Our 13 competencies

As a partner in electronics development and electronics design, we offer our customers help to develop complete specifications. We offer coaching right from the idea stage to ensure that the product will be developed to provide maximum added value to the customer.

A team with representatives from development and customer service ensures that the development projects will be implemented according to agreements.

A successful development project is typically dependent on agreed prices and project plans, as both price and time factor may be crucial for the future of the product. Having some of the best design engineers in hardware, software and firmware, and a business-related market understanding, we ensure that the development projects are implemented to the satisfaction of our customers.

1 – Product Engineering and – Documentation

If the customer decides to develop the product himself we offer assistance to make the PCB layout, product engineering and production of prototypes and we prepare all necessary documentation for the production.

Throughout the development process the customer is free to draw on our extensive component database with information on delivery times, prices etc. The start-up of the production takes place in close cooperation between the customer and our internal project team, which consists of representatives from the purchasing department, customer service and the development department. Throughout the project the customer has a project manager at Crysberg as daily contact.

2 – Procurement of Electronics

As much as we want to be our customers’ preferred partner, equally important is our relationship with our suppliers and subcontractors. Reasonable purchase prices and reliable delivery times are important success factors in industrial electronics.

In cooperation with our customer service the purchasing department ensures that the customer receives relevant feedback on the delivery of components, prices etc. With each client, we enter into individual agreements to the extent the customer wants us to take care of purchasing and stocking of the components etc.

3 – Production of Prototypes

Our separate prototype department makes us prepared for swift delivery of prototypes. In recent years we have seen a growing demand for manufacturing of prototypes. It is often customers, who just need a single prototype or a small lot, but also large customers, who have new products under development. We can help with such a development and production of advanced electronics solutions from idea development to final production. Crysberg’s machines are:

The SMT Prototype line is equipped with an analog Siemens Siplace F4 SMT Pick and Place machine from 2005 with a capacity of 10,000 components /hour.

The SMT Production line consist of a DEK Screen printer model Horizon 03iX with full vision, a Siemens Siplace S-27 SMT Pick and Place machine from 2006 with capacity of 27,000 components /hour and a Siemens Siplace D1 SMT Pick and Place machine from 2009 with capacity of 15,000 components /hour. The throughput of the SMT production line is 42,000 components/hour. The line has a Heller 1706 EXL-N Reflow oven with nitrogen option. The line is equipped with conveyor system and loaders, stackers and un-loaders from TEKNEK.

For machine soldering of THT components a SEHO PSC 8035 with nitrogen-wave option is used.

4 – Electronics Manufacturing and Industrial Electronics

The geographical location of Kvistgaard near the Capital of Denmark, Copenhagen means that we are in close contact with our customers, who expect high quality and security for quick and flexible delivery of small and medium product series.

Crysberg offers production of electronics both SMT and THT, PCB assembly, advanced device assembly and box-build. SMT and leaded electronics assembly occur after the globally recognized IPC-A-610 standard class 1, 2 & 3 and all of our operators are trained and certified accordingly.

Besides PCB assembly, we also offer cleaning, varnishing and encapsulation of PCB. We record all observations of the production in a data collection system, we offer our customers tailored reports for data on their products

Lead-free soldering according to the RoHS directive

The RoHS directive took effect on the 1 of July 2006, and is required to be enforced and become law in all EU member states. This directive restricts the use of six hazardous materials in the manufacture of various types of electronic and electrical equipment.  This means that electronics equipment, with certain exceptions must be lead free. Our soldering process provides the power needed to run lead-free production, so that we meet the guidelines of the RoHS directive.

5 – SMT and Leaded Assembly of Electronics

The SMT Prototype line is equipped with an analog Siemens Siplace F4 SMT Pick and Place machine from 2005 with a capacity of 10,000 components /hour. We mount all types of components e.g. SMT size 0402. The production of SMT is streamlined by more than 40%, because “waiting positions” are avoided. The operators do not move the PCB´s around from process to process and the machines do not stop at breaks nor, when components are loaded on the machines.

