Life Cycle Assessment of Reusable and Disposable Cleanroom Coveralls

Abstract

Cleanroom garments serve a critical role in such industries as pharmaceuticals, life sciences, and semiconductor manufacturing. These textiles are available in reusable and disposable alternatives. In this report, the environmental sustainability of cleanroom coveralls is examined using life cycle assessment technology. The complete supply chain, manufacture, use, and end-of-life phases for reusable and disposable cleanroom coveralls are compared on a cradle-to-end-of-life cycle basis. Three industry representative coveralls are examined: a reusable woven polyethylene terephthalate (PET) coverall, a disposable flash spunbonded high-density polyethylene (HDPE) coverall, and a disposable spunbond-meltblown-spunbond polypropylene (SMS PP) coverall. The reusable cleanroom coverall system shows substantial improvements over both disposable cleanroom coverall systems in all environmental impact categories. The improvements over the disposable HDPE coverall were 34% lower process energy (PE), 23% lower natural resource energy (NRE), 27% lower greenhouse gas (GHG) emissions, and 73% lower blue water consumption. The improvements over the disposable SMS PP coverall were 59% lower PE, 56% lower NRE, 57% lower GHG emissions, and 77% lower blue water consumption. In addition, the reusable system shows a 94–96% reduction in solid waste to the landfill from the cleanroom facility. Between the two disposable cleanroom coveralls, the flash spunbonded HDPE coverall shows a measurable environmental improvement over the SMS PP coverall.

LAY ABSTRACT: Pharmaceutical drugs are manufactured and handled in controlled environments called cleanrooms to ensure the safety and quality of products. In order to maintain strict levels of cleanliness, cleanroom personnel are required to wear garments such as coveralls, hoods, and gloves that restrict the transfer of particles from the person to the environment. These garments are available in reusable and disposable types. Cleanroom operators consider a number of factors when selecting between reusable and disposable garments, including price, comfort, and environmental sustainability.

In this report, the environmental sustainability of reusable and disposable cleanroom coveralls is examined using a technique called life cycle assessment. With this technique, environmental parameters such as energy use and greenhouse gas emissions are quantified and compared for three market representative cleanroom coveralls, from raw material extraction through manufacturing, use, and final disposal. Reusable coveralls were found to substantially outperform disposable coveralls in all environmental parameters examined. This is an important conclusion that supports cleanroom companies that select reusable coveralls to be more sustainable.