Sakae Corporation List of Products and Services

We would like to introduce a case study of the implementation of "liquid heating sheath heaters" for the food distribution industry. Before the implementation, the heaters were prone to corrosion due to their use in water, leading to frequent replacements and significant costs associated with these replacements. By confirming the performance through comparisons of production processes and lifespan with the current manufacturer during the prototype stage, we were able to secure mass production orders for all models of water heating heaters, and it has opened up the possibility for expansion into other new projects. [Case Overview] ■ Issue: The short lifespan of heaters from the current manufacturer led to frequent replacements, creating a bottleneck. ■ Solution: Visualizing the manufacturing process and gaining trust in quality led to mass production orders. ■ Effect: By confirming quality, we were able to ensure the longevity of the heaters. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the implementation of a "compact hand-washing hot water unit" for companies that provide aircraft-related products (interior components, seats, aircraft equipment) and aircraft facilities. The company faced challenges such as "wanting to achieve weight reduction due to rising fuel costs" and "wanting to increase the number of seats through space-saving measures." After the implementation, the hand-washing unit was made more compact, leading to an increase in the number of seats. 【Case Overview】 ■Challenges - Wanting to achieve weight reduction due to rising fuel costs - Wanting to increase the number of seats through space-saving measures ■Solution: Development of a compact hot water unit for aircraft ■Effect: Reduction in fuel costs due to miniaturization *For more details, please download the PDF or feel free to contact us.

To companies that manufacture commercial electric water heating equipment, we would like to introduce a case study on the implementation of "bare heating wire heaters." The background for this implementation is that the current specifications use overseas products that have issues with corrosion and wire breakage, leading to a lack of durability. When considering a switch to domestic products, the increase in costs has been a significant obstacle. We re-evaluated and designed the materials and shapes from scratch, developed heaters for small instantaneous water heaters, and proposed product assembly, resulting in improved quality and longer lifespan. [Case Overview] ■ Issue: Durability problems due to quality issues ■ Solution: Development of heaters for small instantaneous water heaters and proposal for product assembly ■ Effect: Increased lifespan and reduced costs *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the implementation of a "cooling plate" for semiconductor manufacturing equipment manufacturers. The company required a space-saving design for the cooling plates incorporated into semiconductor manufacturing equipment. In response to this challenge, we proposed a manufacturing method using the "rivet method" as an alternative to the casting method, which allowed us to reduce the thickness of the cooling plates while maintaining cooling performance equivalent to that of conventional designs. 【Case Overview】 ■Challenge: Structural constraints due to space-saving requirements ■Solution: Proposal for space-saving and lightweight design using the rivet method ■Effect: Achieving optimization of internal space and maintenance of performance *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the implementation of a "hot plate" for companies that handle automated machinery and labor-saving devices. The background for the implementation was that a ceramic heater was used sandwiched between aluminum plates, but due to significant temperature unevenness on the plate surface, the desired level of temperature distribution could not be achieved, and improvements were needed. After the implementation, by selecting a mica heater, we achieved an improvement in temperature distribution, and further energy savings were realized due to the increased heat transfer area. 【Case Overview】 ■Challenge: Significant temperature unevenness on the plate surface prevented achieving the desired level of temperature distribution. ■Solution: Comprehensive support from prototype to process optimization, including assistance with new outsourcing transfer. ■Effect: Improved temperature distribution and energy savings achieved through the integrated arrangement of hot plates. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where a "cartridge heater" was implemented in an in vitro diagnostic device by a company that handles medical equipment. In in vitro diagnostic devices, it is necessary to warm the reagents to 37°C (approximately body temperature), but due to limited space within the device, a heater that can be utilized in that space was required. By selecting our product, which has wiring arranged on one side to minimize the space needed for wiring, we achieved space-saving. 【Case Overview】 ■ Background: Need for a heater that can be used in the confined space of an in vitro diagnostic device ■ Solution: Proposal for a space-saving heater and unit assembly ■ Effect: Reduction in total costs *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study where a semiconductor manufacturing equipment manufacturer, which handles cleaning devices, coating and developing devices, thermal processing devices, and other auxiliary and special processing equipment for semiconductor manufacturing front-end processes, implemented a "mica heater" in their hot plate unit. The company required minimizing the temperature difference on the wafer on the hot plate to the utmost limit. In conventional heating methods, slight temperature variations could lead to a decrease in product yield, and improving uniformity was a challenge. After implementation, in a 150°C operating environment, the temperature distribution on the wafer achieved a range of 0.2°C or less. This represents an extremely high level of uniformity in the industry, significantly enhancing stability and reproducibility in the manufacturing process. 【Case Overview】 ■ Background: A heating solution with excellent uniformity was required to eliminate temperature variations. ■ Solution: A mica heater with excellent uniformity and heat resistance was adopted, and optimization was carried out from the pattern design. ■ Effect: Achieved a temperature distribution range of 0.2°C or less, improving process safety and the overall reliability of the equipment. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study that solved challenges through the development of a "heater-type roaster" using special steel for a kitchen equipment manufacturer engaged in the design, manufacturing, and sales of commercial cooking equipment, specifically "smokeless roasters." In some restaurants located in urban areas and commercial facilities, the use of gas is restricted. Since conventional smokeless roasters were primarily designed for gas use, it became difficult for these establishments to adopt them, leading to limitations on the expansion of the grilling and cooking industry. With the development of our product, it has become possible to introduce smokeless roasters even in environments where gas usage is restricted. [Case Overview] ■ Background: Restrictions on the expansion of the grilling and cooking industry due to "gas usage restrictions" ■ Solution: Development of a heater-type roaster using special steel ■ Effect: Maintains high performance even in electric models, accommodating various types of business establishments *For more details, please download the PDF or feel free to contact us.

