Air Compressors for the Electronics Industry

In the world of electronics manufacturing, where precision is paramount and even microscopic contaminants can derail production, compressed air plays a crucial role. From powering pneumatic tools to maintaining cleanroom environments, reliable, high-quality compressed air is essential for ensuring product quality, efficiency, and compliance with stringent industry standards.

This guide explores the unique compressed air needs of the electronics industry, examining the types of compressors commonly used, the importance of air purity, and the critical maintenance practices that keep operations running smoothly.

Understanding the Specific Needs of the Electronics Industry

In electronics and semiconductor manufacturing, air purity is of utmost importance. Even microscopic contaminants such as oil droplets or moisture can cause defects in sensitive components like semiconductors and PCBs. These issues can lead to costly product failures, production downtime, and damage to a manufacturer’s reputation.

Manufacturers depend on oil-free air compressors that meet stringent ISO Class 0 air quality standards to prevent contamination. Certified oil-free compressed air eliminates the risk of oil contamination, which is essential for electronics manufacturing. Additionally, clean, dry air is crucial, as moisture can corrode circuit boards and cause short circuits. For this reason, advanced air treatment solutions, such as desiccant or refrigerant dryers, are often integrated into compressed air systems.

Selecting the right air compressor equipment—whether it’s screw or centrifugal compressors—ensures high-quality air, minimises downtime, and optimises production processes. By investing in oil-free solutions, electronics manufacturers can safeguard the integrity of their products and achieve reliable, defect-free results.

Types of Air Compressors Used in Electronics Manufacturing

In the electronics manufacturing industry, the main types of compressors used are:

1. Oil-Free Rotary Screw Air Compressors: These are the most common choice for electronics manufacturing due to their ability to deliver completely oil-free air, which is critical to prevent contamination of sensitive electronic components. They are also known for their reliability, efficiency, and quiet operation. 
   
2. Oil-Free Scroll Compressors: These are another type of oil-free compressor that is gaining popularity in the electronics industry. They are compact, efficient, and have low maintenance requirements, making them well-suited for smaller facilities or applications where space is limited. 
   
3. Oil-Free Reciprocating Compressors: While not as common as rotary screw or scroll compressors, oil-free reciprocating compressors can still be found in some electronics manufacturing facilities. They are generally less expensive upfront but may require more maintenance and can be louder than other types of oil-free compressors.
   

The right compressor involves several key factors. Above all, air quality is paramount, as 100% oil-free air is essential to prevent damage to sensitive components. Reliability is also crucial, as production often runs continuously and any downtime can be costly. Efficiency plays a significant role in minimising operating expenses and reducing the environmental footprint. 

Beyond these primary considerations, the compressor’s size, maintenance requirements, and overall cost must also be factored into the decision, balancing upfront expenses with potential long-term savings. 

Using air compressors in semiconductor and electronics production

The cleanliness standards in electronics manufacturing can be many times higher than in an operating theatre. Despite their sophistication, intricate semiconductors integrated circuits can be surprisingly delicate, and even a single mote of dust in the wrong place during production can result in the failure of electronic devices.

Compressed air plays a critical part in maintaining a cleanroom environment. From removing contaminants as part of an entry protocol, to serving as a contactless tool to move components, or even using the highly filtered pressurised air to regulate temperatures inside.

Customised compression for the electronics industry

We have seen air compressors deployed to power almost any task imaginable. Our design team can create a custom installation that meets your requirements.

Common uses of compressed air can be as straightforward as powering a conveyor and a picking and packing process after manufacture, something that even at that stage requires a delicate touch. However, we can also make an installation that helps you to automate more complex tasks. This might include automated parts of the production process, cleaning of electronic components used during manufacturing, and even testing.

It’s important to design systems for the use you need. You might want class 0 compressed air in a cleanroom, but can use a much lower standard to drive the conveyor belt in your final packing process. An Anglian Compressors’ custom design means you have a system that is perfect for your manufacturing process, and it means you never have to pay more for a higher specification of air than the task demands.

Generating nitrogen on-site

Nitrogen generation is a popular use of air compressors in many industrial sectors. Nitrogen constitutes about 80% of the air we breathe (and compress), and as well as being harmless to humans, it is unreactive. This makes it useful for electronics manufacturing since the lack of oxygen also prevents oxidisation during soldering processes.

