Miraial
Customized Wafer Carriers

Miraial Co., a plastic molding company, has been providing silicon wafer transportation boxes that meet industry cleanliness standards and adapt to evolving client needs since its establishment in 1968. However, the company experienced a significant transformation in the late 1990s to align with the semiconductor industry’s transition from 200 mm to 300 mm wafer chips. This prompted a strategic shift from producing 200 mm wafer carriers to developing and introducing the first-ever 300 mm front opening shipping box (FOSB) and front opening unified pod (FOUP).

The genesis of 300mm FOSB and FOUP can be traced back to the collaboration between the largest US device maker and Japanese wafer maker, and Miraial. The company innovates and customizes wafer carriers to accommodate quality and performance-upgraded chips in accordance with specific client requirements.

“We modify and improve the FOSB/FOUP production process and product designs/functions according to the voice of our customers (VOC) to meet their cleanliness and handling requirements. This approach has resulted in the official launch of 30 to 40 different product variations,” says Takamasa Kato, executive director at Miraial Co.

To develop carriers that protect wafers from visible and invisible contaminants, selecting and combining multiple high-purity plastics is imperative. Miraial collaborates with chosen plastic resin suppliers to acquire premium raw materials for manufacturing FOSB and FOUP that meet client’s cleanliness standards. Apart from raw material selection, the firm implements cleanroom operation processes in its manufacturing plants to ensure high-purity final product.

It also invests in advanced analytical and investigative technologies that enable efficient detection, control, and removal of contamination from FOSB and FOUP.

Miraial’s commitment to quality entails stringent control over the entire manufacturing processes to maintain a pristine environment. Metal molds and injection machines used for production of FOSB and FOUP are also developed within its in-house facility. This enables the plastic molding company to sustain superior product quality, eliminating the possibility of invisible contamination like metal ions and particles during the manufacturing and shipping processes.

For instance, a client’s technical experts of device maker approached Miraial to improve FOSB for handling of chips with single nano features. Each performance improvement requires customized high-purity carrier boxes to reduce contamination while transporting wafers and chips from wafer makers to device makers. In response, the plastic molding company selected premium plastic base materials of high-purity and modified its cleanroom operation processes to enhance cleanliness to launch new varieties of FOSB in the market.

The company relies on its massive team of technology experts and heavily invests in technical innovation and analytical tools utilized by leading semiconductor and wafer manufacturing companies to provide clients with customized offerings. In addition, it regularly optimizes daily operations at manufacturing plants and maintains strong relationships with global distributors to ensure the timely delivery of FOSB and FOUP.

Miraial’s manufacturing plant strategically neighbors the Japanese facilities of clients, facilitating easy networking. It also actively fosters enduring relationships with international customers, undeterred by the vast geographical distances. These active efforts to build sustained affiliations enable the firm to understand and fulfill varying VOC.

The firm aims for carbon neutrality despite the substantial energy required to manufacture plastic-based FOSB and FOUP. It is actively implementing a new business strategy of recycling its product offerings to reduce waste and minimize disposal. For instance, the new 300 mm FOSB is designed to enable easy replacement of product parts. In addition, the firm strives to use a single variety of resin for each part, facilitating easy separation and recycling of the final product. These proactive approaches to align high-purity 300mm FOSB and FOUP with VOC and market trends have been major determinants for Miraial in earning its title as the industry leader for the past 25 years.