Our facilities

All Prefect products are designed and manufactured in the UK. Our head office houses our research and development facility where products are conceived, trialled and tested. Our team modify, maintain and dispatch our products from our workshops and warehousing in Sudbury, Suffolk.

Making Prefect products perfect

The quality assurance process  

It is testament to the quality of Prefect Controls products that in the last couple of years the company has been commissioned to upgrade sites with new generation control systems, where a Prefect product had been installed 15 years previously.  

Long life span. 

A case in point – 1600 controllers removed from a site – all of which were in full working order. It was the development of new features and performance efficiencies that prompted the upgrade. Due to vulnerable positioning and harsh existence, the heater panels are more likely to require replacement than the controllers. This is what signalled, to Energy Managers, the need for a new system. 

People, equipment and processes – certified and examined. 

Prefect has a rigorous quality control programme throughout the design, development and production of its products. The manufacturing facility’s Quality Management System (QMS) is certified to ISO9001:2015 and all staff are fully trained as Certified IPC Specialists (IPC-A-610, IPC J-STD-001 and IPC/WHMA-A-620). 

 Quality is critical to Prefect’s success, it underpins all manufacturing processes, from accuracy of assembly and efficient use of time to minimal wastage of materials. 

 Continual investment in sector leading equipment, technology and processes – coupled with commendable staff–loyalty and retention – forges an outstanding facility that manufactures robust, reliable yet cost-effective products. 

The manufacturing procedure. 

All components are stored in controlled, secure conditions. The stock management software maintains supplies that are drawn down when production requirements are logged on the Bill of Manufacture (BOM). 

Printed circuit boards (PCBs) are produced on site using the ASM Horizon 03iX Stencil Printer with camera fiducial alignment.  

Components are placed on the PCB using a double armed Panasonic CM101-D Pick and Place machine before progressing to and through the Heller Reflow Oven which has a total of 18 heated zones (9 top and 9 bottom). This is where solder is heated, and components are secured. 

The Trident ZDO PCB cleaning machine removes any manufacturing residues. 

Any components that fall outside the capability of automated placement are hand–fixed by the soldering team.

Inspection. Inspection. Inspection!
Each and every circuit board is scrutinised by eye before going through the Automated Optical Inspection (AOI). A ‘perfect example’ is scanned by the MEK PowerSpektor GTAz+GDAz 550BTL and ‘memorised’ for comparison purposes.  

The AOI has top–down/bottom–up cameras and is fitted with 8 digital eyes for side and edge scanning, enabling simultaneous double–sided inspection. Omnidirectional multi–colour LED lighting has the capability to test a range of criteria on all types of solder joints.  

Every PCB passes through the AOI and is compared, photographically, with the ‘perfect example’. Any faults are flagged and rejected from the batch for rectification. 

Testing! Testing!
The PCBs are then placed on purpose-built Prefect test rigs, powered up and examined to ensure they are fully functional.

Assembly.
After testing PCBs are coupled with their chassis, assembled, and where necessary, fascia overlays are applied. The units are then boxed ready for dispatch. 

Performance.
Prefect proudly boast a 99.5% on–site performance record. Likewise, 99% of ‘faulty’ controls are returned to site, following testing, for re-installation – fully functioning! 

Our Testing Department data reveals the most common reason for a product being returned, is that the setting of the PIR or run times have been programmed incorrectly on–site. 

The robust design, meticulous production process and rigorous testing procedures means Prefect is confident in supplying all products with a 5–year warranty, and the assurance that it will probably be another 15 years before replacement is necessary!