蒲田工業 List of Products and Services

It seems that the appearance of the polyethylene tanks for raw material storage installed outdoors at the chemical manufacturer is deteriorating, and you are unsure when to update them. Issues and Points: 1. It is unclear to what extent the tanks have deteriorated, and if they were to break, it would disrupt production. 2. The installation area for the tanks is narrow, making it impossible to use a crane. 3. There is a φ150 welded pipe on the top of the tank, along with other piping connection points. 4. The current foundation (SS frame) cannot be used due to corrosion.

• Other measurement, recording and measuring instruments

The ceramic hose used in the powder injection device in the steel mill's refining process wears out quickly, causing you trouble with the time and effort required for replacement. *The ceramic hose experiences significant wear in areas with large bending angles, necessitating frequent replacements.

• Other machine elements

The chemical company is facing difficulties as corrosion in the concrete pit has progressed, and they want to carry out repairs but cannot due to the tight construction schedule. Issues and Points: 1. The production plan allows for a maximum production stoppage period of only 5 days. 2. The current erosion status of the underlying concrete cannot be assessed. 3. If there is erosion in the concrete, the usual repair method would take more than 20 days. 4. There is a possibility that highly corrosive liquids may flow in, so the surface lining material must be highly resistant to corrosion and have low water absorption.

• others

You were looking for a conveyor that can smoothly transport steamed rice at a food manufacturer, but you couldn't find a satisfactory product and reached out for consultation. Issues: 1. Selection of a non-stick and durable belt. 2. Selection of a conveyor that is easy to clean. 3. Keeping costs down with a combination of standard products.

• Conveyor

We received a request to automate (reduce labor) the process of sprinkling cocoa powder as a decoration on a cake (whole size). Since cocoa powder can scatter and stick to other cakes, resulting in defective products, we need to devise a method that minimizes scattering. Issues: 1. We must eliminate unevenness while still conveying a handmade feel. 2. We want to ensure versatility so that it can be adapted for other cakes in the future. 3. The structure must be easy to clean.

• Other machine elements

In the cooling process using water, to prevent the splashing of the rebound cooling water, it is necessary to cover the surroundings with iron plates every time. Because the iron plates are large and heavy, installing and removing them requires a significant amount of effort, and there is also a risk of falling. It seems that fabric curtains have issues with heat resistance and have not been able to be implemented until now. Issues: 1. The temperature of the rebound cooling water and steam is very high, so ordinary fabric curtains cannot withstand it. 2. Simple fabric will absorb water, posing a risk of falling off the curtain rail. 3. It is necessary to consider the installation method and devise a way that does not require large-scale equipment modifications.

• others

There was an unusual noise coming from the shaft of the mill (crusher) used at the quarry, so I disassembled it for inspection and found wear on the contact surface with the inner ring of the bearing. Issues: 1. Due to the structure incorporating wiring cables inside the shaft, repair methods that involve heat, such as thermal spraying or welding, cannot be used. 2. General-purpose putties like epoxy have durability issues. 3. Finishing lathe machining to the specified shaft dimensions is necessary. 4. The production line cannot be stopped for long periods, so repairs must be completed in a short time.

• others

We propose the Sumitomo 3M Multi-Layer Nano series. This window film is composed of over 200 layers of transparent membranes, offering overwhelming heat insulation effects and high transparency. Points: 1. Cuts over 90% of heat rays (infrared) from entering through window glass, reducing the temperature near the window by up to -5.4°C (according to manufacturer tests). 2. Cuts over 99% of ultraviolet rays (UPF50+, the highest ultraviolet protection factor!). 3. Prevents glass from shattering during disasters such as earthquakes and typhoons, providing safety measures. 4. Does not use metal vapor deposition film, so it does not attenuate mobile phone signals. *As a general rule, window films are applied on the interior side (inside the room). This time, we selected the Multi-Layer Nano primarily for its heat insulation effect (infrared cut). There are also other window films with excellent security and privacy effects. Some products have multiple effects like the Multi-Layer Nano. We will select the optimal film according to your purpose and budget. Please note that some types of glass, such as wired glass or certain double-glazed glass, may not be suitable for installation.

