Rethinking Cleanrooms for a Sustainable Future

Cleanrooms in semiconductor production are among the most resource intensive environments in the industrial landscape. As global demand for microchips surges driven by AI and digitalisation, the environmental impact of these facilities grows in parallel. At Deerns, we see this not just as a challenge, but as a call to action.

The Triple Sustainability Challenge

Cleanrooms face three primary sustainability hurdles:

• Escalating energy use: As chip sizes shrink, manufacturing processes grow more energy intensive.
• High water demand: Wet processing and cooling systems consume large volumes of ultra-pure water.
• Harmful chemical emissions: Semiconductor processes involve greenhouse gases and contaminants with high global warming potential.

The complexity of these challenges makes complete circularity difficult for the present, but sustainability gains can be achieved through engineering innovation and intelligent system design.

Energy: Transitioning to Renewable Inputs

Reducing energy demand is not always feasible given current technology requirements. Instead, the focus shifts to energy source optimisation. At Deerns, our approach focuses on the following key energy strategies:

• Use of renewable energy wherever feasible
• Heat recovery from cooling and exhaust systems
• Integration of high efficiency process and support systems

We integrate renewable energy sources into facility supply where possible. Heat recovery systems from process cooling water and exhaust air are also deployed to make the most of energy already within the system. These systems, combined with energy efficient infrastructure design, help semiconductor facilities offset rising energy demands while delivering long term cost efficiency.

Water: Purification, Reuse & Reduction

Water management is a central focus in our cleanroom projects. Cleanrooms require water of exceptional purity, particularly for wet processes. At Deerns, we implement systems that allow reuse of rinse water without compromising process integrity. For example, in some projects we recover water from second and third cleaning steps, where the contamination level is low. After targeted filtration, this water can be reintroduced into the facility’s operations.

We also develop custom treatment systems that purify wastewater to meet re-entry standards. By closing the water loop where feasible, clients can reduce reliance on fresh water sources, lower operational costs and support broader sustainability goals.

Gas Management: Recovery Over Replacement

The chemicals used in chip production are not easily substituted, and transitions to greener compounds are slow. Instead of waiting for future chemical innovation, Deerns focuses on reducing emissions.

Our approach includes:

• Advanced gas abatement and scrubber systems tailored to process needs
• Hydrogen and noble gas recovery systems enabling reuse of expensive and rare gases
• ROI-driven solutions, with some projects achieving payback in under a year

This method avoids unnecessary waste while supporting regulatory compliance and long-term cost savings.

Tailored Solutions

Deerns designs both greenfield and brownfield projects. New builds allow greater design flexibility, enabling sustainability to be embedded from the outset. Brownfield sites pose more of a challenge, requiring custom solutions that work within the constraints of existing operations.

Yet brownfield projects are often more insightful, providing practical lessons that inform future cleanroom designs. Each site is unique, and we work closely with our clients to understand their processes, consumption levels and operational constraints to tailor the most effective and sustainable engineering approach.

Client Centric Engineering

Sustainable engineering is as much about people as it is about systems. At Deerns, we prioritise close collaboration with our clients. Our engineers maintain a strong on-site presence, often working at facilities several days a week to build trust, gain process insights and develop real-world solutions.

Our collaborative process includes 3 clear steps:

• In-depth feasibility studies aligned to local and global regulations
• Continuous engagement with on-site personnel and operational leads
• Adaptive designs responsive to each facility’s specific requirements

Deerns’ cleanroom portfolio spans both technical and geographic scope. In the Netherlands and abroad, it has supported an OEM (Original Equipment Manufacturer) manufacturer on greenfield and brownfield sites and a semiconductor manufacturer with performance upgrades to existing facilities. Internationally, Deerns has contributed to research focused cleanrooms at R&D nanotechnology facilities in Scandinavia. In the UK, it has delivered brownfield upgrades for a major semiconductor site, applying adaptive design to optimise live environments.

Why Circularity Matters Now

As AI-driven demand accelerates microchip production, the cleanroom industry faces the challenge of expanding sustainably. At Deerns, we integrate circularity and efficiency into every design, ensuring facilities are both future-proof and environmentally responsible. Circularity is no longer a design ideal. It is a data-driven operational strategy built on collaboration and innovation.