Benefits of Using Cleanrooms for Electronics Manufacturing
Benefits of Using Cleanrooms for Electronics Manufacturing

Nov 02, 2021

A tiny particle of dust on certain products can be very damaging, which is why OEMs cannot risk particulate contamination when it comes to manufacturing certain electronics like camera modules, night vision devices, and precision audio products. In fact, contaminated products cost electronics manufacturers millions of dollars each year and lead to the loss of their ISO certifications. To ensure product sterility and stability, manufacturers have strict electrostatic and micro-pollutant requirements. They often use cleanrooms, which are facilities specifically designed to maintain deficient levels of particulates, such as aerosol particles, airborne microbes, dust, and vaporized particles.

Chip-on-board and direct-chip-attach assembly (COB/DCA) is typically performed in a Class 10K cleanroom (10K particles per cubic foot) or better since the manufacturing floor isn’t particle-free. With small wires, airborne particles from the surface mount assembly can cause contamination on top of the die or the bonding wire, and a particle on a fine pitch bond pad can interfere with bonding. Particles can cause items to not stick to a chip, leading to water being accumulated at the particle size and eventually corroding the device. [1]

How Cleanrooms Keep Products Clean

To remove internally generated contaminants, the air inside is constantly recirculated via high-efficiency particulate air (HEPA) and/or ultra-low particulate air (ULPA) filters. The air entering a cleanroom from outside is filtered. Some cleanrooms are kept at positive pressure to prevent unfiltered air from entering the room when there’s a leak. Staff enter the cleanroom via airlocks and wear protective clothing, like face masks. Equipment and furniture are designed to produce minimal particles and to be easy to clean. Materials made from natural fibers, such as paper, are often excluded from cleanrooms.

A discrete, light-scattering airborne particle counter is used to determine the concentration of airborne particles, equal to and larger than the specified sizes, at designated sampling locations. Each facility’s cleanliness level is often defined by the number of particles per cubic meter. The number of particles of size 0.5 µm or larger per cubic foot of air is represented by large numbers, like Class 1,000. They’re not free of uncontrolled microbes or sterile; only airborne particles are controlled. To limit microbial contamination, the U.S. and EU designed very stringent guidelines. [2]

Syrma’s Cleanroom for Manufacturing

Built-in 2006, our main facility is based in Chennai’s Special Economic Zone (SEZ). This site is ANSI/ESD S20.20-2014, ISO9001, ISO 13485, ISO 14001, and IATF 16949 certified and IPC-A-610 class II and III quality standards. It provides semi-cleanroom conditions for optical sensors and other precision electronics. Our equipment at this facility includes Fuji SMT lines that provide a total placement capacity of 200K parts per hour with 40-micron accuracy and capable of 3-sigma. This site provides product design, manufacturing, box build assembly, and aftermarket services for our global customers.

Our new 24K square foot facility in Bawal was built in April 2018. It’s located within the Delhi-Mumbai Industrial Corridor inside a Domestic Tariff Area (DTA), which provides cost-savings for our customers. This facility contains a Class 10K cleanroom for our Fuji SMT lines. Our SMT lines in each facility have a total placement capacity of 200K parts per hour with 25-micron accuracy and capable of 3-sigma. This facility manufactures products designed and sold within India for aerospace, automotive, defense, industrial, and medical verticals. It’s 100% RoHS compliant and fully certified for international quality standards.

Backed by 40 Years of Expertise

We contribute our 40 years of design and manufacturing expertise spanning multiple diverse markets. We look forward to discussing how we can deliver world-class products for OEMs across the globe. We understand our home Indian market, familiar with its vast regulatory and selling environments. We foster growth opportunities within India through our strong technology incubation ecosystem. We also assist global OEMs in entering the Indian market by leveraging the local supply chain and favorable operating environments for cost reductions.

Our flagship Chennai location opened in 2006 and lies within a Special Economic Zone (SEZ) for electronics manufacturing, offering economic incentives for imports and exports. This primary facility is within 90 minutes of the Chennai seaport and 20 minutes to the international airport. Additional road and rail connectivity links to the rest of India and beyond and infrastructure advantages with faster import and export clearances. We also have labor force flexibility, both technical and manual, to scale to demand rapidly.

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