Installation and commissioning
Site survey, structural and power assessment, mounting, system integration, network configuration and operator training — delivered by the plant that built the product.
Capabilities
A full SMT plant, built around display first.
Every GEMCO plant is a complete electronics manufacturing facility: surface-mount assembly, through-hole and selective soldering, optical inspection, calibration, environmental testing and burn-in — plus the engineering centre that will eventually design what runs on it.
Phase one
Two products, one plant
Product line 1
Interactive flat panels
Interactive displays for education, government training centres and corporate meeting rooms.
- 65″, 75″, 86″ and 98″ formats, 4K UHD
- Multi-point touch with anti-glare tempered front glass
- Integrated Android system with an OPS slot for a Windows PC module
- Assembly begins as SKD from partner factories, moving to CKD
- Local warranty, spare parts and service from the same plant
Product line 2
Direct-view LED video wall modules
Modules and cabinets for fixed installation, broadcast, control rooms, retail and outdoor advertising.
- P1.5, P2.0 and P2.5 pixel pitch, indoor and outdoor variants
- Brightness from 800 to 1,500 cd/m² depending on application
- Refresh rate of 3,840 Hz and above for broadcast-safe capture
- Front and rear service access; standard 320 × 160 mm module
- Cabinet integration, calibration and commissioning in-house
Specification
What the LED line is designed to hold
These are the design targets the production line, test equipment and quality system are being specified against.
| Parameter | Design target | Notes |
|---|---|---|
| Pixel pitch | P1.5 / P2.0 / P2.5 | Additional pitches introduced with demand |
| Brightness | 800–1,500 cd/m² | Indoor and outdoor variants |
| Refresh rate | ≥ 3,840 Hz | Flicker-free for broadcast and camera capture |
| Module size | 320 × 160 mm | Industry-standard module and cabinet pitch |
| Soldering | Lead-free | RoHS-compliant process throughout |
| Compliance | CE / FCC / EMC | Electrical safety and electromagnetic compatibility |
| Initial output | 100 m² / week | Scaling toward 100 m² per day as lines are added |
Process
From bare board to packed cabinet
The line is laid out as a one-way flow — goods-in, production, test, storage, dispatch — to keep handling, rework and contamination down.
Solder-paste printing
Automatic-alignment stencil printer with paste inspection, so every board starts with a verified deposit.
SMT placement
High-speed pick-and-place configured for fine-pitch LED packages and driver ICs.
Reflow soldering
Eight-to-ten-zone reflow oven with lead-free profiles and controlled ramp rates.
Automated optical inspection
Post-reflow AOI for misalignment, missing components, tombstoning and solder bridging.
Depaneling
Laser depaneling of multi-board arrays to avoid mechanical stress on LED packages.
Through-hole and selective soldering
Wave and selective soldering for connectors, large capacitors and mechanical parts.
Conformal coating and curing
Spray coating and UV cure for protection against dust, humidity and salt-laden air.
In-circuit testing
Electrical verification of every board before it is allowed into module assembly.
Module and cabinet assembly
LED module integration, frame construction, data and power harnessing, cable management.
Calibration and alignment
Photodiode and spectroradiometer calibration for brightness uniformity and colour accuracy across the wall.
Burn-in and environmental testing
Extended powered operation on burn-in racks, plus temperature and humidity chamber testing.
Final inspection and packing
Visual, functional and compliance checks, then protective packaging, labelling and shipping documentation.
Quality and engineering
Two systems that decide whether the rest works
Quality system
Built to be audited
- Written standard operating procedures for every station
- Defined inspection points with recorded results, not spot checks
- ESD-controlled zones: flooring, benching, wrist straps and grounding
- Incoming component inspection and climate-controlled storage
- Burn-in before dispatch to catch infant mortality in the plant, not on site
- Traceability from component lot to finished module
Engineering centre
Design work done on site
- Requirements analysis: resolution, pitch, brightness, environment, power
- Schematic design, controller selection and connectivity
- PCB layer stack-up, component placement, routing and signal integrity
- Thermal management and power distribution design
- Design-for-manufacture: standardisation, assembly and test provisions
- Prototype fabrication, bring-up and functional qualification
After the sale
Support that stays in the country
Local manufacturing is only worth it if local support comes with it. Each plant carries its own service capability.
Warranty and maintenance
Warranty administration, preventive maintenance plans, service contracts and a spare-parts stock held in country, so a failed module is replaced in days rather than shipped abroad.
Technical support
Direct engineering support, a documented knowledge base, and customer training for both operation and first-line maintenance.