• others

At a steel manufacturing company, a cylinder valve was installed in the factory's piping for flow adjustment, but it was difficult to finely adjust the valve opening, leading to water hammer that damaged the piping. They consulted us about whether there is a valve that can reduce the hammer. Issues: 1. The current cylinder valve makes it difficult to finely adjust the valve opening. (It goes from fully open to fully closed suddenly.) 2. They want to reduce water hammer and extend the lifespan of the piping. *Water hammer refers to a phenomenon, also known as water shock, that occurs when the flow of water in a pressurized pipe is suddenly stopped, causing a shock and high pressure within the pipe due to the inertia of the water. When water or steam in the piping is instantaneously halted, the kinetic energy of the fluid has nowhere to go and is converted into pressure energy, resulting in a rapid increase in pressure within the piping (pressure fluctuation) and the generation of a "surge pressure wave" (shock wave). This pressure wave propagates instantaneously over long distances through the piping and fluid (in the case of water, at speeds exceeding 1,400 meters per second), which can cause unusual noises (such as knocking sounds) in distant locations away from the equipment causing the issue, and can damage the piping or valve body.

• valve

At a machinery manufacturer, equipment that is jointly owned by multiple departments was being moved every time it was used. Since the equipment is heavy, moving it is very labor-intensive and time-consuming. They consulted us to see if there was a way to make it easier to move for more flexible operations. Issues: 1. The equipment is expensive, so it is shared and operated by multiple departments. 2. It is being moved on a cart, but due to its weight, loading and unloading require multiple people. 3. There is a risk of dropping or tipping the equipment when taking it off the cart, which could damage the equipment and pose a danger of injury to the workers.

• Trolley

Customers using numerous carrier rollers in pipe conveyors and shuttle conveyors have been struggling with roller wear for many years. The conveyed items adhered to the rollers, causing surface wear due to friction with the conveyor belt. This led to issues such as the edges of the conveyor belt contacting the worn rollers, causing fraying, and the belt being longitudinally torn due to burrs. The worn rollers also caused belt misalignment. Points: 1. Standard rollers do not have specific wear-resistant measures on their surfaces. 2. When problems occur, the line must be stopped, and recovery work must be carried out. 3. Torn belts may need to be replaced in some cases. 4. The conveyed items contain moisture, making them prone to adhesion.

• roller

You were troubled because there was only a large-capacity special grease available for maintenance by service personnel for food machinery. The usage amount is minimal, and a small-capacity handheld size was needed, but grease manufacturers cannot produce small-capacity sizes unless a certain quantity is ordered. Issues: 1. The standard grease comes in 5kg cans. 2. The amount needed for one maintenance session is very small. 3. Service personnel must carry various tools and parts, so they want small-capacity products. 4. There is a high possibility that the grease will deteriorate before it can be used up in standard sizes. 5. Even if supplied to service personnel nationwide, the required quantity is only a few hundred units.

• tube

We received an inquiry from a customer who manufactures diapers and other sanitary products regarding an issue with the guide rods (SUSφ30×350L) on the transport line for preventing scratches. 1. They were using fluororesin tape for scratch prevention, but as it wears down, there is a risk that wear particles may adhere to the transported items. 2. Static electricity builds up on the tape, causing the non-woven fabric of the transported items to fray, resulting in defective products.

• Surface treatment contract service

We received an inquiry from a machinery manufacturer regarding the nozzle (cast φ50×300L) of their cleaning line, which is experiencing wear due to fluid pressure loads on the inner surface. Issues: 1. Every time a leak occurs due to erosion wear, it is replaced as a consumable, resulting in labor and costs. 2. They were considering a thick application of hard chrome plating (approximately 150μ).

