Case Studies

Automating Your Technology™

Multiple Lane Carrier Tape Forming Process for the Electronics Industry


A manufacturer of electronic components needed a cost effective carrier tape solution for the high volume requirements of three of their key product lines. The solution had to be produced in North America for a number of reasons; they needed to avoid the high logistical costs associated with Asian suppliers. Plus a domestic supplier would also be better able to implement and support their JIT initiatives.


We analyzed the situation and developed a multiple lane carrier tape forming process that nearly quadrupled the speed of manufacturing. This new process utilized a precise cam driven material advancement system with up to four lanes of forming capabilities, as opposed to the one lane that they had been using.

The new high speed multi-lane forming machine featured punching, vision inspection, slitting and options for single or cross winding the completed carrier tape.

It was also able to meet the customer’s high volume consistency and accuracy requirements with production speeds of up to 900 meters per hour and nearly 5,000,000 meters production capacity per machine annually. For more information, see the table below or contact us directly.

Service Name High Speed, Multi-lane Forming Machine
Service Description
  • Up to 4 lanes of production
  • Cam driven
  • Precise forming
  • Quadruple Cross-winding capabilities
  • High Speed with low operator requirements
Capabilities applied/Processes Project Requirements:

  • Needed 1 machine to be able to do the work of 4 standard forming machines, yet keep the same amount of operator involvement as a standard former requires
  • Multiple lane output lowers the material waste
  • Increases speed and output
  • Consistent and Accurate pocket formation
  • Vision inspection system requires 100% product inspection so there is no compromise on quality
  • All processes done inline including slitting, forming and winding
  • High speed + low material wastage + low operator involvement allows us to price the product very competitively to compete against overseas prices
Overall Part Dimensions
  • Can produce 3 lanes of 16mm wide tape at one time
  • Can produce 4 lanes of 12mm wide tape at one time
Tightest Tolerances Able to produce tape holding a +/-.10mm tolerance
Material used in Machine Production KEASTAT™ I.S. Polystyrene or Carbon Polycarbonate
In Process testing/inspection performed Machine has an inline vision inspection system monitoring 100% of the formed pockets
Industry for Use Electronics, Consumer, Medical and Industrial
Volume Up to 5 million meters annually per machine
Standards Met Customer Specifications, produces product adhering to the current EIA 481 standard