• ​Our SMT in-line production equipment combines economies of scale so that our customers receive high quality products at competitive prices and a guaranteed fast and flexible delivery of small and medium product series.
• ​The SMT Production line consists of a DEK Screen printer model Horizon 03iX with full vision, a Siemens Siplace S27 SMT Pick and Place machine from 2006 with capacity of 27,000 components /hour and a Siemens Siplace D1 SMT Pick and Place machine from 2009 with capacity of 15,000 components /hour. The throughput of the SMT production line is 42,000 components/hour.
• ​The line has a Heller 1706 EXL-N Reflow oven with nitrogen option. The line is equipped with conveyor system and loaders, stackers and un-loaders from TEKNEK.

SMT production

• ​The bare PCB´s (Printed Circuit Boards) are initially handled by the Bare Board Loader, which automatically delivers one PCB at a time into the DEK screen printer, where it before printing will be screened in 2D vision. A camera observes that the stencil and the print are correctly positioned over each other. The PCB is then redirected into the SMT Pick and Place robots that automatically mount the various SMT components on the PCB.
• ​The assembled PCB is now running through the inspection line, where the
• operators make a visual inspection and have the option to install components manually. The PCB is then transported into the reflow oven, where 6 special heating zones make the soldering process. Eventually, the finished, mounted printed circuit boards are placed in a loader that in those cases, where there is a need for SMD mounting on both sides of the PCB, can be reversed. In this case the loader acts as an un-loader, and the process starts again.

Machinery in Crysberg´s production
 

• ​DEK Horizon 03iX Screen printer with full 2D vision
• ​Siplace 80-F4 SMT Pick and Place machine with a capacity of 10,000 comp. /hour
• ​Siplace S-27 SMT Pick and Place machine with a capacity of 27,000 comp. /hour
• ​Heller 1706EXL-N Reflow oven (SMT soldering), nitrogen option
• ​TEKNEK conveyor equipment and Loaders, stackers and un-loader
• ​Siemens Siplace D1 SMT Pick and Place machine with a capacity of 15,000 components / hour
• ​SEHO 8035 PCS Wave Soldering for THT, nitrogen option
• ​Machine for cleaning, varnishing and coatin

6 – THT (Through hole technology) electronics assembling

Our department for leaded electronics assembly consists of highly skilled installation technicians with many years experience in the electronics industry. Our staff is flexible and can basically do all the tasks within leaded THT electronics assembly, device assembly and box build. The technicians work in autonomous groups. All our installation technicians are trained and certified according to the Workmanship IPC-A-610 standard Class 1, 2 and 3.

7 – Potting and conformal coating

At Crysberg we have many years experience in cleaning, varnishing and potting of mounted PCB´s. Since the start of the company in 1986 we have cleaned, varnished and potted the decoders for golf irrigation systems sold throughout the world. The Coating machine is built in modules of four floors, where the PCB´s are either mounted in frames or placed in especially-built wireframe that runs through an elevator shaft. The Finishing line can handle PCB´s in a size of up to 30×25 cm.

Clean, varnish and potting

At the bottom module, the subjects are cleaned and varnished. The process is a three phase process followed by a sealing using paint. The items are dipped into three different tubs; the last bath is a special process, which ensures that all residues of fluxes are removed before sealing. After cleaning and drying the PCB´s runs to the actual sealing process. The entire process takes place in a closed system with compulsory extraction.

We use a DuPont PUR Casting Resin CE 12 casting material to all our castings. It is a two-component casting-resin with which we have very good experience. We have used it for more than 20 years to protect the electronics in our golf irrigation decoders. We have decoders spread around the world, which have been buried in soil for over 20 years and still work as intended. Crysberg casts more than 80,000 units a year, and we have broad experience in both fully and partly casted PCB´s.

8 – Device assembly and Box-build

Our section for device assembly and box-build consists of the same highly skilled technicians, who make leaded electronics assembly. From part lists and drawings, we assemble the devices in accordance with customer expectations and high standards for quality and reliability.

Crysberg controls the entire process from procurement of mechanical parts with their own suppliers to coordinate cooperation between the customers and their suppliers to the test of the finished product.

Many of the customers of Crysberg operate in the global market and sell products and services that are often vital to the security of the end users. The cooperation between Crysberg and the customer is based on years of trust that Crysberg delivers error-free products and services of high quality to provide reassurance to the end user

9 – Workman-ship/IPC-A-610

Crysberg mounts and solders PCB´s and makes device assembly according to the globally recognized Workman-ship/IPC-A-610 standard class 1.2 and 3, in which all Crysberg installers are trained and certified.

