The Hidden Sources of Contamination in Cleanrooms:
Why Tape and Labels Matter More Than You Think

Cleanroom environments are designed to maintain strict control over airborne particles, humidity, and other environmental factors. Despite rigorous protocols and advanced filtration systems, contamination can still arise from less obvious sources. Among these, tapes and labels—often considered routine consumables—can introduce particulate and chemical contaminants if not properly engineered for cleanroom use. Understanding and mitigating these risks is essential for maintaining product integrity and operational efficiency in critical industries.

The Contamination Risk You Can’t See

When people think of cleanroom contamination, they often focus on personnel, filtration systems, or equipment. However, consumables like tape and labels—especially those not engineered for cleanroom use—can introduce a host of contaminants. These include particulate matter, volatile organic compounds (VOCs), and adhesive residues that can compromise product integrity, delay production, and even lead to costly recalls.

Common Offenders:

• Paper Cores: Traditional tapes often use cardboard cores, which can flake or shed particles into the environment.
• Adhesive Residue: Non-cleanroom adhesives may leave behind sticky residues that attract dust or interfere with surfaces.
• Label Materials: Paper labels can degrade or release fibers, especially in high-humidity or high-temperature environments.
• Outgassing: Some tapes and labels emit VOCs that can interfere with sensitive processes or equipment.

Where It Goes Wrong: A Closer Look

1) Cores and Edges

Most commercial tapes are wound on cardboard cores. These cores are prone to shedding fibers and particulates, especially when handled or cut. Even plastic cores can be problematic if they have sharp edges or burrs, which can tear gloves or cleanroom bags—compromising gowning protocols and introducing contaminants.

2) Adhesives and Outgassing

Adhesives used in non-cleanroom tapes often contain solvents or chemicals that outgas over time. These emissions can interfere with sensitive instrumentation or chemical processes. Worse, some adhesives leave behind residues that are difficult to clean and can trap dust or microbes.

Even more concerning is the phenomenon of adhesive migration—where adhesive components slowly move beyond the intended bonding area. This can occur under pressure, heat, or over time, leading to contamination of adjacent surfaces or components. In precision environments like semiconductor fabs or pharmaceutical cleanrooms, migrated adhesives can interfere with optical sensors, clog microfluidic channels, or compromise sterile barriers. Cleanroom-certified tapes use specially formulated adhesives that are engineered to remain stable and confined, eliminating this risk.

3) Label Face Stocks and Liners

Labels are essential for identification, tracking, and compliance in cleanroom environments—but they can also be a hidden source of contamination if not properly engineered. The materials used in both the face stock (the printable surface of the label) and the liner (the backing that protects the adhesive) play a critical role in maintaining cleanroom integrity.

Paper-based face stocks are particularly problematic. They can absorb moisture, degrade under elevated temperatures, and shed microscopic fibers. These fibers can become airborne or settle on critical surfaces, leading to contamination that is difficult to detect and even harder to trace. In high-humidity environments, paper labels may curl, peel, or delaminate, exposing adhesive and increasing the risk of particulate release.

Liners, often overlooked, can also be a contamination vector. Traditional liners made from kraft paper or low-grade plastics can generate static, attract dust, or shed particles when peeled. In some cases, the act of removing a label from its liner can cause a burst of static discharge, which not only attracts particles but can also damage sensitive electronic components.

Cleanroom-grade labels, like those from UltraTape, use synthetic face stocks such as polyester or polyimide, which are resistant to tearing, moisture, and chemical exposure. These materials are engineered to remain stable under cleanroom conditions and do not shed fibers. Liners are typically made from low-particulate, anti-static films that peel cleanly and safely, minimizing the risk of contamination during application.

4. Packaging and Handling

Even the cleanest tape or label can become a contamination risk if its packaging and handling are not up to cleanroom standards. This is an area where many facilities unknowingly introduce contaminants.