• Surface treatment contract service

Due to the resin remaining in the mold for resin molding (170×400×40H), it has been causing burrs, so we have been manually peeling off the resin. We received a request to make it easier to peel off because this cleaning process is time-consuming. Points and Issues: - Hard chrome plating was used. It is exposed to a temperature of 180°C. - The cleaning involves blowing compressed air followed by washing with an acidic liquid.

• Surface treatment contract service

The inner surface of the metal piping wears out prematurely because powdered resin is being conveyed through it. The wear is particularly significant at angled sections (such as bend pipes at 45° and 90°) and at the junctions of tee pipes that branch out in two directions, necessitating regular replacement of the metal piping.

• Surface treatment contract service

A component at the tip of the part that bends commercial printed materials is equipped with something called a "triangular plate." To ensure that products flow smoothly over this triangular plate, a fluororesin tape was wrapped around it, but the following issues were encountered: - It wears out quickly due to being defeated by the products. - There is the hassle of reapplying the tape. - Stopping the equipment causes a loss of time.

• Surface treatment contract service

At a major company S specializing in electronic component processing, they were manufacturing molded parts made of elastomer (a semi-finished product of rubber and resin). However, due to the softness and high viscosity of the elastomer, the release properties were poor, leading to deformation during the molding process and a high defect rate, which was a concern. 1. Deformation during the molding process of the parts. 2. High defect rate due to deformation.

• Surface treatment contract service

There was a problem with the turn bar that redirects the product (aluminum film), as it caused scratches on the product due to friction. To address this, a fluororesin tape was applied, but it wore out quickly due to the product's resistance, requiring replacement every week. Issues: 1. Scratches are made on the product (pharmaceutical packaging aluminum film). 2. The fluororesin tape is applied, but its lifespan is short (replaced once a week). 3. The replacement process is cumbersome, requiring the equipment to be stopped each time.

• Surface treatment contract service

We received a consultation from a semiconductor manufacturing company regarding the issue that "when setting products on the stage, there are times when they cannot be positioned correctly, and various surface treatments have been tried but have not resolved the problem." Issues: 1. Can we solve the problem with a surface treatment that has good slip characteristics on the stage? 2. Since it will be used in a clean room, it is necessary to minimize dust generation. 3. To prevent snagging, the dimensional tolerance of the surface should be finished to ±0.01mm, with parallelism of the bottom surface within 0.02, and the finishing of the sides should be within +0 and -0.05.

• Surface treatment contract service

We received your inquiry regarding the severe wear of the guide roll (sheave) for the carrier rope that guides the paper in the dry part of the paper machine at your paper manufacturing company. This wear causes the rope to frequently come off, disrupting production. Issues: 1. Since the carrier rope rotates alone, we would like to change the sheave from aluminum to iron or stainless steel to reduce wear, but the increased weight makes this change impossible. 2. We considered hard chrome plating, but it cannot be applied to aluminum substrates. (Direct electrolytic plating on aluminum is not possible, so a base plating must be applied first, which increases the risk of peeling when hard chrome plating is done on top.) 3. We want to maintain wear resistance even under high temperatures due to heat exposure. 4. Frequent replacements incur manufacturing and replacement costs.

• Surface treatment contract service

At the sugar manufacturing plant, sugar was adhering to the chute for loading into paper bags. Even with a fluororesin coating, it lacked durability and was problematic. Issues: 1. Compliance with food sanitation laws is essential. 2. The highly adhesive sugar should slide off as easily as with a fluororesin coating.

• Surface treatment contract service

During the film transport line, friction occurred between the product and the equipment parts while transporting, causing scratches on the product. There was a need for improvement as the flow of transport was not smooth. Issues: 1. The film must slide smoothly. 2. Scratches must not be made on the film. 3. It must be resistant to wear (durability). * There are methods such as fluorine coating, but there are challenges with durability.

