蒲田工業 List of Products and Services

We received an inquiry from a lime manufacturing company regarding their desire to reduce the replacement work due to wear in the transport piping for powders and slurries. 1. The elbows and bends are particularly worn, leading to leaks, and due to the large quantity, frequent patching and other repairs or replacements are necessary, which takes up a lot of time. 2. Even after repairs, they must be replaced within about a year. 3. Frequent stoppages for repairs and replacements also lead to a decrease in production volume.

• Piping Materials

In factories that manufacture detergents and floor wax, chemical hoses are used for transporting raw materials and additives. Rubber chemical hoses are heavy and have a large minimum bend radius (poor flexibility), making them difficult to handle. Issues: 1. The need to replace hoses depending on the transported material (fluid) creates a significant workload with heavy hoses. 2. When not in use, it is preferable to store them as compactly as possible. 3. It would be helpful if the type of fluid could be easily identified at a glance.

• hose

You were considering the installation of an oil-adsorbing air filter in the exhaust duct from the heating furnace, but there were concerns about the heat resistance of commercially available products. Issues: 1. It is acceptable if the collection efficiency is somewhat lower; we want to install a filter with a high heat resistance. 2. Flammable gases and fluids will pass through, and it will be used in an explosion-proof designated area. 3. There are constraints on the installation space, so it must have a compact structure (especially in terms of thickness).

• Other filters

At a paper processing company, during the cutting and slitting process, issues arose due to static electricity accumulation at the transfer points while transporting with a resin belt, resulting in decreased yield and work efficiency. Issues: 1. Static electricity accumulates on the products, causing them to get caught on the pulley side at the transfer points without leaving the belt, frequently stopping the line and producing defective products. 2. In the accumulation process, when the air becomes dry, it is not possible to stack the items neatly. 3. The areas that accumulate static electricity vary depending on the quality, so it would be preferable to move and use them if possible.

• Anti-static products

We received a consultation from the equipment manager of a chemical company, who mentioned that due to administrative guidance, the entire company is working on energy conservation, and measures to prevent heat loss through insulation of steam and hot water piping have been implemented. However, they would like to take further measures. 1. Areas that require frequent maintenance often involve breaking and re-insulating the insulation covers, which incurs labor and costs, and also generates waste. As a result, there are surprisingly many areas that are not insulated (areas that cannot be insulated include valves, heat exchangers, pumps, etc.). 2. There is also a risk of burns in the above areas, and from the perspective of the working environment, we would like to address this issue.

• Pipe and cable cutters

The chemical manufacturer requested to install fences to make emergency exits (during disasters) safer. There were several requirements to enhance safety that needed to be addressed. Issues: 1. Since there are rotating equipment such as dust collectors and blowers inside the fence, we want to ensure safe walking even in dim light. 2. To prevent tripping, we want to anchor the fence securely without creating any height differences on the floor. 3. The fence should be made of wire mesh with a diameter of φ3 or more instead of boards, to avoid affecting the equipment inside the fence and to withstand heat and fire. 4. Since maintenance is required for the equipment inside the fence, we want to install a door. 5. To ensure safety, the side facing the walkway should be as smooth as possible, making it difficult for clothing or other items to get caught.

• others

You were troubled by the contamination of metal wear powder and wear particles in the conveying pipes for feed ingredients. Issues: 1. Since the metal detector is at the final stage, detection is delayed, which reduces production efficiency. 2. There is almost no free space around the piping line, so we want to implement measures without changing the piping. 3. Since the product unit price is not high, we want to keep costs to a minimum.

• others

We received an inquiry from a facilities manager at a semiconductor component manufacturer regarding the frequent replacement of medium-performance air filters they use extensively and the difficulties they face in disposing of the used filters. 1. They are currently replacing their filters every six months to a year and were looking for options that last a bit longer. 2. They were troubled by the high costs associated with disposing of the used filters. *The filter materials include three types: the filter medium is glass paper, the separator (to prevent the filter medium from sticking) is aluminum, and the frame is either wood or steel. The disposal costs are high because the waste disposal company has to separate the materials. If the customer attempts to disassemble them, it takes a considerable amount of time, especially since removing the separator is quite challenging.

