INTEGRATED DESIGN & BUILD: THE 4-MONTH CONVERSION OF SENTEC’S NEARLY 9,000M² ADVANCED ELECTRONICS FACILITY WITH FIRST-TIME-PASS VALIDATION

Amidst the global relocation of high-tech supply chains, converting existing industrial assets (Brownfield projects) demands top-tier engineering foresight and rigorous project management. Recently, acting as the Design & Build (D&B) Contractor, BSE successfully delivered an advanced electronic components and semiconductor-supporting infrastructure project for Sentec Group (Sentec Group Taiwan) at Ho Nai Industrial Park, Dong Nai. This case study details how BSE overcame complex technical challenges to hand over this high-spec infrastructure under an aggressive timeline.

➡️ The Brownfield Challenge & High-Precision Infrastructure Integration

The project presented a complex conversion challenge initiated by the Client, Sentec: Transforming the entire functional infrastructure from an EMISSION CONTROL SOLUTIONS factory into an advanced ELECTRO CERAMIC & DEVICE manufacturing plant.

Shifting from traditional automotive support components to an advanced electronics facility required a complete overhaul of the building’s "circulatory system" and microclimate. The infrastructure had to support highly sensitive, integrated packaging and component manufacturing lines, including:

• Multi-Layer Ceramic (MLC) & Circuit Substrates: High-density interconnect pathways embedded within technical ceramic structures, requiring maximum thermal and mechanical stability.
• Low Temperature Co-fired Ceramic (LTCC) Substrates: Low-temperature ceramic-metal co-firing modules demanding minimal signal insertion loss in high-frequency applications.
• Advanced Packaging Infrastructure: Specialized cleanroom spaces designed for multilayer ceramic substrates combined with multilayer thin-film metallization for Wafer Probe Cards, supporting high-precision Level 1 and Level 2 semiconductor packaging processes.
• RF & Microwave Components: Signal-filtering and high-frequency transmission components that are highly vulnerable to airborne particulates and electrostatic discharge.
  

To support this sophisticated technology layout across a floor area of nearly 9,000 m², BSE operated under a critical 4-month timeline. This window encompassed all phases—from initial site survey and engineering design to structural modification, MEP installation, and Testing & Commissioning (T&C)—aiming to deliver a certified clean space ready for immediate production machinery installation.

➡️ Synergized MEP & Cleanroom Engineering Solutions by BSE

Recognizing the sensitive nature of Sentec's advanced electronic components and RF modules, BSE’s engineering team deployed fully integrated, turnkey infrastructure solutions:

• Advanced Cleanroom & Specialized HVAC Systems: BSE established a strictly controlled positive-pressure cleanroom zone to protect thin-film circuit printing lines. The system utilizes high-capacity Air Handling Units (AHUs) paired with high-efficiency HEPA filters, maintaining continuous air change rates to rigorously eliminate fine airborne particulates.
  
• Thermal-Insulated Cleanroom Panel Systems: Specialized, anti-static, and dust-resistant sandwich panels were installed with seamless air-tight sealing to isolate the manufacturing zone from external contaminants while ensuring optimal acoustic and thermal insulation.
• Industrial Deionized (DI) Ultrapure Water System: BSE directly engineered and built a high-capacity DI water filtration system vital for substrate washing and microcircuit surface treatments. The output water is tightly monitored for electrical conductivity and resistivity, eliminating trace ionic impurities.
• Niagara-based Building Management System: BSE integrated an open-framework Niagara BMS to centrally monitor and automate the facility's critical infrastructure. This system ensures real-time precision control over ambient temperatures, relative humidity, and cleanroom differential pressure, while optimizing energy efficiency and safeguarding continuous production

➡️ Validation & Commissioning: First-Time-Pass Excellence

The ultimate benchmark for any high-tech cleanroom contractor is the Testing & Commissioning (T&C) phase. Driven by BSE’s stringent quality assurance protocols, the entire mechanical, electrical, cleanroom, DI water, and architectural panel infrastructure passed 100% of the rigorous parameter tests monitored by Sentec's technical experts, achieving official compliance and validation on the very first try (First-time-pass).