Texecom’s New Wave Solder Machine Revolutionises Processes, Build Quality and Efficiency

In the highly competitive world of security technology, Texecom is taking bold strides to stay ahead of the curve. A significant investment in a new wave solder machine has revolutionised the company’s production processes, greatly improving both efficiency and the build quality of its products. As described by Phil Clegg from Texecom, this upgrade has led to remarkable improvements in sustainability, precision, and overall product reliability. Let’s explore how these advancements are reshaping Texecom’s operations.

1. Eco-Friendly Processes: Reducing Waste and Emissions

Texecom’s new wave solder machine is a shining example of the company’s commitment to sustainability. Thanks to a high-accuracy fluxer, Texecom now uses less flux and has drastically reduced waste. Previously, the soldering process generated up to 120 kilograms of dross each month, but with the new system, that figure has dropped to just 10 kilograms. This significant reduction helps cut costs and minimises the environmental footprint.

Moreover, the machine’s air extraction system features carbon & HEPA filters, ensuring that the air expelled is cleaner than the ambient air in the factory. This improvement not only contributes to a healthier workplace but also supports Texecom’s environmental initiatives by enhancing air quality and reducing harmful emissions​.

2. Improving Build Quality with Nitrogen Atmosphere Soldering

One of the most impressive advancements with the new machine is its full length nitrogen tunnel, which greatly enhances the build quality of Texecom’s products. Previously, soldering was done in ambient air, exposing the process to the risk of oxidation, which can affect solder joints. Now, the machine operates in a nitrogen environment with controlled oxygen levels between 100 to 500 parts per million. This atmosphere ensures superior solder-ability, creating stronger and more reliable connections that significantly improve the overall durability and performance of the product​.

By transitioning from ambient air to nitrogen, the soldering process has become far more consistent and efficient, directly contributing to higher-quality end products. This step is critical for Texecom’s security technology, where reliability and precision are paramount.

3. Greater Efficiency with On-Site Nitrogen Generation

Texecom has also made strides in improving cost and process efficiency by generating nitrogen on-site. This eliminates the need for costly liquid nitrogen and ensures a constant, reliable supply of nitrogen for the soldering machine. This improvement not only enhances soldering quality but also boosts operational sustainability.

4. Upgraded Compressor Systems for Cleaner, More Efficient Operations

In addition to the wave solder machine, Texecom has invested in upgrading its compressor system. The new compressors are designed to run only when needed, drastically reducing energy waste. The system produces cleaner, drier compressed air, which is essential for the company’s other equipment, including pick-and-place machines, testers, and vacuum generators.

This more efficient setup also includes nitrogen generators, further enhancing the reliability and precision of the soldering process. The reduction in energy consumption and improved air quality are crucial steps in maximising operational efficiency.

5. Real-Time Feedback with Advanced PCB Checking System

In the quest for superior product quality, Texecom has introduced a PCB (Printed Circuit Board) checking system. Equipped with a 60-megapixel Sony camera, this system allows for real-time verification of components. The system identifies missing or misplaced parts instantly, ensuring that any errors are caught and corrected immediately. This rapid feedback loop enhances the build quality by preventing defects from moving further along the production line​.

6. Selective Wave Soldering: Consistency and Reliability

Texecom has introduced selective wave soldering for specific components like the SmartCom. Selective wave soldering ensures a level of consistency that hand soldering cannot achieve. Hand soldering often introduces variability, which can impact the reliability of the finished product. The selective soldering process eliminates this risk, resulting in consistently high-quality joints that enhance the overall durability and performance of Texecom’s products​.

7. Enhanced Build Quality Across the Board

Perhaps the most significant outcome of these innovations is the overall improvement in product build quality. From the use of nitrogen to eliminate oxidation to the introduction of selective soldering, Texecom’s products now feature stronger, more reliable connections. These advancements lead to longer-lasting, more durable products that meet the rigorous demands of the security industry. The improvements also mean fewer defects and greater consistency across all product lines, from control panels to bell boxes​.

Conclusion

Texecom’s investment in a new wave solder machine and supporting infrastructure has brought about numerous positive changes, not only in operational efficiency but also in the build quality of its products. With eco-friendly processes, state-of-the-art soldering techniques, and cutting-edge quality control systems, Texecom is setting new standards for excellence in the security technology industry. By continually embracing innovation, Texecom ensures that its products are built to the highest quality standards while remaining environmentally responsible and cost-effective.