• others

A chemical manufacturer was looking for a highly sealed storage cabinet for chemicals, taking into account size and usability. Issues: 1. There are no pre-made sizes that fit the space. 2. Since there are volatile chemicals, it is necessary to have high sealing properties and the ability to connect to a draft duct. 3. Sparks due to static electricity are strictly prohibited. 4. To facilitate the easy insertion and removal of containers and the extraction of liquids from containers, numerous sealed opening and closing doors are needed on the top and sides.

• others

The food manufacturer is considering updating the product transport line and has requested a quick response, including design, as some special specifications for the conveyor will be necessary. Issues: 1. There are areas in the conveyor line that cross emergency evacuation routes, and we want to ensure that a clear passage can be easily secured during an evacuation. 2. After the specifications are determined, we want to complete everything from design to installation and trial operation in about one month. 3. There are products that are about 45mm in size; they are small and light, but we want to ensure smooth transfer between conveyors.

• Conveyor

We received a consultation from the Manufacturing Technology Department of a paper company regarding a section of the production line that requires showering. They were previously using a strainer (for washing) to circulate water, but now they are using it as disposable, leading to a significant increase in water usage, which has become a problem for them. 1. When using circulating water, dirty water frequently clogged the shower nozzles, which number in the hundreds, requiring frequent cleaning and replacement. 2. As a countermeasure, they used an auto strainer to reduce nozzle clogging, but the maintenance of the strainer was quite burdensome. 3. To reduce strainer maintenance, they increased the mesh size of the filter, but this led to frequent clogging of the shower nozzles, creating a vicious cycle that made cleaning more labor-intensive. Ultimately, they gave up on using circulating water and resorted to disposables, increasing their usage. They want to find a way to reduce waste of water resources.

• others

Water was being flowed on the floor of the food factory, and the boundary areas with the grating and the side mortar of the drainage pit were deteriorating. It was unsanitary, and further deterioration seemed likely due to the cracks, so they wanted to carry out repairs, but they were troubled by the difficulty of stopping factory operations for an extended period. Issues: 1. Since water is flowing on the floor, measures should be taken to prevent workers and carts from slipping and falling. 2. Only one day is available to secure the construction period. 3. As it is a food factory, substances that produce strong odors cannot be used.

• others

At the paper processing factory, when the shafts of the rolls became worn and unusable, they were replaced with new ones, which was a source of concern due to the costs involved. Issues: 1. There are many rolls in use (including rubber rolls), and they want to reduce the manufacturing costs of the rolls as much as possible. 2. They want to extend the lifespan of the rolls and reduce the hassle and time involved in replacements. 3. It is difficult to predict shaft wear, and if there are no spare parts available, it can disrupt production.

• Surface treatment contract service

There was a concern that insects could enter through the opening where the conveyor line, which transports finished cardboard packaging to the shipping area, penetrates the wall and enters the warehouse. Issues: 1. Pest control measures must be implemented. 2. Due to ventilation, there is always a negative pressure. We want to minimize this condition as much as possible.

• curtain

A customer in food manufacturing has consulted us about automating the process of transferring powder, which is the raw material, into a mobile tank. Issues: 1. Currently, workers are carrying the raw material and climbing onto a platform to pour it into the tank (approximately 4 meters high). 2. The amount poured at one time is 25 kg, making it a very labor-intensive task. 3. Since the work is being done at a height, it is also a dangerous task.

• Powder Conveyor Device

In the raw materials and products warehouse and logistics department, measures to prevent the dropping of transported items when using forklifts were being considered. There is a possibility of sudden braking or sharp turns to avoid accidents, which could pose a danger to workers and those nearby due to the collapse of transported items. Therefore, safety measures were necessary. Furthermore, collapses can lead to losses of raw materials and products. Issues: 1. Since switching from wooden pallets to resin and metal pallets, the pallets have become particularly slippery, increasing the risk (especially dangerous in rainy conditions). 2. When sudden braking occurs, metal pallets can slip, causing items to fall from the forks and potentially resulting in accidents. 3. In the case of sharp turns, balance can be lost, making it more likely for items to fall or for mistakes in steering to occur. 4. Although anti-slip rubber mats with magnets are being used as a countermeasure, there were difficulties due to the issues listed below.

