Amorair Engineering Case-Semiconductor Cleanroom FFU Energy-Saving Upgrade

High-Efficiency EC Motor + Low-Resistance HEPA Filter for Better Cleanroom Performance and Lower Energy Consumption

       3191 Units       4,134,560 kWh       351,090 $       71.41 %

          FFU Replacement          Annual Energy Saving           Annual Cost Saving       Energy Reduction

In semiconductor manufacturing, cleanrooms need continuous air filtration to control airborne particles and maintain strict cleanliness requirements.

Fan Filter Units (FFUs) are an important part of the cleanroom air circulation and filtration system. A large number of FFUs are installed in the cleanroom ceiling. They continuously move air through HEPA filters and supply clean air to the production area.This means:

The more FFUs a cleanroom has and the longer they operate, the more important energy consumption becomes.

For large semiconductor cleanrooms, even a small difference in power consumption per FFU can result in significant energy savings when thousands of units are running continuously.

At the same time, filter resistance also affects the operating load of the FFU. A filter with lower resistance can help reduce the energy required to move air through the system.

Project Background

A large semiconductor manufacturer had a cleanroom operating at a high load for a long period of time. As production capacity increased, the energy consumption from thousands of continuously operating FFUs became a growing concern.

High energy consumption and high operating costs had become important challenges for the customer.

The customer needed to reduce the long-term energy cost of the cleanroom air filtration system without affecting cleanroom performance or production stability. To address this challenge, the customer asked Amorair to evaluate the existing FFU system and develop a practical FFU energy-saving upgrade solution.

The goal was simple: Reduce energy consumption while maintaining stable airflow and cleanroom performance.

Amorair's Semiconductor Air Filtration Solution

01｜High-Efficiency EC Motor FFU

The project uses high-efficiency EC motor FFUs to improve fan and motor efficiency. Compared with traditional fan systems, EC motor technology provides more efficient operation while delivering the required airflow for the cleanroom.

For semiconductor cleanrooms that operate 24/7, improving FFU efficiency can create significant long-term energy savings.

Higher FFU efficiency → Lower power consumption → Lower operating costs

02｜Low-Resistance Glass Fiber HEPA Filters

The air filter is one of the main sources of resistance in an FFU system. For this project, we used low-resistance fiberglass HEPA filters. The filters provide the required filtration performance while reducing the resistance to airflow.

The basic principle is: Lower filter resistance → Lower fan load → Lower FFU energy consumption

Therefore, the filter does more than remove airborne particles. Its resistance also has a direct impact on the energy efficiency of the entire FFU system. Choosing the right HEPA filter is an important part of a complete semiconductor air filtration solution.

Energy-Saving Results

By combining high-efficiency FFUs with low-resistance HEPA filters, the project achieved a better balance between cleanroom performance and energy efficiency.

     Items                                                Q1                              Q2                               Q3                               Q4                                Total

Actual Power Consumption（kWh）             416,460                           412,620                          403,800                          422,310                          1,655,190

Baseline Power Consumption（kWh）       1,447,437.6                   1,447,437.6                    1,447,437.6                     1,447,437.6                     5,789,750.4

Energy Saved（kWh）                             1,030,977.6                   1,034,817.6                     1,043,637.6                     1,025,127.6                     4,134,560.4

Cost Saved（$）                                            92,633                            85,357                             87,218                             85,882                            351,090

Customer Value

- Lower Operating Costs： The project saves approximately RMB 2.38 million in electricity costs every year, helping reduce the long-term operating cost of the cleanroom.

- Higher Energy Efficiency：The overall energy consumption of the FFU system was reduced by 71.41%, significantly improving energy efficiency.

- Stable Cleanroom Performance： The upgraded FFU and HEPA filtration system continues to provide stable airflow and high-efficiency particle filtration for semiconductor manufacturing.

- Support for Green Manufacturing： The project saves more than 4.13 million kWh of electricity annually, helping the customer reduce energy consumption and support its energy-saving, carbon-reduction and ESG goals.

Amorair Global | Air Filtration Solution Provider with 20 years of experience 

Amorair provides air filtration solutions for cleanrooms, including FFU, HEPA filters and other cleanroom air filtration products.

From product selection to system optimization, we help customers find a better balance between:

Cleanroom Performance + Energy Efficiency + Long-Term Operating Cost

If your semiconductor cleanroom is facing high FFU energy consumption, high operating costs, or you are considering an FFU energy-saving upgrade, contact Amorair to discuss your project requirements and find a suitable air filtration solution.