• Surface treatment contract service

A food manufacturing company has a process for transporting finely crushed products through stainless steel piping and is facing the following issues: - The packing material at the pipe joints (ferrules) is made of silicone and Teflon, leading to deterioration and breakage (chipping), which contaminates the products. - Thorough management (regular checks and cleaning) takes a significant amount of time. - There is no clear guideline for when to replace the packing, resulting in high running costs.

• Other machine elements

When shipping products at the paper manufacturing company, there were the following issues between the winder (the device that rolls paper from the paper machine onto a paper tube) and the packaging device (commonly known as the one-pack packaging machine): - The products were being transported about 30 meters with a team of four people (using a forklift) to the one-pack packaging machine. - Along the way, there were weighing devices and temporary stockers, which added the effort of unloading and loading.

• Conveyor

There was an issue with the rubber roll (φ190×3700L) of the post-dryer entrance (a roll-type device that directly dries paper) after the size press (a device that applies a treatment to the paper surface for easier printing). - The sizing solution (coating liquid) adheres to it. - Furthermore, paper dust sticks to it and proliferates. - This proliferation leads to dirt, peeling, and negatively impacts the equipment and products.

• tube

There was equipment for transporting toilet paper to customers that manufactures it, using a resin belt (conveyor system) as a transport line to wrap paper around the "core." To add "fragrance" to the "core" as added value for the product, a new "sprayer" was installed to spray that fragrance. The fragrance contains a small amount of oil, which caused the following issues: Issues: - The transport belt (resin belt) generally has joints that are bonded with adhesive, but the oil penetrates that area and causes delamination. - Since several types of fragrance are used, the fragrance previously used remained on the transport belt, resulting in a mixture of new and old fragrances.

• belt

○Existing Equipment In the bagging process during shipping (conveyor line), powder products are lifted to about 4 meters in height via a flexible screw conveyor from the receiving hopper, and then transported directly below (for bagging and sorting). The transported products are sorted and bagged by operators and shipped as finished products. ○Points of Concern - Damage to the spring, which is critical for transportation - Slow transportation speed due to the structure that relies on the spring for lifting - Maintenance is challenging due to the structural design - Issues such as "bridging" and "rat holes" frequently occur in the receiving hopper, and although a vibrator was installed, its effectiveness was low.

• Conveyor

When cleaning the interior of the raw material underground tank, high-pressure washing was used, but there was a problem with poor dirt removal, making cleaning difficult. Additionally, because the raw materials are acidic, the existing resin coating tends to peel off easily, which can lead to the underlying concrete corroding. Issues: 1. Generally, using a high-pressure washer can apply too much pressure, causing the resin coating to peel off. 2. Cleaning takes a considerable amount of time (over 2 hours). *Neglecting cleaning can lead to the underground pit tank corroding and aging due to hydrogen sulfide and other factors. If left unattended, this can result in the leakage of hazardous materials, leading to serious environmental issues.

• tank

When cleaning the resin material that adheres to the screw of the extrusion molding machine, it is done manually using a hand brush, which takes a considerable amount of time for cleaning. Issues: 1. The adhering resin material is very hard, and the cleaning process takes about a day. 2. I borrowed a regular high-pressure washer from another department to try, but it was unable to remove the adhered dirt.

• High pressure cleaner

A customer in food manufacturing uses a tube-type strainer to remove impurities when piping liquid products (extractions) to storage tanks. They have encountered the following issues during cleaning: Issues: 1. Although the element is cleaned daily at the start of work, dirt is difficult to remove from the welded areas of the frame and mesh, as well as from fine details. 2. In the event of mesh damage due to aging, repairs from the manufacturer take about 14 days for delivery.

