Optimize Electronic Manufacturing Process With Reliable Measurement Solutions
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Optimize Electronic Manufacturing Process With Reliable Measurement Solutions

By 06/12/2022December 15th, 2022No Comments

At the heart of electronics devices are a wide range of components. Component types include semiconductors (transistors, diodes integrated circuits, passive (resistors, capacitors, inductors), sensors (position, motion, force, thermal magnetic etc), and display (such as LEDs).  Electronics manufacturing involves the handling and assembly of several delicate, moisture-sensitive components. Electronic devices are exposed to varying and harsh environments and thus common reasons for failures in electronics are environmental contaminants and conditions such as temperature, humidity and dew point with other failures deriving, for example, from vibration, ripple voltage, overvoltage and corrosion. These all affect the reliability of electronic components.

Maintaining the proper moisture levels in electronics manufacturing facilities is critical for preserving component quality and minimizing the risk of safety hazards. At Dpstar, we provide state-of-the-art control solutions that optimize moisture levels for a range of sensitive electronics manufacturing environments.  We have been the industry leader in temperature, humidity and dew point measurement for over 30 years and is able to create solutions even for very demanding measurement conditions. Vaisala’s HUMICAP® and DRYCAP® technologies have been trusted for decades due to their accuracy and stability. Both technologies include capacitive thin-film polymer sensors. Designed, manufactured, and tested in-house, our systems are capable of meeting even the most challenging process parameters.

At the heart of electronics devices are a wide range of components. Component types include semiconductors (transistors, diodes integrated circuits, passive (resistors, capacitors, inductors), sensors (position, motion, force, thermal magnetic etc), and display (such as LEDs).  Electronics manufacturing involves the handling and assembly of several delicate, moisture-sensitive components. Electronic devices are exposed to varying and harsh environments and thus common reasons for failures in electronics are environmental contaminants and conditions such as temperature, humidity and dew point with other failures deriving, for example, from vibration, ripple voltage, overvoltage and corrosion. These all affect the reliability of electronic components.

Maintaining the proper moisture levels in electronics manufacturing facilities is critical for preserving component quality and minimizing the risk of safety hazards. At Dpstar, we provide state-of-the-art control solutions that optimize moisture levels for a range of sensitive electronics manufacturing environments.  We have been the industry leader in temperature, humidity and dew point measurement for over 30 years and is able to create solutions even for very demanding measurement conditions. Vaisala’s HUMICAP® and DRYCAP® technologies have been trusted for decades due to their accuracy and stability. Both technologies include capacitive thin-film polymer sensors. Designed, manufactured, and tested in-house, our systems are capable of meeting even the most challenging process parameters.

Our Capabilities

Proven Quality & Reliability

With 30 years of experience in sensor production and thin-film technology, we ensure superior sensor stability, accuracy, and repeatability.

The perfect solution for every measurement

Dpstar offers an extensive portfolio of measuring devices for a variety of starting points and environmental conditions.

Experience & Dedicated Team

Our expert team understands the specific requirements of applications in a wide range of industries and can quickly provide state-of-the-art and tailor-made solutions.

One-Stop Testing & Measurement Solution

Thanks to the application-specific selection of processed materials, Dpstar sensors and transmitters operate accurately and reliably in the long term.

Our Capabilities

Proven Quality & Reliability

With 30 years of experience in sensor production and thin-film technology, we ensure superior sensor stability, accuracy, and repeatability.

The perfect solution for every measurement

Dpstar offers an extensive portfolio of measuring devices for a variety of starting points and environmental conditions.

Experience & Dedicated Team

Our expert team understands the specific requirements of applications in a wide range of industries and can quickly provide state-of-the-art and tailor-made solutions.

One-Stop Testing & Measurement Solution

Thanks to the application-specific selection of processed materials, Dpstar sensors and transmitters operate accurately and reliably in the long term.