• others

At the factory of a manufacturer of mechanical parts, mercury lamps were used for lighting. Shadows appeared at the work area, and the brightness was insufficient, hindering the processing work. Issues: 1. When cutting steel materials to millimeter precision, the light from the ceiling's mercury lamps does not reach adequately, making it difficult to see the markings. 2. The worker's own multiple shadows (multi-shadow) fall on the object, making it hard to see the work area. 3. The difficulty in seeing the work leads to increased fatigue for the workers. 4. The lifespan of mercury lamps is short, lasting only 1 to 2 years, and their replacement involves time and costs.

• Other lighting equipment

We received an inquiry from a representative of a research department conducting tests on printing performance and equipment, asking us to look for a gantry crane that can lift a special resin sheet printed in a clean room while remaining on a frame (approximately 2m x 2m). 1. They searched for off-the-shelf gantry cranes suitable for clean room specifications, but the prices exceeded their budget significantly, so they are looking for options that fit within their budget. 2. Due to limited space around the machinery, they are looking for a compact option. 3. Since the crane may need to be fine-tuned or moved to other machines, they are looking for one with casters that remains stable during movement.

• crane

In the raw material air transport line, a diverter valve is used to distribute the tanks for input. Due to aging, we want to update it, but the manufacturer that originally produced it is no longer in business. Issues and Points 1. Even if we replace it with another manufacturer, the dimensions such as diverter angle and spacing do not match. 2. There are no mechanical drawings or related documents for the existing equipment. 3. When removing and installing the diverter valve, disconnection and reconnection must be performed, which requires shutting off the main power supply, but we want to keep other lines operational.

• valve

We received an inquiry from a resin film manufacturing company regarding the inspection process of their high-performance resin films, as they are experiencing issues with dust adhering to the films. 1. Dust adheres to the films, and they have to be removed each time using adhesive rollers, which is time-consuming and labor-intensive. 2. It is also difficult to separate the inspection workspace with clean booths or similar measures due to the nature of the process.

• Other polymer materials

A food company has decided to install large-diameter duct piping due to the expansion of their manufacturing line. Since the piping will carry exhaust gases containing solvents, it is necessary to use stainless steel ducts. They requested to keep costs as low as possible. Issues: 1. A φ500 stainless steel duct must be installed from the manufacturing building to the outdoor scrubber over a distance of 150 meters. 2. With stainless steel spiral ducts, leaks occur at the seam. 3. If standard stainless steel pipe products are used, only thick-walled specifications are available, which increases costs and weight. 4. Since this work will be done simultaneously with other construction, it is necessary to devise a work schedule within the construction period.

• Piping Materials

You were troubled by having to perform frequent maintenance due to leaks from the valve in the pure water generation system. Issues: 1. Leaks are occurring at the valve through which the raw water mixed with sodium hypochlorite passes in the pure water generation system. The leaked liquid drips onto the control valve below, causing corrosion. 2. The corrosion of the control valve leads to operational failures, making flow adjustment very time-consuming and problematic. 3. Although in small amounts, the leaked liquid could potentially cause soil contamination. (Simple countermeasures have been implemented) (Sodium hypochlorite is a specific substance that is not classified as one of the 28 harmful substances defined by the Water Pollution Control Law, but it may eventually be designated as a harmful substance.)

• others

The food company was struggling with dust control measures in the process of feeding raw materials into tanks. Issues: 1. When a person pours powder into the inlet of a small tank, dust swirls throughout the room. 2. There is a steam exhaust outlet at the top of the tank. 3. When dust on the floor and equipment gets moisture, it becomes sticky, requiring cleaning every time work is done. 4. For hygiene reasons, it is not possible to wash the floor with a hose. 5. There are no scaffolding or platforms around the tank, making work difficult.

