Circuits Assembly - January 2008 - (Page 26)

ESD Control Moreover, the cost of electricity to drive the compressor was very expensive.” • Noise. The system annoyed workers with a high-pitched whine and spawned constant complaints. Anderson looked at other humidification technologies, including ultrasonic and electric steam systems, but was unhappy with his options. He estimated that an electric steam system would have energy costs of about $25,000 annually, and would require large amounts of time-consuming, costly maintenance and nozzles and steam cores replacement. Energy costs for an ultrasonic system would have been less expensive than electric steam, but more expensive than a highpressure system. An ultrasonic system’s open water bath would require constant maintenance to prevent bacteria and possible air quality problems. Anderson was also concerned about the ultrasonic system’s high installation costs. Furthermore, steam and ultrasonic systems were plumbed with stainless steel pipes, making them more expensive to install and virtually impossible to reconfigure, as Itron’s plant layout changed several times a year. On a suggestion from his energy company, Anderson investigated high-pressure humidification systems as a way to cut his energy costs. He decided on a system from ML System (mlsystem.dk) for a number of reasons: • The high-capacity humidifiers have the capacity (10 gph) and Figure 1. Situated above the manufacturing line, this high-pressure humidification system helps maintain RH levels of 50% year-round. Looking for customers? Look here! The 2007 CIRCUITS ASSEMBLY Directory of EMS Companies • More than 1,250 EMS facility listings • Detailed info on sales, size, contacts, and more! • Price: Only $999 Order online at circuitsassembly.com/dems 26 Circuits Assembly JANUARY 2008 versatility the job required, and could work individually or be aggregated in groups. • The system produces a fine, cool mist that is quickly absorbed into the air. • Integral distribution fans make possible faster, more complete absorption of moisture, even in areas with low ceilings. • The system would provide more precise and consistent humidification. • Estimated energy costs would be $300 a year, less than 10% the cost of the compressor-driven system and 1-2% the cost of an electric steam system. • The system is plumbed with a high-pressure hydraulic hose instead of steel pipe. Anderson determined that would save money on the system’s installation and make future plant layout revisions faster, easier and far less costly. • A payback analysis conducted by his energy company predicted the system would pay for itself with energy savings and improved defect rates in fewer than two years. The new system included eight units configured in two zones: one for warehouse areas, the other for production. The system includes reverse osmosis (RO) water to eliminate minerals in the water by 97%, and a UV filter to kill bacteria. Humidity sensors in each zone monitor RH levels and report to a remote PLC that controls the system. If RH in a zone drops below Itron’s 40% set point, the PLC activates the units in that zone until RH returns to the desired level. The effects were immediate and dramatic. Anderson says, “We could feel the difference in the RH level almost immediately, and the system kept it at a uniform level. Our ESD numbers improved quickly.” Anderson says Itron has had very few mechanical problems with the system. When the plant was expanded in 2004, six more units were added, almost doubling the number of units, without having to increase pump capacity. “Now it’s virtually automatic; we rarely think about dry air and static electricity,” he says. “They really aren’t issues anymore.” ■ Pierre Husson is president of Husson Inc.(hussoninc.com); husson@hussoninc.com. circuitsassembly.com http://circuitsassembly.com/dems http://www.hussoninc.com http://circuitsassembly.com

Table of Contents Feed for the Digital Edition of Circuits Assembly - January 2008

Circuits Assembly - January 2008 Contents Caveat Lector Industry News Market Watch Talking Heads Focus on Business On the Forefront Screen Printing Better Manufacturing Walking on Water Flux Selection for Lead-Free Wave Soldering An A-to-Z Guide to X-Ray Inspection, Part II Evolution in Action Research Priorities for the Electronics Industry Selective Soldering Process Doctor Pb-Free Lessons Learned Materials World Product Spotlight Ad Index Assembly Insider Technical Abstracts

Circuits Assembly - January 2008

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