Mixed SMT Lines
Flexible, High-Throughput PCB Assembly for Diverse Products
Mixed SMT lines refer to high volume assembly lines with the ability to produce a number of different PCB products or mixed (SMT + through-hole) products within one single line. Unlike a single product line with one design board and one family of parts, a mixed SMT is versatile to quickly change boards and parts. Mixed SMT lines typically include module-based multi-lane configurations with smart machinery to support responsiveness to fluctuations in orders. In a competitive market today with a high mix of products demanded at volume scale order level, mixed SMT lines fill a volume-versatility gap between low-mix high-volume lines and low-volume prototyping lines. A mixed line fundamentally maintains high volume efficiency but is variable enough to handle a high number of different product configurations in parallel. Such flexibility is imperative because OEMs and EMS providers must meet rising orders for different types of IoT, automotive and consumer electronic devices with a high volume.
Key Benefits Of A Mixed SMT Lines
Flexibility
Modern mixed lines use modular machines and parallel lanes so they can switch jobs with minimal downtime. For example, “modular machines help the line change jobs quickly” – enabling rapid product changeovers. This means a factory can handle different PCB sizes or variants without lengthy retooling.
High Throughput
By running boards in parallel lanes and using high-speed equipment, mixed lines can still produce large volumes. Dual-lane setups can process twice as many boards in the same time frame, “enabling higher volumes to be produced”. With well-coordinated conveyors and automated feeders, throughput remains strong even for complex, varied product runs.
Cost-Efficiency
Mixed lines maximize equipment utilization and floor space. Operating two lanes or combining multiple processes in one line often yields a “cost-effective and space-efficient solution” to meet high production targets. By reducing changeover losses and sharing setups across products, unit costs drop without requiring separate dedicated lines for each board type. Over time this drives better ROI for mixed-product operations.
Main Components in a Mixed SMT Line
A typical mixed line is built from best-in-class equipment in each category. Meraif supplies all key elements, including:
Pick & Place Machines (Chip Mounters)
High-speed mounters from leading brands such as Fuji, Juki, Hanwha, Panasonic, Yamaha (and Meraif) to place a variety of SMT components. These machines feature multi-head placement and flexible feeders for varied part sizes.
Solder Paste Printers
Precision stencil printers from DEK, GKG, and Meraif deliver consistent solder paste application for different board layouts. (Meraif offers printers compatible with popular DEK/GKG printers, ensuring seamless integration.)
Reflow Ovens
Continuous reflow ovens from Heller, JT, Kait, Suneast, and Meraif provide precise thermal profiles. Meraif’s portfolio includes conveyorized and chamber reflow models. For example, Meraif sells both its own and partner ovens alongside Heller and JT reflow units.
AOI/SPI Inspection
Automated optical (AOI) and solder-paste (SPI) inspection systems from Koh Young, Mirtec, JUTZE, SAKI, Pemtron, Yamaha, and Meraif ensure quality on every board. These 3D inspection machines detect placement errors or paste defects inline. (Meraif carries AOI and SPI machines under its brand as well as all major names.
Cleaning Machines
Inline cleaners for PCBs, stencils, and feeders help prevent defects. Meraif offers ultrasonic and spray cleaning systems for printed boards and stencils, plus nozzle/feeder cleaning tools. Effective cleaning is especially important in mixed lines to maintain yield across diverse jobs.
Soldering Machines
Meraif provides selective soldering and robotic soldering systems for through-hole components. (Its in-house Selective Wave Soldering Machine and wave-soldering lines complement the SMT line.) These allow mixed lines to include both SMT and inserted parts in one pass.
ESD & Storage Solutions
Organized, ESD-safe kitting and storage keep multi-board production smooth. Meraif stocks ESD magazine racks, feeder carts, reel carts and other storage carts to support complex feeding setups.
| Characteristic | Standard SMT Line | Mixed SMT Line |
|---|---|---|
| Flexibility | Low – dedicated to one product run | High – modular machines and lanes allow rapid changeovers |
| Throughput | Very high for large, consistent orders | High, but balanced across product variants (multi-lane helps maintain volume) |
| Changeover Time | Long – optimized for one setup | Short – designed for frequent job changes |
| Cost Efficiency | Excellent for large volumes (low per-board cost) | Better ROI at low-medium volumes (lower setup cost) |
| Typical Use | Mass-production (e.g. smartphones, LED panels) | Mixed-volume runs (e.g. medical devices, automotive electronics) |