But on-site nitrogen generators are not just about convenience, it is cheaper than relying on bottled supplies. Not only do you avoid having to pay for costly deliveries because you control the generation, but you also get exactly the specification and volume of gas that you need.

And it’s safer, too, as you no longer have to manage, store, and move heavy compressed gas cylinders. Plus, it’s all done without any harmful by-products, the ‘waste’ from generation is ordinary water and oxygen.

Maintenance Tips for Optimal Performance

Just like any vital piece of equipment, your air compressor requires regular maintenance to ensure optimal performance, maximise its lifespan, and prevent costly downtime.

While we’ve covered air quality testing and specific equipment choices, remember that simple, routine maintenance tasks can make a world of difference:

• Drain condensate tanks regularly: This removes excess moisture that can lead to corrosion and microbial growth.
  
• Replace air filters according to the manufacturer’s recommendations: Clogged filters reduce efficiency and can impact air quality.
  
• Be vigilant about air leaks: Even small leaks can significantly reduce compressor efficiency and increase energy costs. If you suspect a leak, address it promptly.
  

For expert guidance and to ensure compliance with industry standards, schedule professional inspections with us! 

Future Trends in Air Compression Technology

The future of air compressors in electronics manufacturing is focused on efficiency and innovation. Variable Speed Drive (VSD) compressors are becoming increasingly popular due to their ability to adjust output based on demand, reduce energy consumption, and optimise production processes.

Another key trend is the rise of smart compressors, which utilise IoT technology to monitor performance in real time, helping manufacturers minimise downtime and maintain consistent air quality. In cleanroom environments, where purity is crucial, oil-free air compressors ensure certified oil-free air, eliminating the risk of contamination.

Sustainability is also driving the adoption of energy recovery systems, which repurpose the heat generated by compressors, further enhancing efficiency and reducing costs. These advancements enable electronics and semiconductor manufacturers to boost productivity while adhering to strict air quality standards.

A crucial part of electronics manufacturing

Compressed air has been used in manufacturing and industry for over a hundred years — even longer if you include the bellows used in forges — and it might feel out of place in high-tech sectors like electronics.

However, it is becoming more, not less, essential as technology advances.

The need to ensure that semiconductors are manufactured without the slightest bit of contamination, or that printed circuit board solders are effective, or that components are placed accurately, and with the correct level of force, means that high-quality, calibrated equipment is essential. And compressed air can power all those uses and more.

But when your processes rely on this, you need to be able to rely on your air compressor.

Anglian Compressors has been installing and servicing air compressors for electronic manufacturing for decades. Our team can design and install a system using one of Atlas-Copco’s award-winning range of compressors that will meet your needs exactly. And if you already have a compressor, our engineers can service any model of air compressor.

Our service plans range from call-out options to full servicing and maintenance programmes. We audit and test equipment at every visit, so you can be sure that your compressor is working exactly as you need, and that the air or gas you rely on meets the standards you require, however demanding they might be.

Just get in touch with our team and find out how Anglian Compressors can help you with your compressed air needs, both now and in the future.

FAQ

Why do manufacturers prefer oil-free air compressors for electronics manufacturing?

Manufacturers prefer oil-free air compressors for electronics manufacturing because they eliminate the risk of oil contamination, which is critical for maintaining clean air for sensitive electronic components. Oil-free compressors ensure compliance with stringent ISO Class 0 standards, protecting products from defects caused by contaminants and optimising the overall production process.

How do air compressors ensure cleanroom standards in semiconductor manufacturing?

In semiconductor manufacturing, maintaining cleanroom environments is essential to prevent contamination. Compressed air solutions for semiconductor applications typically involve oil-free air compressors to ensure ultra-pure, contaminant-free air. These systems are designed to provide the high level of compressed air quality required for precise and sensitive operations in cleanrooms.

What are the benefits of using Variable Speed Drive (VSD) air compressors in electronics manufacturing?

Variable Speed Drive (VSD) air compressors offer high energy efficiency by adjusting air output according to real-time demand, reducing energy consumption and operational costs. These high-performance air compressors are ideal for electronics manufacturing, where precise air control is needed to minimise downtime and optimise production processes.