We would like to introduce examples of proactive proposals for process improvements aimed at enhancing efficiency for companies engaged in the electrical equipment and measurement instrument industries, which handle electronics products and various inspection devices. The company was looking for a manufacturer capable of mass production due to an increase in usage beyond previous levels. They were also considering ways to reduce costs. With our equipment designed for mass production, we were able to increase the production of heaters for warm water washing toilets to the desired quantity. Furthermore, by improving the work processes in each manufacturing stage, we achieved cost reduction without causing any delays in delivery. 【Case Summary】 ■ Background: Desire for mass production and cost reduction ■ Solution: Enhanced production facilities and process improvements ■ Effect: Increased production of heaters for warm water washing toilets and cost reduction *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we made proposals that included not only individual heaters but also units for a dryer manufacturer engaged in design, development, can manufacturing, and assembly, regarding the production of commercial dryers. Initially, the company was using heaters from another manufacturer, but due to a lack of personnel with heater expertise in-house, there were many meetings and consultations, and because the transactions were long-distance, the development did not progress smoothly. By proposing units, we were able to shorten the design workload, and by ensuring consistent arrangements during mass production, we reduced the effort required for ordering components, resulting in a shorter manufacturing lead time. [Case Overview] ■ Background: The lack of personnel with heater expertise in-house was a bottleneck. ■ Solution: By requesting a manufacturer in our area of expertise, evaluations could be conducted as planned. ■ Effect: Quick responses allowed for a reduction in time from product development to mass production. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we proposed the integration of metal piping into aluminum castings using gravity casting for a medical device company that handles analytical instruments, specifically for their reagent heating unit components. The company had a product that embedded piping within aluminum machined parts using low-melting-point alloys, with heaters attached for external heating. There was a risk of the low-melting-point alloy melting during overheating, leading to potential damage. By changing from low-melting-point alloys to aluminum castings, the risk of melting during overheating was eliminated, thus protecting the product. 【Case Overview】 ■ Background: Risk of product damage during thermal runaway ■ Solution: Integration of aluminum machining + metal piping + low-melting-point alloy using a casting method ■ Effect: Elimination of damage risk and improved temperature performance through integration *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we proposed a review of the poor flow of molten metal that causes chipping, casting defects, and appearance issues in cast heaters for oil boilers used by companies dealing with home equipment, industrial equipment, and medical device parts. The company was struggling with low yield due to frequent occurrences of chipping, casting defects (the phenomenon of cavities forming inside cast products), and appearance issues when performing casting processes together with the heaters. They were looking for a manufacturer that could improve defects under the same casting conditions as the heaters. By changing the structure of the casting mold and the flow of molten metal, we were able to reduce the yield loss, leading to improved quality, securing mass production orders, and achieving stable supply. [Case Overview] ■ Background: Desire to improve casting defects ■ Solution: Review of the molten metal flow in the casting heater mold ■ Effect: Acquisition of mass production orders due to quality improvement *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study on optimizing heating performance using mica heaters with high watt density and rapid heating for companies involved in semiconductor manufacturing equipment. In the company's equipment, gas used during the processing stage solidified in a low-temperature environment, affecting the safe operation of the equipment and processing accuracy. The existing heaters were unable to reach the necessary temperatures, resulting in the need for frequent maintenance. As a result of this countermeasure, the solidification of gas inside the equipment has been significantly reduced, leading to a remarkable decrease in the frequency of maintenance that had been a challenge until now. Additionally, the rapid heating provided by the mica heaters has shortened the startup time of the processing stage. [Case Overview] ■ Background: Existing heaters cannot prevent gas solidification ■ Solution: Optimization of heating performance using mica heaters with high watt density and rapid heating ■ Effect: Contributed to achieving stable operation and improving equipment efficiency *For more details, please download the PDF or feel free to contact us.