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Mar 30 2023

Moore’s Law and MATHESON

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Moore’s Law is the observation that the number of transistors in an integrated circuit doubles every two years. Named after Gordon Moore, the co-founder of Fairchild Semiconductor and former CEO of Intel, Moore’s thoughts in 1965 were less of a measurement, and more of a challenge to the industry for the pace of future developments.

It was Caltech professor Carver Mead who popularized the term “Moore’s Law” in the late 70’s, when it became a shared competitive goal among players in the semiconductor manufacturing space. Since 1975, the goals pioneered by Moore’s thoughts have largely stood up. Those of us who are old enough remember the computers of the 80’s, the cell phones of the 90’s and the iPhone of 2007.  Each was a breakthrough in its day, and each is woefully inadequate today. That is Moore’s Law at work.

Another way to state Moore’s law is that every two years, the size of the transistors in integrated circuits is cut in half. Today’s transistors sizes are just a few nanometers (a nanometer is roughly 10 atoms across) and ten thousand transistors lined up side by side are less than the width of a human hair. With such small sizes, it is easy to imagine how any small imperfection could ruin an entire microchip. 

For people in the semiconductor manufacturing business, MATHESON needs no introduction. MATHESON has been supporting the semiconductor fab business with our ultrapure products for decades. MATHESON has worked, and evolved, side-by-side with technology innovators in both academia and industry. As the transistor sizes have shrunk, we have produced gas products at higher purities with tighter specifications to enable higher fabrication precision, smaller scale, and fewer defects. These include pure and dopant mixtures, etchants, process gases, new materials, purification technology and gas handling equipment. A good example is MATHESON’s  Etch 5 Grade SiCl4 which was developed to reduce “first wafer” scrap that customers experienced with standard SiCl4 due to variable etch rates. The Etch 5 Grade SiCl4 dramatically reduced or eliminated first wafer scrap by providing a much more stable etch rate.  

MATHESON has also developed new analytical methods to allow for the detection of the most miniscule impurities to allow for the extremely clean and pure gases that the ever shrinking transistors require. 

The R&D team in MATHESON’s Advanced Technology Center in Longmont, Colorado has achieved a milestone in purifier capability to remove Total Organic Contamination (TOC) in inert gas. The R&D team has developed a NANOCHEM® purifier, INX-Plus™, that removes hydrocarbons to less than 426 ppq (parts per quadrillion). A ppq is 1×10-15. The INX-Plus™ purifier was used in gas phase argon and demonstrated that Xylene could be removed down to 426 ppq when challenged with 100 ppb of the hydrocarbon. These levels are difficult to achieve due to the complex interactions that are necessary for the impurity to be removed at these levels as well as the sophisticated analytical techniques that had to be developed in order to measure such low levels.

At MATHESON we consider ourselves to be partners in the development of advanced integrated circuits, not simply suppliers. Let MATHESON help you achieve the future advances required to continue Moore’s Law.

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Written by mathesongas · Categorized: Our Solutions

Feb 22 2023

More Efficient Cell Therapy Cryo-Storage Solution

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MATHESON’s biotechnology team recently collaborated with a leading research hospital to develop an efficient system for handling and storing cell samples. The FDA requires that cell samples be maintained at a temperature below -150⁰ C while in storage and requires that the hospital track and maintain accurate records of all freezers in the cryobank. 

MATHESON’s team installed a universal tank switcher with a fully automated manifold connected to the Dewars of liquid nitrogen supplying the cell storage freezers.  The universal tank switcher allows liquid nitrogen to be pulled from one Dewar, and then switched to a new Dewar once the original Dewar is emptied, thus ensuring a continuous supply of liquid nitrogen. The system also provides remote access to a cloud-based system for better monitoring and oversight and features an alert mechanism at the first indication of an issue.

The efficiency of the new system has reduced the amount of liquid nitrogen consumption by 30% thus decreasing the number of needed deliveries which equates to a decrease in CO2 emissions and an increase in fuel economy for the delivery vehicles…

Read and download the Full case study

Written by mathesongas · Categorized: Our Solutions

Jan 13 2023

Tech Bulletin – Weld Cost Analysis

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 Weld Cost Analysis 

At MATHESON, we are committed to partnering with our customers to help them be the most competitive in their respective industries. As part of that commitment, we work with customers on welding cost reduction. Every day we see opportunities to help our customers save money in their welding operations.

In this bulletin, we’ll discuss MIG welding, but many of the principles can be applied to any process and technology.

Managers working at fabricators and manufacturers must make decisions about welding-related costs all the time. These decisions might be about comparing outsourcing versus in house fabrication – or perhaps considering the payback on a capital expense such as a robot. At the core of it all is the complicated question of how to accurately calculate Cost Per Piece in the first place. We will open the discussion on that question here. You be the judge on what works for your shop. 