Workmanship/IPC610 is one of the world’s most widely used standards for electronics assemblies and is a must for everyone involved in quality assurance in the soldered electrical and electronics collections. IPC 610 standard is divided into three classes, where class 3 is the best.

Classification Accept and/or reject decisions shall be based on applicable documentation such as contracts, drawings, specifications, standards and reference documents. Criteria defined in this document reflect three classes, which are as follows:

Class 1: General Electronic Products Includes products suitable for applications, where the major requirement is function of the completed assembly.

Class 2: Dedicated Service Electronic Products. Includes products, where continued performance and extended life is required, and for which uninterrupted service is desired, but not critical. Typically the end-use environment would not cause failures.

Class 3: High Performance Electronic Products. Includes products, where continued high performance or performance-on-demand are critical, equipment downtime cannot be tolerated, end-use environment may be uncommonly harsh, and the equipment must function, when required, such as life support or other critical systems.

RoHS directive and unleaded solders IPC-A-610, which internationally is the most popular standard approval for the electronics industry has been released in a new version of IPC-A-610D, which is adapted to new production technologies and component – and types of materials and the use of unleaded metal compositions, etc.

Crysberg has upgraded all production employees to the new standard IPC-A-610D, so they are trained and certified under the guidelines in the RoHS Directive. Qualcert is Crysberg’s partner in IPC-A-610 training and diplomas.

RoHS (Restriction of Hazardous Substances Directive) RoHS is often referred to as the lead-free directive, but it restricts the use of the following six substances:

• ​Lead (Pb)
• ​Mercury (Hg)
• Cadmium (Cd)
• Hexavalent chromium (Cr6+)
• Polybrominated biphenyls (PBB)
• Polybrominated diphenyl ether (PBDE)

PBB and PBDE are flame retardants used in several plastics. Crysberg works according to the RoHS directive

10 – PCB layout and preparation for production

At Crysberg we have extensive experience and expertise in helping our customers with layout of PCB (Printed Circuit Boards).

When you work with Crysberg, you have all the expertise under one roof. This means that we have design engineers and production technicians, who daily work closely together. Precisely that is our strength layout of PCB´s. We have staff, who both understands the products’ functionality, and we have staff, who knows how the production works.

As a partner in our clients’ projects we are involved in all aspects ranging from the concept phase, where we discuss the market situation to product functionality in the development process and the production of the finished electronics solution. We ask a lot of questions in the process, and together with our customers, we find the answers that bring us safely through the process.

The completed projects have taught us, among other things: It might fail in production, when the PCB layout has not taken into account for:

• ​fiducial marks
• Shrinking of SMD pads and proper use of solder masks
• Routing Design in accordance with EMC standards, etc.

We act as liaison between our client’s development and our own production. It is advantageous to contact Crysberg as early as possible in the development process in order to avoid inconveniences during the PCB layout process. At Crysberg we want to help you safely through the PCB layout from schematics through digital processing to finished, assembled and tested PCB.

11 – Test of industrial electronics

Optimum market opportunities require that end users have flawless products. At Crysberg every product is unique. We customize our testing of the electronics products to the individual needs and wishes of the customers, their application and its impacts on the environment. Therefore no electronics assembly leaves Crysberg without being thoroughly test.

In our test department we develop and construct test equipment for industrial electronics and control electronics. We also offer this service to customers, who prefer to do the development of the electronics products themselves

12 – Packaging and shipping

The shipping department packs and ships the finished electronic products according to the agreement made with the customer. We closely follow the instructions and guidelines, our customers have given us. Therefore we have many types of material for packaging: For transport, for the return and recycling and the ultimate end-user package, where we pack the product with user manuals, extra accessories and more.

To conserve resources among customers and reduce delivery time, we offer to stock and deliver finished products directly to end users.

We offer to design the packaging and have a transportation test performed. An example of a test facility is FedEx test service.

13 – After Market Service and electronics repair service

As a courtesy to our partners we can repair the products throughout the product lifecycle.

All products are marked with serial numbers that are stored in a relational database, where all electronics manufacturing, test – and repair data are organized under the individual serial number.

In the event that a component is obsolete and no more available, our purchasing and technical department helps to find alternatives for our electronics customers. If it is not possible, we can assist in our client’s needs and help in making a new design of printed circuit assembly, so it meets the same performance specifications as the original.