Why Moisture Control Important In Electronic Manufacturing Process

Moisture control is an important aspect of the manufacturing processes. Identifying a target moisture range and taking steps to achieve that target range will optimize the process control of virtually any manufactured product. The ideal moisture level typically depends on factors such as the ambient environment and the specifications of the components and devices being manufactured. For example, maintaining a consistent relative humidity of 50% may be ideal for some manufacturing environments, whereas others may require slightly lower levels to avoid condensation and corrosion in highly moisture-sensitive components. Electronic devices and components are highly sensitive to moisture levels. Insufficient, excessive and inconsistent moisture levels cause damage and defects in electronic components and pose safety concerns due to electrostatic discharge, de-soldering occurrences and brittle components. Ensuring proper moisture control in your facility will improve production output, elevate product quality and ultimately, boost ROI.

Increase Product Consistency

Implementing moisture measurement and control technology provides the manufacturer the ability to spot product inconsistencies in real-time and make process adjustments before the finished products are damaged or produced with poor quality.

Product Analysis

Utilizing moisture measurement and control provides a user with the ability to experiment, test, research, and perform product analysis. A producer’s ability to better understand their product provides an understanding of their production process as a whole and encourages greater productivity.

Reduce Product Waste

Without knowing the moisture content, in real-time, a producer may continue to manufacture the unfit product and learn of its poor quality only after a significant quantity has been produced. This real-time measurement gives the producer the ability to make immediate adjustments in their process and to avoid the pitfall of manufacturing a product that is unfit for the customer.

Improve Quality Control

Implementing moisture measurement and control technology into the process provides the ability to maintain consistency in your product’s moisture and will improve the quality control of virtually any production process.

Reduce Energy Costs

Energy costs are a significant source of operational expenses and reducing these costs can mean significant cost savings. Having a real-time measurement of moisture can prevent over-drying and unnecessary energy usage.

Effective Process Control

Real-time moisture measurement of a product as it is being manufactured will allow the producer to adjust their process to achieve the target range and effectively control their manufacturing process with minimal downtime and maximum efficiency.

Why Moisture Control Important In Electronic Manufacturing Process

Moisture control is an important aspect of the manufacturing processes. Identifying a target moisture range and taking steps to achieve that target range will optimize the process control of virtually any manufactured product. The ideal moisture level typically depends on factors such as the ambient environment and the specifications of the components and devices being manufactured. For example, maintaining a consistent relative humidity of 50% may be ideal for some manufacturing environments, whereas others may require slightly lower levels to avoid condensation and corrosion in highly moisture-sensitive components. Electronic devices and components are highly sensitive to moisture levels. Insufficient, excessive and inconsistent moisture levels cause damage and defects in electronic components and pose safety concerns due to electrostatic discharge, de-soldering occurrences and brittle components. Ensuring proper moisture control in your facility will improve production output, elevate product quality and ultimately, boost ROI.

Increase Product Consistency

Implementing moisture measurement and control technology provides the manufacturer the ability to spot product inconsistencies in real-time and make process adjustments before the finished products are damaged or produced with poor quality.

Product Analysis

Utilizing moisture measurement and control provides a user with the ability to experiment, test, research, and perform product analysis. A producer’s ability to better understand their product provides an understanding of their production process as a whole and encourages greater productivity.

Reduce Product Waste

Without knowing the moisture content, in real-time, a producer may continue to manufacture the unfit product and learn of its poor quality only after a significant quantity has been produced. This real-time measurement gives the producer the ability to make immediate adjustments in their process and to avoid the pitfall of manufacturing a product that is unfit for the customer.

Improve Quality Control

Implementing moisture measurement and control technology into the process provides the ability to maintain consistency in your product’s moisture and will improve the quality control of virtually any production process.

Reduce Energy Costs

Energy costs are a significant source of operational expenses and reducing these costs can mean significant cost savings. Having a real-time measurement of moisture can prevent over-drying and unnecessary energy usage.

Effective Process Control

Real-time moisture measurement of a product as it is being manufactured will allow the producer to adjust their process to achieve the target range and effectively control their manufacturing process with minimal downtime and maximum efficiency.

