Built for Uptime: How PBSC Transfer Hatches Support Cleanroom Reliability

Unplanned downtime continues to be one of the most significant challenges in pharmaceutical laboratories and manufacturing facilities—impacting productivity, compliance, and product integrity. Even short interruptions can result in wasted materials, idle staff, and costly production delays.

Industry studies underline the scale of the issue:

• 73% of laboratory professionals cite unplanned downtime as a leading productivity barrier.

• 60% of labs experience major disruptions due to equipment failures, missed calibrations, or difficulties locating assets.
  These problems can reduce operational capacity by over 10% in mid-to-large laboratories, resulting in increased costs, emergency maintenance, and compromised batch quality.

Compliance and Risk Management

Regulatory authorities such as the European Medicines Agency (EMA) and the U.S. Food and Drug Administration (FDA) stress the importance of reducing contamination and equipment-related risks.
The revised EU GMP Annex 1 (2023), for instance, specifies that aseptic areas must use interlocked pass-through hatches with pressure protection and air flushing systems to prevent contamination. Similarly, FDA guidance on aseptic processing calls for validated environmental controls and interlocked systems to avoid product loss or rework.

PBSC Solutions for Reliability and Uptime

To help facilities maintain continuous operation and regulatory compliance, PBSC has developed a range of transfer hatches designed to deliver reliability, safety, and flexibility—even during power interruptions.

Passive Mechanical Interlocks: Fail-Safe by Design

PBSC’s mechanical interlock system operates independently of power and is securely housed between two hatch skins. This passive, fail-safe mechanism ensures continuous functionality, even in the event of a power outage.
Its concealed design minimises tampering risk and enforces strict door sequencing to maintain cleanroom pressure cascades and segregation. With minimal maintenance requirements, this solution reduces failure risk and supports long-term uptime.

Electronic Control Options: Smarter, Automated Operation

For facilities that rely on automated control, PBSC’s electronic interlock systems offer enhanced flexibility. The advanced control panel allows for adjustable time delays—ideal for purge cycles, UV disinfection, or pressure stabilisation—and includes visual status indicators on both sides of the hatch.
The system can also integrate seamlessly with Building Management Systems (BMS), aligning with validated workflows used in biotech, pharmaceutical, and high-containment environments. This automation not only improves efficiency but also supports traceability and compliance.

Proactive Maintenance: The Key to Long-Term Reliability

Even the most advanced systems benefit from structured maintenance. Planned preventive maintenance programmes are proven to reduce downtime, extend equipment lifespan, and ensure continued compliance readiness.

PBSC offers tailored service and maintenance solutions, including regular inspections, calibration, and performance testing, to keep equipment operating at its best. Partnering with PBSC ensures ongoing protection for your cleanroom—and for your productivity.

🔗 Learn more about PBSC’s transfer hatch maintenance and service options:
PBSC Planned Preventative Maintenance

For more information on Built for Uptime: How PBSC Transfer Hatches Support Cleanroom Reliability talk to PBSC Limited