Electronics Manufacturing

Creating An Optimised Compressed Air System

• Compressed air plays a critical role in the manufacturing of electronics and semiconductors
• Why is air quality so important?
• How can Ingersoll Rand help you build an optimised system?

From semiconductor assembly, electronic components manufacturing, fuel cell production, and printed circuit boards and board systems (PCB) to flat screen and display manufacturing, compressed air plays a vital role in the electronics industry. All of these processes require Class 0, high-quality compressed air.

Why Is Air Quality So Important?

In the electronic and semiconductor sectors, product quality and safety are two critical considerations, as product defects can have serious consequences. Even the slightest amount of contamination can compromise sensitive electronic components, which renders air purity uncompromisable! It’s, therefore, essential to have a reliable compressed air system in place that not only operates efficiently but also delivers a continuous flow of high-quality Class 0 air to the point of use. This is where Ingersoll Rand comes in!

How Can Ingersoll Rand Help You Build An Optimised System?

We’ve worked with global electronic and semiconductor manufacturers to understand what it takes to build an optimised system that meets industry and application requirements. As a result, we’ve devised a 6-step plan of action…

1. Prioritise Air Quality

As mentioned above, the slightest bit of contamination can compromise product quality, making Class 0 air essential. Ingersoll Rand offers industrial oil-free rotary and centrifugal equipment ideal for this industry. Our machines are ISO 8573-01:2010 certified to mitigate all risks of oil content in the downstream installation and point-of-use. This ensures the continuous delivery of application-appropriate air. We’d also urge you here, though, to not forget about air treatment! Compressed air dryers are designed as the perfect companion to your system, ensuring your air is not only clean but dry! Removing moisture this way can largely benefit your electronics facility, as it helps protect your manufacturing and processing equipment from rusting and corrosion. 

2. Optimising System Design

Did you know that most, if not all, downtime can be attributed to incorrect or unmaintained equipment? This makes it important to consider your system’s design, as a good, optimised design maximises efficiency and reduces operational costs. On the other hand, a badly designed system can lead to catastrophic product spoilage and downtime. There are 3 things to consider when optimising your system design: 

Correct Sizing: When it comes to compressors, one size really doesn’t fit all. Therefore, it’s vital that your machines are appropriately sized for the scale and demand of your electronics manufacturing. Otherwise, oversized equipment can lead to unnecessary energy consumption, while undersized equipment can make it difficult to meet demand.

Piping Layout: To minimise costly pressure drops, design your piping system using the shortest, most direct routes with the fewest fittings and elbows.

Leak Detection and Repair: Implementing a leak detection program to identify and repair leaks promptly can help prevent significant energy losses caused by even minor leaks.

3. Implement Energy-Efficient Solutions

Energy efficiency = cost savings and environmental sustainability. For example, implementing energy-efficient solutions can benefit you as a 1% improvement in efficiency equates to roughly a 1% savings in operational costs. With only a 1% efficiency improvement, a 1,000kW compressor running 24 hours daily could save as much as 90,828 kWh per year. You can also implement variable speed drives (VSDs) to keep up with fluctuating demand and arrange regular energy audits to make sure you are operating at your most energy efficient.

4. Ensure System Redundancy

Redundancy = preventing downtime, which is critical in maintaining continuous electronic and semiconductor production. Using multiple compresses in a staged or backup configuration can prevent unplanned downtime by ensuring a working compressor is always available. Automated controls also help here, as these systems can enable the seamless switch between compressors to manage load distribution effectively. Proactive control can be enabled through Ingersoll Rand’s EcoPlant. 

5. Regular Monitoring and Maintenance

Most unexpected and costly inefficiency can be solved through regular monitoring and maintenance! It also helps to maximise uptime and extend the lifespan of your system. Remote monitoring can be enabled using Ingersoll Rand’s 24/7 Helix™ Connected Platform, which can alert you of issues before they become downtime. We also offer a suite of CARE™ maintenance packages to suit your electronic facility’s exact needs. 

6. Work With Experts

Professional guidance ensures your system is designed and maintained to the highest standards. Ingersoll Rand offers consultation services with compressed air experts, as well as OEM parts and services, to ensure quality is upheld!