Capacitor Construction

A capacitor is a basic electronic component that is able to reserve electrical charge. Capacitors are used in filters, power supplies, oscillator circuits, and other electrical systems.  A capacitor is constructed out of two metal plates, separated by an insulating material called dielectric.  The plates are conductive and they are usually made of aluminum, tantalum or other metals, while the dielectric can be made out of any kind of insulating material such as paper, glass, ceramic or anything that obstructs the flow of the current. The capacitance of a capacitor, measured in the SI unit Farad [F], is directly proportional to the surface area of the two plates, as well as the permittivity ε of the dielectric, while the smaller distance between the plates the greater capacitance.

Capacitor Construction

A capacitor is a basic electronic component that is able to reserve electrical charge. Capacitors are used in filters, power supplies, oscillator circuits, and other electrical systems.  A capacitor is constructed out of two metal plates, separated by an insulating material called dielectric.  The plates are conductive and they are usually made of aluminum, tantalum or other metals, while the dielectric can be made out of any kind of insulating material such as paper, glass, ceramic or anything that obstructs the flow of the current. The capacitance of a capacitor, measured in the SI unit Farad [F], is directly proportional to the surface area of the two plates, as well as the permittivity ε of the dielectric, while the smaller distance between the plates the greater capacitance.

Our Success Story

Moisture Control in Paper Capacitor Manufacturing

Capacitors are important electrical components used in electronic circuits. Capacitor paper has to be completely dry to ensure high quality and yield. Over-drying limits the manufacturing capacity and affects energy consumption. Being able to monitor the conditions inside the dryer offers significant potential for developing various aspects of the process: increasing production capacity, reducing energy consumption, and improving the overall control of the process. In paper capacitor manufacturing, the capacitor paper rolls are heated in heating chambers and dried in vacuum driers. The dried paper is metalized in a vacuum deposition stage and then cut into strips, which are wound into radial capacitors. Moisture control is essential in this process for many reasons.

The metallization stage requires a high vacuum. If the paper is not dry enough during the vapor deposition stage, it is difficult to maintain a sufficiently high vacuum due to evaporating water vapor that increases vapor pressure and thus decreases vacuum. Because of variable humidity requirements, some parts of the manufacturing process take place in dry rooms, where air conditioning is used to maintain a stable environment. The connector leads and protective epoxy are applied, followed by the final drying stage, electrical testing, and packaging. The vacuum drying takes place in two phases:

Flushing

The first phase involves heating the oven with hot water coils at up to +120 °C while applying a 10-mbar absolute vacuum by feeding a small supply of air into the vacuum chamber during the operation of the vacuum pump.

Final Drying

The second phase involves closing the air supply and maintaining approximately a 1 mbar absolute vacuum until the required dryness is achieved.

How Vaisala Instruments Optimized Electronic Manufacturing Process?

Our client wants to improve their dryer capacity and reduce energy consumption while maintaining quality and yield. Previously they didn’t monitor humidity levels in all the relevant positions, partly due to limitations in the measurement range and operating temperatures of their existing equipment. They’ve now noticed that it’s essential to study the conditions throughout the whole process.

The DMT348 dew point transmitter was installed on the vacuum pump coupling to monitor the drying process. Despite the high temperature in the oven heating coils, the low heat conductance in a vacuum keeps the probe temperature within the measurable range. The heat is conducted into the probe mostly through the installation flange, meaning that the operating temperature for the measurement probe remains close to the surface temperature at the installation position.

The Vaisala DMT348 is suitable for installation in pressurized processes between 0 and 40 bars. It allows easy vapor-tight installation, making it ideal for vacuum drying applications. Encouraged by the success in the drying stage, dew point and humidity measurements with a Vaisala MI70 handheld indicator connected to HMP75 and DMP7 humidity and dew point probes for overall process control.

Changes in dew point temperature during the drying process in a test run. Knowing the optimum cut-off point helps to avoid over-drying while ensuring sufficient dryness and maintaining quality.

