Press Release – LED Lighting Solutions Ltd – 11 th Sept 2013

LED Lighting Solutions, the Burscough based light engine manufacturer is pleased to announce that it will install an LED ‘Super-Line’.

This line is designed to enable the production of a very high volume light engines within a short period of time.

The company currently has 3 pick and place machines on its head office site, a further 9 machines at its Burscough site. These are serviced by 9 fully automated stencil printers and four 100kW IMS reflow ovens and assorted ancillary equipment.

The new ‘Super-line’ will incorporate 8 linked pick and place machines, a high speed dual lane stencil printer and 100kVA Nitrogen interting forced cooling reflow with the associated loader and off-loader systems to allow for un-manned operation. Picking LEDs from 48 reels at once with triple loaded feeders means that it can be loaded as a line with 288,000 LEDs which are picked by 48 heads in parallel. An LED TACT time of just 15 mSec – equivalent to 66 LEDs per second. The purchase of another 100 feeders and 160 placement specific nozzles adds to the flexibility of the operation.

This line will allow placement of 240,000 LEDs per hour and will double the companies capacity to 480,000 devices per hour.

This is the first line in the UK to be installed using ‘floating board’ technology which allows the machines to move the PCB around during the build to self-optimise the process. In addition, for the first time, laser co-planarity scanning is included to determine the exact 3 three dimensional profile of the PCB within the placement environment and optimise placement travel.

The increase in power available due to completion of a new sub-station ( now a total of 0.5MVA of power ) also means that the purchase of a further three reflow ovens ( taking the total to 7 at the LED site ) provides increased flexibility for the company to operate the smaller machines.

New optimisation software also being installed allows complete transparency of running jobs across any of the available lines and streamlines job planning and costing accuracy.

Commissioning of the line is due in December 2013 in the new 6000 sqft dedicated assembly area which has just been completed.

The addition of this £2.1m investment in UK manufacturing to the £1.3m invested in machines in August 2012 and the £3.1 of LED stock places the company in a strong position to provide competitive light engines, built in the UK to exacting standards with a very non-UK leadtime package.

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A massive investment program has now been completed resulting in the aquisition of the following brand new state of the art equipment

 
New factory at Burscough - Brand new facility, air conditioned and climate controlled
  • Latest DEK Horizon 03i stencil printer with under stencil cleaning system
  • I-pulse M4e mounting system ( 12,000 CPH )
  • I-Pulse M2 mounting system ( 18,000 CPH )
  • Total placement of 30,000 CPH
  • Cooper Rason Board de-stacker
  • Cooper Rason Board Offloader
  • 2 x Cooper Rason inspection conveyors
  • JT NS900 Nitrogen inerting 16 zone oven with forced cooling
  • K5L AOI inspection system
  • SDG 3D CNC router, 3.0 metres by 2.0 metres working bed
  • SDG CNC laser system
  • Xtreme Humidity chamber for storage of LEDs
  • LED illumination
  • Heat recovey system to minimise overheads and provide both heating, cooling and de-humidification
  • Off-site meeting rooms in addition to main site
 
New equipment at existing Factory at Wight Moss Way
 
  • Europlacer Iineo VLW line capable of placing PCBs of 1.6 metres by 400mm - can be reversed to produce 3.2 x 400mm PCBs in a single pass - additional 15,000 CPH
  • Total CPH is now 71,000 CPH through 5 lines, 3 stencil printers, 2 ovens
  • I-Pulse K5L AOI system
  • Cooper Rason conveyor system
  • JTNS900 16 Zone reflow oven with forced cooling system
  • Purex Fume and heat recovery system

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KLH orders another Europlacer line

The new model Flexys 10 placer has now been ordered and delivery confirmed for the end of March. This has full on the fly vision centering, 8 heads from a bank of 32 dot coded nozzles. The unit can handle PCBs up to 500 x 480mm and has a feeder capacity of 128 lanes plus 10 matrix trays. 0201s, CSPs and flip chips are the machines lower size limits with 01005s as an option, 50mm components being the largest standard component that can be placed.

This affords another 400,000 component placements per week and will primarily be used for uBGA and flip chip work having specialist control of the Z axis movement. In full line mode, this now takes our achievable placement to 53,500 per hour or some 2.1 million devices per week on standard shifts.

Also just ordered are a further 82 feeders for tape / reel, all smart feeders with barcode recognition. These are usable on the new line as well as the primary high speed line. This takes our tape and reel feeder to in excess of 365 lanes. These can be moved 'on the fly' to optimise machine utilisation.

Additionally, we have just completed negotiations with Europlacer for two very high speed belt feeders for ICs where they are not available on tape and reel or we need to place less than 2500 devices. Each of these 10 lane devices can feed at up to 6 ICs per second per lane and can be used on the 24, 8 or 4 head machines. In addition to our vibratory feeders, we can now feed a total of 38 lanes of stick fed ICs onto 5 different placement;turrets with a total of 37 heads.

Finally, we have also ordered a further matrix tray feeder which increases our capacity from 12 to 22 different tray fed components. These can be combined to allow for in excess of 1000 devices to be held on the line before reloading in required.

All the additions will of course be integrated into our line optimisation software to ensure maximum throughput and optimisation of productivity.