• tank

The safety cover surrounding the manufacturing line has deteriorated, and we would like to update it. Due to changes in the line, it has been constructed multiple times in the past with extensions, resulting in a lack of overall cohesion and poor appearance. Some of the resin panels also show signs of damage. Issues: 1. Instead of enclosing the entire manufacturing line broadly, we want to cover it compactly in accordance with the equipment's contours. 2. Using commercially available aluminum frames for customers to design and fabricate the cover themselves is very labor-intensive. 3. The existing product uses resin panels, which are prone to cracking and pose risks of foreign material intrusion and contamination; therefore, we would like to use expanded metal, which has a proven track record in other locations, as the material for the panels.

• others

You were looking for a shoe rack at a food processing company, but you consulted us because you couldn't find any low-priced products. Issues: 1. Since it's a food factory, you prefer stainless steel material that prevents corrosion and rust. 2. The quantity is insufficient. 3. Since it's not directly on the production line, you want to reduce costs as much as possible.

• others

In the filling process of a food manufacturer, parts and tools were being cleaned with hot water, but they consulted us because they wanted to reduce labor and time. Issues: 1. Several times a day, parts were removed and cleaned after each process was completed. 2. Due to hand washing, one person spends 3 to 4 hours a day on this task. 3. The shapes of the parts vary, and some are difficult to clean.

• Other cleaning machines

The dust collector in the crusher room of the cement manufacturing company was not functioning properly, leading to a decrease in dust collection capacity, and immediate measures were necessary. Issues and Points 1. We considered repairs, but obtaining the necessary parts was difficult. 2. We want to improve the working environment as quickly as possible. 3. It is a condition that it can be done at a lower cost than repairs.

• Dust collector

At the factory of a food manufacturer, the floor coating had started to peel, and there were the following issues: Issues: 1. Since products are supplied to convenience stores, there is very little time available for repairs. 2. Because the manufacturing site and the construction area are close together, the use of organic solvents that could affect the products and materials that might transfer odors should be avoided. 3. A repair that is long-lasting and has good heat resistance is desired.

• others

We were troubled by the very high cost of consumable parts (pump parts for transporting food) used in food machinery. Issues: 1. PEEK material is inherently expensive, and since we purchase it as a consumable part from the manufacturer, it incurs high costs and has a lead time of over 45 days. 2. Due to harsh usage conditions, it only has a lifespan of two months. 3. It needs to meet requirements for heat resistance, wear resistance, sliding properties, and compliance with food sanitation laws. 4. There are no dimensional drawings, making it difficult for anyone other than the manufacturer to address the issue.

• Other pumps

We received a consultation from a food factory regarding effective measures to eliminate the possibility of foreign matter contamination and mold growth at the air conditioning vents. Issues: 1. The fundamental solution would be to update the air conditioning system to a new model, but there is no budget available for that. 2. The customer had temporarily installed filters themselves, but the pressure loss was significant, hindering airflow and cooling effectiveness, and the appearance was poor, leading to a lack of confidence in the effectiveness of the measures.

• others

At the bento manufacturing factory, we use a hopper made of resin (polypropylene) for the machine that packs cooked rice into bento boxes. Due to frequent installation and removal for cleaning, the welded feet can come off, and cracks can appear at the joints. Similarly, the chute made of resin (nylon) shows signs of aging, such as splinters, fuzziness, and scratches on the surface, making it difficult to clean. Issues: 1. Parts are purchased from the machine manufacturer, but they are never cheap. 2. We attempt self-repair (by securing with tape), but it peels off again quickly. 3. It is very unfortunate that the hopper, which is still usable in terms of surface condition, cannot be used because the joints have come off. 4. The chute still seems usable, but if the dirt cannot be removed, the risk of mold and bacteria growth increases significantly.

• others

At the paper mill, damage occurred to the insulation material of the exhaust duct due to the impact of the earthquake. An ISO audit and a factory tour for users are scheduled, and we have been consulted about urgently repairing it before then. Issues: 1. Due to the old equipment, there are no existing drawings or specifications, so we must take measurements on-site and carry out repairs. 2. There are only about 10 days until the desired completion date for the construction. 3. It is necessary to finish the work in harmony with the surrounding lines.

