From Batch to Inline – Systematic Scaling SELECTIVE SOLDERING / Eltroplan Group

Over decades, Eltroplan has evolved from a layout specialist into a high-performance systems provider. Consequently, the company today offers electronics manufacturing and development services all under one roof - covering classical electronics to complex system solutions. The goal remains not only to design new products, but also to transfer them safely into production. The Eltroplan Group is serving customers from demanding industries such as automotive, aerospace and defense, medical technology, and industrial electronics – sectors where quality, traceability, and stable processes are crucial for series production and the service life of assemblies.

The product range has shifted significantly: Eltroplan continues to manufacture products in batch sizes as small as one but has become a mass-production supplier for many products. “Typical production volumes range from 2,000 to 5,000 assemblies. In some cases they can be significantly higher, reaching between 200,000 and 300,000 units. The VERSAFLOW 4/55 is our response to the need to scale up our production – moving away from our previous batch system toward inline production,” says Dario Hennig, Head of Production at Eltroplan. With the Ersa selective soldering machine, Eltroplan also meets the requirements of regulated sectors such as medical technology and defense, delivering reproducible results, clear process windows, and high process transparency.

Decision made at the Demo Center regarding VERSAFLOW 4/55

The decision was made following a structured benchmarking process involving several manufacturers. A key component of this process was the soldering test conducted at Ersa in Wertheim – for which Eltroplan brought one of its most complex assemblies. “The VERSAFLOW 4/55 proved its capabilities in the demo center – whether in terms of size, heat transfer, or complexity, everything could be handled reliably and reproducibly,” says Dario Hennig.

Traceability and dual pot machine layout

A key criterion was that the system meets additional requirements such as traceability and data transparency, for example when logging soldering profiles. Automated testing and monitoring functions, such as monitoring the solder wave height, as well as controlled solder feed and solder level monitoring, were also important. In practice, the dual pot machine layout proves its strength: Eltroplan can handle both lead-free and lead-containing processes and can switch flexibly between jobs – an important advantage when handling both high-volume and smaller orders in parallel.

The benefits of the inline solution are also evident in day-to-day operations: By eliminating frames and transferring the circuit boards directly via a conveyor belt, changeovers can be completed quickly. This sometimes happens multiple times a day, while on other days a single product runs continuously in series production. This combination of flexibility and throughput supports the integration of series production without slowing down the typical EMS business, which involves frequent product changes. “The machine’s utilization has turned out exactly as we had anticipated. Adding another soldering module is possible at any time – so we still have the option to scale up further at short notice,” says Ersa Area Sales Manager Stefan Wurster, who is responsible for Southern Germany and Switzerland and has been with the company for over 30 years.

Further digitization planned

“In addition to supplying the hardware, the collaboration with Ersa has been a key factor in our success. It is professional and reliable throughout every single phase: project planning, the demo center, installation, inspection, and service. Ersa’s application support is also extremely valuable to us,” explains Dario Hennig. “Ersa takes the application into account and delivers not just a machine, but a reliable solution for reproducible processes.” In future, Eltroplan will rely even more heavily on automation and digitization in its manufacturing processes. At the same time, having a second source – in terms of both machinery and locations – remains a strategic priority to ensure long-term growth, quality, and delivery reliability.