Packaging materials for non-cleanroom tapes and labels often include cardboard boxes, paper inserts, or polyethylene bags that are not cleanroom-certified. These materials can carry dust, fibers, or microbial contaminants into the cleanroom. Worse, they may not be double-bagged, which is a standard requirement for transferring items through airlocks or pass-through chambers.

Handling practices are equally important. If tapes and labels are stored in uncontrolled environments or handled without gloves, they can accumulate oils, skin cells, and other contaminants. Improper storage—such as placing rolls directly on shelves or near vents—can expose them to airborne particles or temperature fluctuations that degrade adhesive performance.

UltraTape addresses these risks by packaging its products in double-bagged, cleanroom-compatible polyethylene. Each lot is traceable, and irradiation options are available to ensure sterility. Products are also labeled with cleanroom-safe inks and barcodes, allowing for safe tracking and inventory management without introducing foreign materials.

To maintain cleanliness during handling, best practices include:

• Opening outer bags only in gowning or staging areas.
• Using gloves and cleanroom wipes when transferring products.
• Storing tapes and labels in sealed containers or dispensers designed for cleanroom use.

UltraTape: Engineered for Cleanroom Integrity

UltraTape, a division of Delphon, has developed a comprehensive line of cleanroom tapes and labels designed to eliminate these risks. Their products are manufactured in ISO-certified cleanroom environments and undergo rigorous testing to ensure compliance with the most stringent cleanliness standards.

Key Features of UltraTape Products:

• Plastic Cores: Non-shedding, smooth plastic cores prevent particulate release and reduce glove-tearing risks.
• Low-Outgassing Adhesives: Specially formulated to minimize chemical emissions and leave no residue.
• Synthetic Label Materials: Durable, fiber-free materials that withstand cleanroom conditions without degrading.
• Cleanroom Packaging: Products are double-bagged in cleanroom polyethylene and can be irradiated with full lot traceability.

Why It Matters: Real-World Impacts

In cleanroom-dependent industries, the stakes are high. A single fiber or chemical emission can ruin an entire batch of semiconductors, contaminate a pharmaceutical formulation, or compromise a medical device. The cost of such failures can be astronomical—not just in terms of product loss, but also in regulatory penalties, reputational damage, and patient safety.

By switching to cleanroom-certified tapes and labels like those from UltraTape, organizations can significantly reduce contamination risk and maintain the integrity of their controlled environments.

Beyond Tape: A Holistic Approach to Contamination Control

While tape and labels are critical, they are just one piece of the contamination control puzzle. Other hidden sources include:

• Personnel: Improper gowning, infrequent garment changes, or damaged suits can release particles into the air. Cuff-sealing tape is a simple but effective tool to minimize this risk.
• Equipment and Tools: Unclean or poorly maintained tools can introduce particulates or chemical residues.
• Raw Materials: Incoming materials must be cleaned and inspected before entering the cleanroom.
• Cleaning Products: Household or industrial cleaners are not suitable for cleanroom use. Only certified cleanroom cleaning agents should be used.

Best Practices for Cleanroom Tape and Label Use

To ensure optimal performance and cleanliness, follow these guidelines:

• Source from Certified Suppliers: Only purchase tapes and labels from vendors who specialize in cleanroom consumables.
• Inspect Before Use: Check for damage, residue, or improper packaging.
• Store Properly: Keep products in their original packaging until use, and store them in clean, dry environments.
• Train Personnel: Ensure staff understand the importance of using cleanroom-certified materials and how to handle them correctly.
• Audit Regularly: Periodically review your cleanroom consumables and update them as needed to meet evolving standards.

Conclusion: Small Details, Big Impact

In cleanroom environments, the smallest details can have the biggest impact. Tapes and labels may seem trivial, but their potential to introduce contamination is significant. By understanding the risks and choosing the right products—like those from UltraTape—cleanroom managers can uphold the highest standards of cleanliness and protect the integrity of their operations.