蒲田工業 List of Products and Services

The clean room as a structural facility for CPF (Cell Culture Processing Facility) must comply with relevant laws and regulations (Regenerative Medicine Law, Pharmaceutical and Medical Device Act) and require advanced management in accordance with GCTP ministerial ordinance. It is designed and constructed not only to achieve the appropriate cleanliness, room pressure, and temperature and humidity for each area, including sterile management areas, cleanliness management areas, and general management areas, but also to ensure sterility through thorough environmental monitoring after operation. Our company designs and constructs facilities tailored to your needs, from large CPFs to small CPFs located within clinics. 【Features】 - Control of cleanliness, temperature and humidity, and airflow through an environmental monitoring system - Centralized automatic control of room pressure management - Design that considers the flow of workers and materials, achieving advanced sterile management - Comprehensive construction including validation, sanitation, and microbial testing *For more details, please refer to the PDF materials or feel free to contact us.

• Other clean room equipment and facilities

In a case at a pharmaceutical company, a filter-integrated gasket incorporated into a rubber-lined tank was damaged, causing expensive resin material to leak outside the tank, which required urgent response. Considering the dissatisfaction with the airtightness, we proposed a review of the structure and a redesign for production. As a result, we were able to complete the replacement work for the affected tower in about a month after the consultation. Not only did we shorten the delivery time, but our safety management system for the construction was also appreciated, leading to the request for the replacement work of all remaining towers. [Case Study] ■ Issues - The filter had a tear, causing expensive resin material to continue leaking outside the tank, resulting in daily losses. ■ Proposal - Considering the dissatisfaction with the airtightness, we reviewed the structure and proposed a redesign for production. *For more details, please refer to the PDF document or feel free to contact us.

• others

Kamata Industrial Co., Ltd. provides a "Clean Air System" suitable for each site and the needs of our customers. In manufacturing environments such as semiconductors, LCDs, and precision machinery, the miniaturization of integrated circuits and other components has progressed, and as a result, the cleanliness level of clean rooms has inevitably required enhancement, leading us to carry out construction at the necessary levels. As an important clean system, we offer various equipment that suppresses and removes not only dust but also gas substances generated from materials, static electricity, and vibrations at a high level, supporting the supply of high-quality products. 【Features】 ■ Provides various equipment that suppresses and removes at a high level ■ Supports the supply of high-quality products ■ Designs and produces air showers tailored to the customer's usage conditions and purposes *For more details, please refer to the PDF materials or feel free to contact us.

• Other clean room equipment and facilities

The food company was troubled by odors entering the clean room where product analysis and testing are conducted from the adjacent work process. We proposed the "Photocatalytic Deodorization System" from Renatec, which has minimal pressure loss and a very high deodorization speed. As a result, the odor concentration after installation was reduced to approximately 1/6, creating an environment in the clean room where odors are hardly detectable. 【Case Study】 ■ Issues - Odors are not acceptable in the clean room as sensory tests are conducted. - We want to avoid worsening the cleanliness of the clean room. ■ Proposal - Proposed the Renatec photocatalytic deodorization system. *For more details, please refer to the PDF document or feel free to contact us.

• Clean Booth

A customer manufacturing rubber hoses was struggling with poor work efficiency in the inspection process. We proposed a pressure-resistant "collet joint type quick coupler." As a result, work efficiency was overwhelmingly improved. When actually installed, it was clearly communicated through sound and feel that it was securely fastened, leading to feedback that it could be used with confidence. 【Case Study】 ■ Issues - High-pressure rubber hoses undergo pressure testing for all units before shipment. - When there are large orders, inspections are handled using a manpower-intensive approach. ■ Proposal - Proposed a pressure-resistant collet joint type quick coupler. *For more details, please refer to the PDF document or feel free to contact us.

• Coupler

We would like to introduce a case study of solving our customer's problems. They were experiencing issues with the impact rollers used under the chute of a conveyor belt for transporting raw materials, as their lifespan was short. We proposed replacing the impact rollers with our conveyor belt shock-absorbing material "Kurepacto." As a result, there were no more sudden breakage accidents with the impact rollers. Additionally, the amount of falling debris was drastically reduced, and cleaning time was shortened. By stocking just two types of Kurepacto, we can accommodate all belt widths, making it economical with minimal inventory. [Case Study] ■ Issues - Short lifespan of impact rollers ■ Proposal - Suggested replacing the impact rollers with the conveyor belt shock-absorbing material "Kurepacto." *For more details, please refer to the PDF document or feel free to contact us.

• others

A customer manufacturing automotive parts was struggling with the inefficiency of their inspection process. We proposed a "one-touch sealing adapter" specially designed to fit their work. As a result, the time spent on inspections was significantly reduced. The flanges were located in hard-to-reach places, which alleviated the physical burden on workers and eliminated large tasks. [Case Study] ■ Issues - There are flanged pipes that must be sealed during testing. - Sealing the flanges requires tightening bolts in three places, and we wanted to improve this process. ■ Proposal - We proposed a one-touch sealing adapter specially designed to fit the work. *For more details, please refer to the PDF document or feel free to contact us.

