Manufacturing processes in micromechanics, electronic and optical devices, as well as batteries and fuel cells, are sensitive. Even the smallest particles of dirt can lead to costly defects. The conveyor technology specialist "mk" has mastered cleanroom solutions and offers pristine "mini-environments".
Following a completely different kind of "mess"—namely, an IT attack by unknown perpetrators in mid-May of this year—the company in Troisdorf had to contend with significant disruptions for a total of four months. For security reasons, all systems had to be shut down while the IT department, together with external specialists, worked on an orderly restart of the systems. During this time, according to management, material movements were impossible and communication was severely limited. Operational capability could only be restored gradually. Large volumes of inquiries and orders piled up without being processed.
In between, everything was turned down
It took two weeks before operations could resume in some areas. By mid-June, the automated warehouse was back online, allowing us to supply profiles and components without design elements. Shortly thereafter, the aluminum profile online shop was reactivated, and the design department was partially restored to working order, enabling us to process orders for conveyor technology and transfer systems.
This is a significant challenge for a company that is currently making remarkable progress in cleanroom technology. The importance of automation in cleanrooms and laboratories is constantly increasing. More and more technical products place high demands on technical cleanliness during their manufacturing. Manufacturers and integrators face the challenge of relocating automated processes, and thus also the conveyor technology, to meticulously clean environments. Alternatively, automation solutions are also implemented as so-called mini-environments, for example, in encapsulated systems. At mk, these are designed for low particle emissions, optimized for easy cleaning, and certifiable according to ISO standard 14644.
All photos: mk Technology Group
Cleanrooms are classified according to ISO 14644 based on the quantity and size of contaminating particles, ranging from cleanroom class 1 (highest purity) to cleanroom class 9.
Manufacturing processes in the aforementioned industries typically take place in cleanrooms or mini-environments of classes 5-9. mk has also specialized its conveyor belts for these cleanroom classes and adapts them to the respective cleanroom concept. Belt conveyors and toothed belt conveyors are customized to meet the requirements. For example, the GUF-R 2000 cleanroom belt conveyor with a smooth-walled motor, designed for minimal wear, bythe Fraunhofer Institute for Manufacturing Engineering and Automation IPA as early as 2015.
Since no standards exist for the design of cleanroom conveyor technology, the supplier's know-how and experience are crucial. At mk, surfaces in cleanroom technology are smooth, easy to clean, and corrosion-resistant against cleaning fluids, as are conveyor belts; a direct drive with a suitable motor (smooth-bore or drum motor); drive rollers, bottom belt plates, etc., made of stainless steel; and cleanroom profiles preferably in a closed design.
Fire vent: Protection against microparticles
Moving parts that could potentially generate abrasion are located below the transport level and positioned according to the airflow direction. Conveyor drives only run when transport is required; speeds are regulated ("no faster than necessary"); and stagnation with relative movement between the conveyed medium and the conveyed goods is avoided.
Specifications also take into account ESD, LABS, microorganisms, and other aspects of technical cleanliness. After a break-in period (with documented decay curve) and final cleaning, the conveyor belts are delivered hermetically sealed. This ensures rapid commissioning in the user's cleanroom. Furthermore, individual testing and certification of the conveyors by an independent testing institute is also possible.
