Zeal Electronics Ltd
Church View Business Park
Coney Green Road
Clay Cross, Chesterfield
S45 9HA
United Kingdom
Services
Surface Mount
The Surface Mount section of Zeal’s Production process utilises fully automated pick and place machinery. With a dedicated
team of trained operators a Mycronic MY300LX with a 4K vision system provides the functionality of a system capable of placing
up to 16,000 components per hour with an accuracy of placement accuracy of +/- 15um. This meets the requirements for all
components including 01005 passives and the ultra-fine pitch/ BGA components
Through Hole and General Assembly
There are still PCB assemblies requiring through hole components, required for robust connectivity, high voltage, certified
products or legacy products
Zeal can accomodate all through hole requirements and mixed technology assemblies.
A 2020 investment in an ERSA ECOSELECT1 selective soldering machine allows us to provide repeatable quality for double
sided mixed technology assemblies
As part of our services we can also advise on production processes to allow assembly to be more cost effective
Cable Assembly
Our services range from simple termination and connector assembly, to the production of complex looms and specialist
cables
We have a great deal of experience in the following areas :
Preformed power, Alarm and control looms for enclosure assembly in the telecommunication and Control industries.
Coaxial cable assembly and termination.
Precision termination of “D” and miniature “D” connectors, including PCB incorporation into back shells.
Ribbon cable assemblies.
Specialist balun manufacture.
Assembly into cable interface frames.
All cables and looms are fully tested and coded to our customer's requirements and certified before shipment to their
manufacturing or installation sites
In addition we also assemble non-PCB assemblies such as battery packs and other electro-mechanical assemblies
We have expertise on bespoke assemblies serving the specialist needs of very large companies and the needs of SME's. Full
flow soldering, cropping and test facilities, IC programming, support the assembly operations
Enclosure Builds
We also provide an enclosure assembly service. We can machine off the shelf enclosures to customer specification,
manufacture bespoke plastic enclosures or can assist in having enclosures manufactured out of various materials
The enclosures can be supplied unassembled, part or fully assembled with connectors or cables as required. We can also
provide a label to your specification with serial numbers, bar-codes, QR codes and customer logo’s
We also have experience with 19” rack and control panel assemblies which we have assembled for the railway sector, power
stations and the food industry
Encapsulation, Conformal Coating & Lacquering
As required by some customers, we have the ability and expertise to be able to encapsulate products as required. Our
dispensing equipment is setup to dispense two part mixtures
We also conformal coat and lacquer PCB’s and other items as requested using various approved products and various
applications
Procurement
The variety of work we carry out for customers often displays cost benefits in supplying a comprehensive package of
assemblies and components, for use in our customers’ production line assembly or site installation
By controlling the supply chain on behalf of our customers we can offer a single source and control of component delivery
Such examples of procurement may include the supply of electronic assemblies, their interconnecting cabling, power wiring,
fusing, tooling, and all of the fixings and consumables for final installation at site. Such practices can often save significant
installation time and guarantee quality for customers
Engraving
In order to support our own manufacture of specialist, engraved components, we have extensive computer controlled
engraving and plastic milling facilities
As per customer requirement we have a dedicated routing machine which allows many proprietary enclosures to be machined
to customer specification. This removes the need to outsource to another supplier which helps us control the lead times and
quality of the final product
Our pick and place equipment is augmented by a 10 zone re-flow oven achieving a fully controllable temperature profile (KIC
profile and monitoring) for lead free and leaded assemblies, two Mycronic MY600 Jet Printers, and two MANTIS rework stations
with 3D magnification to sustain the quality of the product
We have a full range of Agilis feeders to a allow better pick rates on all components. This allows the best yield out of any
materials either purchased by us or supplied by our customers
Inspection
Zeal has a 2021 Model K series 3D AOI machine from Mycronic at the end of the surface mount line. The department is also
supported by a ScanSpection AOI system. These machines are programmed for each individual assembly to allow the PCB’s to
be inspected for missing, incorrectly fitted or wrong value parts. The 3D AOI machine can also inspect for poor solder ability and
components that are not located correctly
These machines can also be configured for mixed and through hole technology assemblies and using the comparator program
they can compare an approved sample with another assembly to highlight any differences between the two
All machines are connected to our company network and a capture of each PCB assembly is stored against the works order and
unique serial number for full trace ability
We can further inspect the solder ability of the PCB’s using our 3D magnification MANTIS inspection equipment