One misconception is that the cost of materials – gas, filler, flux, consumable parts – is the path to savings. Many fabricators find it easier to add up the costs of consumables for the shop versus quantifying other weld-related costs. However, it has been shown that cost reductions derived from labor savings and quality improvements are typically more impactful, more controllable, and more sustainable. MATHESON can help you examine these factors. 

View/Download the Complete Bulletin

Written by mathesongas · Categorized: Our Solutions

Oct 20 2022

Production Capacity Success Story: Cryogenic Freezing

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OBJECTIVES

To keep up with pet food demands that quickly skyrocketed during COVID lockdowns and double production until a new plant can be constructed.


CHALLENGES

A leading manufacturer of high-quality dog food saw steady growth of their product lines over the last decades. A new plant was under construction but would not be ready for a few years. There have been massive spikes in sales due to COVID quickly exceeding the production capacity for the current location. This company needed to double production in a short time frame without substantial capital expenditures or plant expansions.

MATHESON SOLUTION

This pet food manufacturer used an older cryogenic 3-pass tunnel freezer at their manufacturing facilities for many years as part of their only existing production line. The freezing process was the limiting factor to additional production. The customer ran this line beyond its design capacity, trying to maximize throughput. Constant breakdowns and high wear caused the unit to require frequent and expensive maintenance. As a critical process, it would often bring the entire plant to a standstill when breakdowns occurred. The small production area limited their ability to use a larger freezer that was more suitable for their production goals.

Approximately six months before being approached by this customer, MATHESON purchased a used 3-pass freezer. MBI Cryogenics, Inc., a MATHESON owned cryogenic food freezing and chilling equipment manufacturer, refurbished the freezer to ensure it was in good operational condition.  This 3-pass freezer could be the interim solution for this pet food manufacturer.

After rigorous testing and economic analysis were conducted by the logistics, cryogenic service, gas applications, and sales teams, it was determined that the 3-pass freezer would be a great solution. The overall size of the freezer was the same as the current system, allowing them to be placed in parallel identically configured production. A thorough review of the customer requirements indicated that the belt speed and liquid nitrogen flows had to be dramatically increased, calling for additional modifications. The unit was modified in Los Angeles as nitrogen tanks were ordered and installed. 

A team of skilled and experienced contractors installed the system under the supervision of the MATHESON Application Engineer. New vacuum-insulated piping and stainless steel exhaust systems were quickly installed over a few days. The system was tested using the actual product, and a few minor modifications were made to better accommodate customer’s specific requirements.

The customer was greatly impressed with the ease of utilizing MATHESON as a total solution provider to investigate the production problem, procure the equipment, commission the system, deliver the gas, and provide technical support to maintain the production while installing and starting up the equipment.  Production capacity was dramatically increased with a new redundancy provided by two identical, parallel production lines. MATHESON brought the entire system online within the customer’s six-month window. The total cost was about half the price of a new system. 

Download the success story
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Written by mathesongas · Categorized: Our Solutions

Aug 18 2022

Beat the Summer Heat with Nitro Coffee

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Nitro coffee is ice-cold coffee on tap. It’s treated with nitrogen and/or carbon dioxide under high pressure, then chilled in a keg and served on draught with a foamy top layer. 

MATHESON supplies beverage grade nitrogen and complete equipment solutions for Nitro Coffee.

This specific type of coffee is not only rich and creamy, it’s also slightly effervescent due to the tiny bubbles suspended inside the refreshing beverage. Nitro coffee also has a chocolate-like sweetness to it and is less acidic compared to large-batch cold brewed coffee, all without the need for sugar or creamer. 

Nitrogen is insoluble in liquid, which is what contributes to the thick mouth feel. This effect is helped by a special piece of tap equipment that forces the coffee through tiny holes before it lands in the glass. That process causes the “rising” effect that is topped with the head. It’s worth noting that really only the bubbles on the sides of the glass are the ones that fall. Inside they are actually rising, as typically seen with many poured carbonated beverages. 

MATHESON manufactures and supplies both nitrogen and carbon dioxide in a full range of purity grades and a variety of container sizes and types. 

MATHESON also offers configured specialized systems that will deliver premium Nitro Coffee to your customers and help increase sales. We supply and install the entire system including all stainless steel containers, fittings, faucets, food grade fittings, tubing, etc. 

We at MATHESON will even provide our exclusive recipe to make your Nitro Coffee a differentiator for your business. 

Learn More About Beverage Gases

Written by mathesongas · Categorized: Our Solutions

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