How our Production Process Ensures Premium PSU's Quality

By Raúl Orense (Head of Production) – Premium PSU

“At Premium PSU, behind every product there is much more than advanced power electronics technology: there is a demanding process where verification, traceability and attention to detail are as important as innovation itself. That is why I want to take you through each step of the production process, to show you how we build reliability from the inside out.

What truly sets a Premium PSU product apart?

Beyond technology, the key lies in an in‑house production process that follows strict international quality standards. Every detail matters: from the exhaustive control of each component to full unit traceability, multi‑stage verifications and an unwavering commitment to reliability. This is a step‑by‑step journey to discover how trust is forged into every unit before it reaches your hands.

1. Reception and initial control of sub‑assemblies

Everything begins with the reception of materials and sub‑assemblies at our Barcelona facilities. Each batch is recorded and linked to a serial number in our system, ensuring complete traceability.

Unitary inspection of sub‑assemblies: key components, printed circuit boards and modules are inspected before integration. This initial control rules out origin errors and ensures that only flawless parts continue in the process.

2. Pre‑verification and software programming

Before assembly, control boards and other PCBs undergo an initial round of electrical pre‑verification. They are validated one by one to detect factory faults and to confirm that they meet technical specifications.

At this stage, software is also programmed into the control boards, loading the firmware and control algorithms specific to each product.

3. Individual board testing and calibration

Each board goes through individual test benches where the following are performed:

Electrical and safety tests.
Firmware programming.
Calibration of the unit to match the specifications defined in the datasheet (CA).

EVA test benches are used to carry out short‑circuit tests and other critical functional checks.

4. Mechanical assembly and tropicalization

After board verification, units move to the assembly line where boards, cabling and mechanics are integrated.

Mechanical assembly: precise mounting of components into the housing or mechanical structure.
Structural adhesive and silicone deposition: mechanical reinforcement and protection against vibration.
Tropicalization (when required): application of protective coatings against humidity, salinity, corrosion or extreme temperatures.

5. Insulation and dielectric strength tests

Before final assembly, products undergo dielectric strength tests in a dedicated isolated room, where voltages up to 10 kV are applied.

This ensures that the electrical insulation can withstand voltages far above nominal without leakage or failure, guaranteeing product safety and reliability.

6. Final assembly and functional verification

With all sub‑blocks validated, the final assembly of the product is completed. Here, first power‑up tests are carried out to ensure that the system starts correctly and operates within parameters.

7. Electrical tests and burn‑in

Each unit undergoes functional, insulation and safety tests. It then enters the burn‑in chamber: continuous operation at nominal conditions under controlled environments, designed to detect latent failures before delivery.

8. Final verification and finishing

After burn‑in, each product goes through a final verification stage covering electrical, functional and safety parameters.

In the finishing area, serial number labels and any customer‑specific protections are applied. All data is recorded in the product’s historical log linked to its serial number.

9. Cleaning, packaging and shipping

Some products go through the cleanroom (ISO 14644, ISO8–ISO6) for cleaning and packaging under controlled conditions. Finally, products are securely packed and prepared for shipping, accompanied by their verification and traceability reports.

Conclusion: Production driven by trust

This carefully controlled process from start to finish is what allows Premium PSU to deliver robust, reliable products that meet the most demanding industry requirements.

Choosing Premium PSU means relying on a value chain where engineering, production and quality work hand in hand to ensure maximum reliability. Contact us to find the energy conversion system perfect for you, created with an intern process designed with precision.