Our Success Story

Moisture Control in Paper Capacitor Manufacturing

Capacitors are important electrical components used in electronic circuits. Capacitor paper has to be completely dry to ensure high quality and yield. Over-drying limits the manufacturing capacity and affects energy consumption. Being able to monitor the conditions inside the dryer offers significant potential for developing various aspects of the process: increasing production capacity, reducing energy consumption, and improving the overall control of the process. In paper capacitor manufacturing, the capacitor paper rolls are heated in heating chambers and dried in vacuum driers. The dried paper is metalized in a vacuum deposition stage and then cut into strips, which are wound into radial capacitors. Moisture control is essential in this process for many reasons.

The metallization stage requires a high vacuum. If the paper is not dry enough during the vapor deposition stage, it is difficult to maintain a sufficiently high vacuum due to evaporating water vapor that increases vapor pressure and thus decreases vacuum. Because of variable humidity requirements, some parts of the manufacturing process take place in dry rooms, where air conditioning is used to maintain a stable environment. The connector leads and protective epoxy are applied, followed by the final drying stage, electrical testing, and packaging. The vacuum drying takes place in two phases:

Flushing

The first phase involves heating the oven with hot water coils at up to +120 °C while applying a 10-mbar absolute vacuum by feeding a small supply of air into the vacuum chamber during the operation of the vacuum pump.

Final Drying

The second phase involves closing the air supply and maintaining approximately a 1 mbar absolute vacuum until the required dryness is achieved.

How Vaisala Instruments Optimized Electronic Manufacturing Process?

Our client wants to improve their dryer capacity and reduce energy consumption while maintaining quality and yield. Previously they didn’t monitor humidity levels in all the relevant positions, partly due to limitations in the measurement range and operating temperatures of their existing equipment. They’ve now noticed that it’s essential to study the conditions throughout the whole process.

The DMT348 dew point transmitter was installed on the vacuum pump coupling to monitor the drying process. Despite the high temperature in the oven heating coils, the low heat conductance in a vacuum keeps the probe temperature within the measurable range. The heat is conducted into the probe mostly through the installation flange, meaning that the operating temperature for the measurement probe remains close to the surface temperature at the installation position.

The Vaisala DMT348 is suitable for installation in pressurized processes between 0 and 40 bars. It allows easy vapor-tight installation, making it ideal for vacuum drying applications. Encouraged by the success in the drying stage, dew point and humidity measurements with a Vaisala MI70 handheld indicator connected to HMP75 and DMP7 humidity and dew point probes for overall process control.

Changes in dew point temperature during the drying process in a test run. Knowing the optimum cut-off point helps to avoid over-drying while ensuring sufficient dryness and maintaining quality.

Customer Benefits 

Improved yield at the vacuum deposit stage 

Increased drying capacity 

Shorter drying times

Cost savings in the drying stage

Improved control during the whole process

Our Product Solution

Vaisala DMT340 Series Dew Point & Temperature Meter

Vaisala DMP7 Dew Point & Temperature Probe

Vaisala HM70 Handheld Humidity & Temperature Meter

Vaisala MI70 Handheld Measurement Indicator

Ensure Product Quality & Production Efficiency with Dpstar Measurement Solutions

Implementing an effective humidity control strategy is important for maintaining compliance with the electronics manufacturing industry’s strict requirements regarding the production environment. Proper humidity control ensures a more consistent product output, leading to greater production yields. As a solution provider company, we innovate for business with one consistent belief; there is always a peace of mind solution to allow businesses to focus on their best profession. Dpstar sensors and transmitters use thin-film sensing elements, ongoing research and development, state-of-the-art production technology, and extensive calibration expertise resulting in reliable products for high-precision measurement.

Get In Touch With Our Experts Today!

Dpstar Group
No 35, Jalan OP ½, Pusat Perdagangan One Puchong,
Off Jalan Puchong, 47160 Puchong,
Selangor Darul Ehsan, Malaysia.
Email: [email protected]

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