid dust and particle accumulation.

2. Audio Quality in Noisy Environments

   • Strong airflow, masks, and background equipment noise made communication difficult.

3. Integration with IT & Compliance Requirements

   • The system had to integrate with SIP infrastructure, support data recording, and meet GMP traceability standards.

4. Emergency Preparedness

   • Staff in cleanrooms needed direct access to the control room with a single action.

Solution

LightCom proposed a tailored cleanroom intercom system using the following equipment:

• X210-IP Enterprise SIP Master Station(Control desk unit for supervisors and operators – View Product)

• LC308-KB Clean-Room Telephone (VoIP)(Flush-mounted, cleanroom-rated intercom device – View Product)

• LCIS-1000S Intercom Server(Centralized SIP intercom server for call routing, recording, and traceability – View Product)

• LC308-1PB-S Flush Mounting Rugged Help Point Telephone (Single-button device for warehouses and non-classified areas – View Product)

Key Features Implemented:

• The telephone is equipped with an acoustic echo processing system, ensuring high-quality calls even in noisy environments.

• Based on the on-site environment, the system provides audio intercom, video linkage, SIP calls, call recording, and data storage traceability management.

• Flush-mounted emergency telephones were installed inside cleanrooms, allowing staff to quickly reach the control center by dialing a preset number.

Deployment

1. Cleanroom Zones (Grade A/B)

   • Installed LC308-KB Clean-Room Telephones flush-mounted into walls.

   • Connected to the LCIS-1000S Intercom Server for SIP routing and data logging.

2. Control Room

   • Deployed X210-IP Master Station for supervisors to monitor, respond, and record calls.

3. Support & Warehouse Areas

   • Installed LC308-1PB-S Help Point Intercoms where cleanroom standards were not required but emergency communication was still necessary.

4. IT Integration

   • System was integrated into the client’s VoIP network.

   • Call recording and traceability functions were activated for GMP compliance.

Results

• Regulatory Compliance: The intercom system passed internal validation and aligned with GMP, ISO 14644, and FDA audit requirements.

• Improved Safety: Cleanroom operators could reach the control center instantly without breaking gowning protocols.

• Operational Efficiency: Reduced the number of unnecessary cleanroom exits by 35%, saving time and minimizing contamination risk.

• Superior Audio Quality: Acoustic echo cancellation enabled clear communication despite HVAC and background noise.

• Traceability: All calls were logged with time stamps, user data, and recordings, supporting audits and incident reviews.

Conclusion

This case demonstrates how a cleanroom intercom system can be strategically deployed in pharmaceutical manufacturing facilities to ensure compliance, safety, and efficiency. By combining flush-mounted cleanroom telephones, a SIP master station, and an intercom server with full traceability, LightCom delivered a reliable communication infrastructure tailored to the demanding requirements of pharmaceutical cleanrooms.