• others

At the H-beam factory of A Steel Works, products (H-beams) are inspected for defects while being rotated on rail steel. This inspection process is conducted continuously 24 hours a day, and the H-beams being inspected range from small ones measuring 244w×252h×11m and weighing 0.7t, to larger ones measuring 890w×299h×15.5m and weighing 3.3t. The noise level in this factory was tremendous. The noise exceeded 120 dB, which is quite loud, and even with earplugs, there is a risk of hearing loss in the working environment, prompting inquiries about noise prevention measures. 1. The noise during the flipping of H-beams is severe. 2. There is constant noise 24 hours a day due to multiple inspection lines. 3. Even with earplugs, it can lead to occupational hazards for workers (such as hearing loss). 4. Despite inspecting for defects, there were instances where beams were dropped, causing scratches.

• Rubber

Due to the presence of delamination and cracks in the corrosion-resistant lining inside the exhaust gas treatment device's chimney, we have received inquiries regarding the investigation of the causes of delamination of the existing lining and consultations for extending its lifespan during the renewal process. 1. The existing lining was installed by the plant manufacturer at the time of equipment introduction, so details such as the construction method, components, and film thickness are unknown. 2. Since the existing lining became unusable in about six years, we would like to ensure a durability of over ten years for the renewal. 3. It is necessary to extend the lifespan while staying within the specified budget and construction period.

• others

In the adhesive tape manufacturing line, there was an unavoidable process where the adhesive surface came into contact with the roll. Various non-adhesive rolls were tested, but satisfactory performance was not achieved, leading to frequent line stoppages, and each time, cleaning work had to be carried out. Issues: 1. It is not possible to create a mechanism that does not touch the adhesive surface. 2. Based on past experience, surface treatments with excessive roughness are unsuitable as the adhesive material tends to get trapped in the valleys. 3. The release properties obtained from fluorine-based surface treatments do not meet the required standards.

• others

At the A Steelworks, you were struggling with dust generation and spillage issues on the powder material transport conveyor line. In the transition areas of steep belt conveyors, materials are prone to spillage and dust generation. As a countermeasure, skirt rubber has been installed to address spillage and dust from the sides of the belt. This skirt rubber was made from cutting old belt conveyors. When the skirt rubber from the old belt is pressed against the surface of the belt, it causes uneven wear in the areas where the skirt rubber makes contact, and the belt can slip due to the pressure applied. As a result, it was used with a gap, which meant that spillage and dust generation could not be controlled. Issues: 1. Uneven wear of the belt occurs. 2. The belt slips due to pressure. 3. Using it with a gap prevents spillage and dust generation from stopping.

• others

We have decided to introduce a hygienic stainless steel conveyor to the bento manufacturing line. We want to meet the required specifications while keeping costs as low as possible. Issues: 1. To perform the food plating work, tables are needed on both sides of the conveyor. However, we would like them to be removable so they do not get in the way when plating is not being done. 2. We want to change the line speed depending on the items flowing on the conveyor, so we would like the speed to be displayed digitally for the operators. 3. There are many specifications required for the conveyor, but we want to keep costs to a minimum.

• others

The blower's exhaust port had not been specifically addressed for noise reduction. We received a request for noise reduction from the neighboring factory, and measures are now necessary. Issues: 1. We would like to address the issue only by modifying the exhaust port without updating or altering the blower itself. 2. We want a 10dB reduction at the exhaust port outlet. 3. Since it is installed outdoors, we would like measures to prevent corrosion.

• others

You were troubled by the adhesion issues with the glue pot for the back gluing of the binding machine and the perfect binding machine. The glue used is a reactive hot melt adhesive that has a very strong bonding power even in small quantities, and it is a high-priced specialty product. Once it hardens while adhered, the peeling process becomes very difficult, and it cannot be reused, resulting in significant waste. Issues: 1. Since the glue has a strong bonding power, high non-stick properties are required. 2. As it is hot melt, the glue pot is constantly heated with a heater. 3. After removing the glue pot for processing, it must be immediately surface-treated and delivered for installation.

• others

This is a case study from a customer in the mining industry. A ropeway has been installed in the factory for transporting materials. When the carrier (the suspended transport device) passes through the support, significant friction occurs between the balance saddle and the wire rope (locked coil), leading to long-standing issues with wire breakage. Additionally, there is a load on the supports, causing loud creaking noises. Issues: 1. Measures are needed to reduce friction at the balance saddle. 2. Since it is an outdoor high location, extensive renovation work is difficult, and welding operations are also challenging. 3. A solution that does not require maintenance is particularly desirable. 4. There are more than 50 locations that require measures.