• Processing Jig

There is a ventilation opening in the upper wall above the entrance door of the laboratory, through which black smoke soot and dust generated on the rooftop are entering the room mixed with outside air. Although a filter-equipped outlet was installed at the ventilation opening, the outlet is fixed to the wall and cannot be removed, so the filter has been used for many years and is no longer functioning at all. Additionally, there are gaps between the outlet and the filter, allowing dust to enter, so we have been consulted about wanting to improve these issues in a simple manner without extensive construction. Issues: 1. Improve to allow for filter replacement. 2. Eliminate gaps to prevent dust intrusion. 3. Complete the installation work without incurring costs or taking time.

• others

At an industrial machinery equipment manufacturer, various parts used timing belts, flat belts, and V-belts, along with numerous drive belts. When these belts were put into operation at the delivery site, some of the installed belts had a short lifespan, causing disruptions in operations, and they wanted to find a way to improve this. They also inquired about shortening the time required for belt tension adjustment. Issues: The management and adjustment of tension during belt installation significantly affect belt lifespan. 1. To avoid belt troubles, we want to ensure that anyone performing the work can accurately adjust the tension to the proper level. 2. We want to manage belt tension with specific numerical values to contribute to stable operations at the delivery site. 3. Due to the large number of installed belts, we want to reduce the time spent on tension adjustment tasks.

• belt

We received a consultation from a paper processing company that is planning to change its manufacturing line due to an increase in product production. Issues: 1. They would like us to handle everything from listening to their requests, to planning, design, construction, project management, and trial operation. 2. There is one cutter (processing machine) for two manufacturing machines, so they cannot produce with both machines simultaneously. 3. The packaging machine is only able to operate at less than half of its capacity. 4. There are no reliable drawings of the current building.

• others

At the paper manufacturing company, in the dry part of the paper machine (the machine used to produce paper), there was a high usage of steam, leading to significant costs, and frequent maintenance was causing issues in terms of time, effort, and expenses. Issues: 1. The amount of steam supplied to the cylinder dryers is high. 2. To increase production, there is a desire to increase machine speed. 3. The wear of the seal rings (carbon) in the rotary joints currently in use is rapid, leading to significant losses due to steam leakage, and maintenance requires a lot of time and effort. 4. There are temperature inconsistencies on the surface of the cylinder dryers, resulting in poor product yield. In the process of manufacturing thick paper at the paper mill, a large amount of steam is introduced into the interiors of several large cylinder dryers (approximately φ2000) to heat the surfaces and dry the paper.

• joint

At the pulp dissolving facility of the paper mill, corrosive gases were generated and flowed into the adjacent machine control room, causing corrosion of the control boards and resulting in frequent emergency stops of the machines. Issues: 1. The machine building, including the dissolving equipment, is maintained at positive pressure, causing the generated corrosive gases to flow into and fill the adjacent control room. 2. Corrosive gases such as sulfur dioxide and hydrogen sulfide are being produced, but the exact composition and concentration of the gases are unknown. 3. Due to the inability to accurately determine the gas composition, effective countermeasures cannot be implemented.

• others

We received information from a hygiene products manufacturer that they are reviewing the costs of various purchased items and are striving for environmental conservation. Issues: We have decided to consider whether we can contribute to cost reduction and the reduction of industrial waste with the wide timing belts that Kamata Industries supplies, which have sponge adhesion and silicone coating processing. Currently, the timing belts themselves show almost no visible damage, but the surface sponge and coating have been damaged and replaced with new ones. 1. Is it possible to reuse the main body of the used belt with its remaining strength? 2. Can the main body of the belt be reused and the surface reprocessed to be as good as new? 3. Is it possible to lower the unit price through reprocessing?

• belt

You were using soft PVC sheets processed into a tubular shape at the joint section of the line that transports dry powder from the filling machine of a food processing factory to the bagging process, but you were facing many troubles. Issues and Points: 1. Due to the need for flexibility, you are using 0.8mm soft PVC sheets, but they wear out quickly and develop holes in a short time. 2. The joints frequently peel off. 3. You do not want to use soft PVC sheets due to concerns about environmental hormones and dioxins. 4. Since there are areas where food ingredients flow directly, you want products that comply with food sanitation laws. 5. You want to check the flow of materials inside.

