Case Study: Maximising Operations and Manufacturing at BluGlass

Australian semiconductor technology developer BluGlass Limited has developed a revolutionary approach to manufacturing gallium nitride (GaN), an essential component of LEDs, which are used in millions of electronic devices globally. LEDs are found in devices such as TVs, laptops, mobile phones, watches, and virtual reality headsets.

BluGlass wanted to incorporate its new technology of remote plasma chemical vapour deposition (RPCVD) into its existing facility in Silverwater, Sydney, so they would be able to support the rapidly growing market for better-performing, lower-cost and more environmentally sustainable LEDs.

The project required extensive design, fabrication and installation of the following equipment and services for their existing warehouse:

• Two nano reactor clean rooms
• One mezzanine platform
• One 7000L liquid nitrogen vessel and vaporizing station
• All associated water chilling and heating services
• All electrical service upgrades
• All interconnecting high-purity gas lines (hydrogen, ammonia, nitrogen and compressed air)
• All interconnecting exhaust pipework and extraction fans, located on the ceiling and which included gas scrubbing units

Originally, Scale Up Partners was asked to quote on gas services and electrical upgrades; however, BluGlass was discouraged about finding reputable suppliers and contractor groups to design and execute the project. They were especially concerned about finding a company that understood how to sequence the works in the most optimal way and deliver quality results with reasonable costs.

Following several initial project scope meetings, we were able to develop a level of trust by asking probing questions on exactly what their key requirements were. After approximately two months of pre-engineering the base solution, BluGlass requested we also look at works for the clean rooms and the mezzanine platform.

We were awarded gas and electrical services, plus the mezzanine and the cleanrooms. BluGlass then asked us to design and quote the full water chilling and heating services, which we were awarded, along with significant sections of the building’s HVAC upgrades.

The project was started in April 2018, with scoping and pre-engineering phases commencing immediately. The final project value was $1.5 million, and the resulting improvements allowed BluGlass to open two new laboratories at the Silverwater facility in August 2019, which tripled its production of gallium nitride using RPCVD processes. There were zero safety incidents, zero reportable incidents and minimal variations charged back to the client.