InsightsSmall Cause, Big Impact: Production Halt in Pretzel Manufacturing
An inconspicuous solder mask triggered machine downtime and revenue losses.
failure analysis When Pretzel Production Stalls
Homemade pretzels are the hallmark of any good Bavarian bakery. But what happens when the pretzel baking machine suddenly stops working? Not only are customers left disappointed, but the bakery itself faces significant revenue losses. A machine breakdown can quickly become a serious problem that calls for swift solutions.
problem descriptionReliability Test Reveals Weakness in Control Module
As part of the troubleshooting process, an end-of-life test was carried out to identify the cause of the unexpected machine downtime. This brought a module into focus that was responsible for motor control. Although it was coated with a special protective layer intended to increase robustness, functional limitations became apparent.
Further analysis revealed significantly increased contact resistance at the pins of the signal connector. This impaired the control function and was ultimately responsible for the machine failure.
failure analysisThe Hidden Source of the Malfunction
In the next step, the affected module was examined in greater detail. The initially suspected link to the coating process was quickly ruled out—it was not responsible for the malfunction.
Instead, signs of previously unexplained sulfur corrosion were discovered. A detailed analysis of all materials and components used ultimately revealed the true cause: the solder mask released sulfiding substances. This reaction led to increased contact resistance in the connector and, consequently, to the control system malfunction.
solution The Solution Was in the Details: Temperature Control Adjusted
Based on the detailed failure analysis, an effective solution was developed for the customer. By specifically optimizing the temperature control in the coating curing process, the outgassing of volatile components from the solder mask could be reliably prevented. As a result, sulfur-induced corrosion on the connector pins was permanently eliminated.
Even when the root cause is not immediately obvious, one thing is clear: with systematic analysis, even unexpected sources of failure can be resolved sustainably. This ensures that your production keeps running and your customers can continue enjoying their pretzels as usual.
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whitepaper-collectionImproving the Quality of Protective Coatings
This Whitepaper explores how production parameters affect conformal coatings in electronics during thermal shock tests, revealing that production residues contribute to failures. Cleaning procedures positively influence performance, with the paper offering a ranking of factors influencing thermal shock resistance.
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