AVX

AVX is a leading global manufacturer of advanced electronic components. As of 2010, their flagship manufacturing plant was based in Paignton, Devon, UK.

Working at AVX from 1999 to 2013.

Paignton is feted more as a gentle seaside resort rather than for its high tech credentials, but the AVX tantalum capacitor facility was the spearhead operation of a $120 million investment that was made in the UK, Czech Republic and El Salvador. The central focus of the work at Paignton was the miniaturization of surface mountable capacitors.

The AVX Facility in Paignton was geared up to undertake the full manufacturing cycle of tantalum capacitor TAC microchip from beginning to end.
It was a ‘wafer’ based system where tantalum powder was built onto the wafer, chemically processed, then using dicing techniques taken from the semiconductor industry was loaded into carrier tape.

In 1999 I incorporated DDA (UK) Limited having been established to take on the responsibility of development, design, manufacture, assembly and commissioning of four automated process to be installed at AVX Long Road, Paignton. 19 people were taken on full time to undertake this work.

Operating in a toxic and hazardous environment, the total system comprised of heavy-duty robotic gantries, loading and unloading stations, chemical dipping tanks, continuous and static ovens, indexing and continuously running conveyors, automatic door and oven lid opening mechanisms and numerous safety systems.

Below are sections of the actual process line installed at the Paignton site along with electrical and electronic systems connected with the project.

AVX, Long Road, Painton. The project was to design and build the complete electrical/ PLC control systems and mechanical handling assemblies for 5 large, automated cells to include chemical processing, heating, and drying of wafer mounted electronic devices.

The process was the repeated immersion of tantalum anodes into tanks containing dilute manganese nitrate, followed by several passages through two 25m ovens operating at approximately 260 Degrees C.

Then after a specified number of repetitions, the product was treated electrolytically to reform (repair) damage to the anodes.

The system involved the precise controls and synchronisation of six heavy duty robotic gantries working in three dimensions to both static and moving targets in sequences determined by a ‘Scheduling Programme’ developed by
Professor Paul Rhodes of Bradford University.

Polypropylene was used for handling manganese nitrate chemical solution in dip tank assemblies.

Operation of each gantry involved the carrying of heavy trays of multiple anodes covering distances of up to 130sq m.

Panel build of Parker Zeta 6104 Stepper Motor Drives. Chosen to control critical manganese levels across 68 dipping tanks.

Nine networked Mitsubishi A1S series PLC’s and eighteen Compax NMD10/ NMD20 Servo Drives were chosen to precisely control the gantries and complementary safety systems.

The completed system had an overall guarded area of approximately 782sq m. All operations were required to be carried out without any manual intervention.

Finalizing completion of Stepper Motor Drive cabinet.

‘In House’ designed Opto Isolated Relay Output Boards working in conjunction with Zeta 6104 Drives.

‘In House’ designed electrolytically treated process control.

Spencer Coope at DDA (UK) offices overseeing important technical detail.

Steve L, DDA store facilities. Oak Tree House, Aspen Way, Paignton.

By the end of 2001, AVX had 26 plants in 12 countries, 21,000 employees, and sales revenues of $2.6 billion.

But the boom in the capacitor industry proved temporary. Customers bought more products than they needed, and coupled with a recession, put an end to the good times.

Revenues dropped and layoffs reduced employees to 12,500. Production moved to Czech Republic in 2009 and China 2010 onwards. AVX Paignton finally closed its doors in 2010.

Decommissioned and shipped to Czech 2009

The entire manganese process line was stripped down, shipped and reinstalled at AVX Lanškroun, Czech Republic.