Multiple Lane Carrier Tape Forming Process for the Electronics Industry

The Challenge:

An electronics-component manufacturer needed a cost-effective carrier tape solution for the high-volume requirements of its three key product lines.

It solution had to be made in North America to avoid the high logistics costs of Asian suppliers and to support the customer’s just-in-time (JIT) initiatives with a domestic partner.

The Solution:

Keaco analyzed the requirement and developed a multiple-lane carrier tape forming process that nearly quadrupled manufacturing speed versus the customer’s previous single-lane setup.

The high-speed machine uses a precise cam-driven material advancement system with up to four forming lanes, plus inline punching, vision inspection, slitting and single or cross-winding.

Running all processes inline, with high speed, low material waste, and low operator involvement, let Keaco price the tape competitively against overseas suppliers.

The Results:

Production speeds up to 900 meters per hour, and nearly 5,000,000 meters of annual capacity per machine.

100% of formed pockets inspected by an inline vision system. No compromise on quality at speed.

A domestic, JIT-friendly supply the customer could rely on for three product lines at once, to EIA-481 standard.

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

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