• others

When conducting maintenance work on large-diameter gas piping, it is best from a safety standpoint to completely evacuate the gas before starting the work. However, due to the total length of the piping at A Steel Works being several kilometers, it is impossible to evacuate all the gas within that piping. According to A Steel Works' safety standards, work cannot commence unless double isolation is performed to ensure safety. While water seal valves (which fill the V-shaped sections of the piping with water to stop the gas) are installed at certain intervals along the gas piping, relying solely on these water seal valves does not constitute double isolation, leaving the work unable to commence even if there are valves to be replaced or areas to be repaired. We received inquiries about whether there might be another method to isolate the gas to allow the work to proceed. Although proposals for installing shielding plates were made, the costs associated with such work are prohibitively high, making it difficult to carry out. 1. To ensure safety during the work, double isolation (Note 1) must be performed before commencing. 2. Water seal valves are installed, but there is no other isolation method available. 3. Establishing new shielding plates or valves would incur very high costs. 4. The piping lines are located throughout the factory, making it impossible to install shielding plates or valves everywhere.

• others

Overview of Equipment This switching valve has a high switching frequency, occurring once every few seconds. Additionally, the exhaust gases are extremely hot, making the operating conditions quite harsh for the valve. Conventional valves (switching valves) have a lifespan of 1 to 2 years, during which operational failures frequently occurred. The cause was dust and tar entering the gap between the body and shaft of the fuel gas switching valve and exhaust gas switching valve, causing them to stick. As a result, there was a decrease in production efficiency, and in some cases, line stoppages occurred. Moreover, not only the switching valve itself but also the drive unit (air cylinder) frequently experienced failures, leading to a loss of functionality. Due to the necessity of regularly disassembling, cleaning, and replacing these switching valves (during each repair), the maintenance costs became quite substantial. 1. Operational failures of the valve due to dust and tar ingress 2. Operational failures due to drive unit (air cylinder) malfunctions 3. Loss of raw material costs due to poor sealing of the valve 4. Burden of labor and costs associated with disassembly and cleaning

• valve

At the steelworks, a belt cleaner has been installed as a measure against material spillage from the raw material transport belt. However, the previously used cleaner had a scraping part (tip) made of super steel. While the super steel tips were effective in scraping, they caused issues when there were partial repairs or uneven wear on the belt, as they would dig in and damage the belt or cause uneven wear. In some cases, they even caused significant damage such as longitudinal tears by digging into the belt itself. They were looking for a good solution to achieve the conflicting objectives of cleaning the belt surface (scraping) and preventing damage to the belt. Additionally, poor scraping effectiveness on the belt surface could lead to spillage of the transported raw materials, resulting in increased labor and costs for cleaning up spills in the factory. 1. Measures against material spillage from the conveyor belt. 2. Measures to prevent damage to the belt from the belt cleaner.

• Conveyor

At the Tokyo Kanefuku seafood manufacturer, the quality load fluctuations of the wastewater discharged from the factory were significant and unstable. As a result, they faced issues with stabilizing the water quality after treatment and the associated operational management efforts. 1. The quality of the discharged wastewater is unstable. 2. Operational management is very labor-intensive for stabilizing the numerical values. 【Current Wastewater Treatment Equipment】 Treatment Device Name: Multi-chamber Resin Net Treatment Device Treatment Method: Contact Aeration Immersion Filtration Contact Oxidation Method Treated Water: Wastewater generated during the production of seafood (mentaiko)

• others

You were looking for an emergency shower room for a semiconductor manufacturing company in case of exposure to chemicals (semiconductor cleaning agents). Despite searching extensively, it seemed that the available options were quite expensive, which made you hesitant to purchase and install one. Therefore, you sought advice on whether an emergency shower room could be obtained at a lower cost. 1. I want to install an emergency shower booth for when chemicals are exposed. 2. I have searched various options, but only expensive ones were available. I want to find a more affordable option.

• others