• Pipe Fittings

In the line manufacturing powder for a chemical company, there are two bag filter dust collectors for drying and cooling. Various countermeasures have been implemented, but none have resulted in satisfactory products, leading to concerns about maintenance effort, costs, and safety. Issues: 1. The filter media for drying is at high temperature and low humidity, which poses a risk of static electricity accumulating and causing sparks that could lead to fires. 2. Even when using static electricity countermeasure filter media, the charge level remains high, and there have been near-fire incidents. 3. The filters for cooling become wet due to condensation of the powder, and even with pulse cleaning, the clogging of the filter media is not resolved, necessitating frequent replacements. 4. Although high water-repellent filter media have been used, they perform well immediately after replacement but do not last as long as expected.

• others

A machinery manufacturer needs to improve the transport performance of the outer film for a wrap packaging machine and has consulted us regarding the selection of belts. Issues: 1. To transport the film accurately and quickly, an air suction method is adopted, requiring suction holes in the belt. 2. The belt must also transport synchronously and accurately. 3. For vertical transport, the belt and film should not slip, but the release properties must be good.

• belt

A food manufacturer has consulted us about installing a pass box for the transfer of products within a clean room. Issues: 1. The weight and size of the products to be transferred cannot be accommodated by standard pass boxes. 2. Due to the weight of the products, we would like to install a conveyor. 3. The floor must be cleaned and washed regularly.

• others

We received an inquiry from a food company about installing an inspection ladder and safety railing at the top of a tank. Additionally, they would like to weld the cracked area of a frame that has been temporarily repaired for a permanent fix. Issues: 1. The top of the tank is sloped, slippery, and narrow, making it dangerous without safety rails. 2. Accessing the top of the tank is infrequent, occurring only a few times a year for maintenance of the valves located there and during other emergencies, so we want to minimize costs as much as possible. 3. Welding directly onto the tank will cause burn marks on the inner surface of the tank. These burn marks must be removed and cleaned, which incurs additional labor and costs. 4. The working time on-site (downtime) must be minimized as much as possible.

• tank

Juice beverage manufacturer. On the second floor, juice-filled bags are opened and fed into the production line. Once a certain amount of opened bags accumulates, they are transported to the first floor, where they are washed at the sink for reuse. In updating the sink, we would like to design a chute that allows for the bags to be flowed down and transported from the second floor, eliminating the need for the bag transport unloading process on the first floor. Issues: 1. There are constraints on installation space, and considering size and usability, it is difficult to use off-the-shelf products for the sink. 2. The installation position of the drainage outlet needs to be tailored to the site. 3. We want to flow water through the bag transport chute to improve transportability. 4. While meeting the above conditions, we want to keep costs as low as possible during production.

• others

At a stone quarry factory with washing equipment, the use of asbestos in the gland packing of slurry pumps has been prohibited, and it has been changed to non-asbestos materials (Note 1). Previously, there were no issues for about three months, but now leaks occur in about a week, necessitating replacement, which has caused problems due to the frequency of pump leaks and maintenance. 1. The packing replacement work takes about an hour for a weekly replacement. 2. Slurry leaks also adhere to the bearings near the packing, requiring the pump to be disassembled every six months and taking half a day for replacement. 3. Slurry leaks onto the surrounding floor, necessitating daily cleaning. We have received a request to reduce these tasks as much as possible.

• Special Pump

The cart for thawing frozen carcasses had deteriorated due to years of use. Its large size and the fact that there are 50 units meant that completely replacing them would incur enormous costs, so they continued to be used despite the issues. Issues: 1. The caster wheels are worn out, and due to their weight, moving them requires a significant amount of effort. 2. Water generated during the thawing of vacuum-packed frozen carcasses accumulates on the factory floor, making it slippery and unsanitary. 3. The stainless steel basket body is still sufficiently usable.

• others