• others

"Preliar i" is a system that displays the pressure distribution applied to an ultra-thin approximately 0.1mm thick film sensor sheet on a PC or tablet screen. The sensing points can reach up to approximately 2000, allowing for the display of high-density pressure distribution. It is compatible with PCs and tablets equipped with Windows OS, and measurement can be performed simply by pressing the operation buttons in order from the top. 【Features】 ■ Compatible with PCs and tablets equipped with Windows OS ■ Measurement can be performed by pressing the operation buttons in order from the top ■ Sensing points can reach up to approximately 2000, displaying high-density pressure distribution ■ Real-time display of pressure distribution, enabling measurement of time-series changes ■ Measurement possible with a maximum sampling rate of 100Hz *For more details, please refer to the PDF document or feel free to contact us.

• Other measurement, recording and measuring instruments

We would like to introduce a case study of solving customer issues. You were troubled by the lack of efficiency in the airtightness testing of the refrigerant piping for car air conditioning. Our company proposed a specially designed "one-thread clamp" tailored to the work, along with an automatic release system using air after the inspection was completed. As a result, the time previously spent on inspections was significantly reduced, allowing for additional tasks to be added within the inspection time. [Case Study] ■ Issues - The review of processes led to additional tasks being added during helium testing, resulting in decreased work efficiency. ■ Proposal - We proposed a specially designed one-thread clamp tailored to the work. - We proposed an automatic release system using air after the inspection was completed. *For more details, please refer to the PDF document or feel free to contact us.

• joint

We would like to introduce a case study of solving problems for customers who manufacture electronic components. They were using suction pads from other companies in their operations, but they were struggling with poor suction, and even when the pads did adhere, they would sometimes drop the items during the process, which hindered their work efficiency. We proposed suitable "suction pads" in collaboration with a specialized manufacturer of vacuum transport equipment. The selection of suction pads involved borrowing the items to be transported from the customer and conducting tests with multiple suction pads, after which we submitted a test report. After reviewing the test results, the customer decided to adopt our solution immediately. They are very pleased with the improved workability. [Case Study] ■ Issues - The parts are packaged individually in bags, and due to wrinkles, they are difficult to adhere to. ■ Proposal - We proposed suitable suction pads in collaboration with a specialized manufacturer of vacuum transport equipment. *For more details, please refer to the PDF document or feel free to contact us.

• others

We received an inquiry from a customer who manufactures water heaters, seeking to improve the efficiency of their inspection process, which includes checking for cracks in the piping and leaks from welds through water flow tests before shipment. We proposed a specially designed "male joint" tailored to their work. As a result, the time required for inspections has been significantly reduced. The number of units that can be inspected per day has increased from 80 to 240, tripling the output. [Case Study] ■ Issues - Installation and removal take a long time - There have been past incidents of seal tape fragments entering the piping ■ Proposal - We proposed a male joint specially designed to fit their work *For more details, please refer to the PDF document or feel free to contact us.

• joint

A customer manufacturing air conditioning units was experiencing issues in the airtightness testing process of the refrigerant piping. We proposed a "straight pipe ball joint" that can also accommodate aluminum pipes. As a result, we were able to eliminate the process of cutting the pipes after inspection, significantly improving the work efficiency related to the testing. [Case Study] ■ Issues - The lever-type clamp has a thick diameter and requires clearance for lever operation, making it impossible to inspect products in parallel. ■ Proposal - We proposed the straight pipe ball joint. *For more details, please refer to the PDF document or feel free to contact us.

• joint

A food company consulted us about a system to measure and record noise generated in their factory. We proposed the "Noise Monitoring System" manufactured by Rion. After installation, we made adjustments such as setting the measurement angles and started measuring and recording. As a result, we were able to remove noise from vehicles that was captured before the adjustments from the recordings, allowing us to measure and record only the noise generated by the factory. [Case Study] ■ Issues - We want to continuously monitor and record whether the noise generated by factory equipment exceeds the standard values. - A system that can record stably without interruption is needed. ■ Proposal - We proposed the Rion Noise Monitoring System. *For more details, please refer to the PDF document or feel free to contact us.

• Noise Inspection

At a certain research facility, the "NBS valve" has been adopted for high-temperature gas piping. We have also received a request for the production of a "heat-resistant flange gasket" that can be used at fluid temperatures of 650°C. Additionally, we proposed the "Thermiculite gasket," which excels in chemical resistance and heat resistance. As a result, concerns regarding heat resistance and oxidation were alleviated, given the numerous adoption records in chemical plants and other applications. [Case Study] ■ Issues - High-temperature metal jacket gaskets cannot be used as they require high tightening force. ■ Proposal - We proposed the Thermiculite gasket, which excels in chemical resistance and heat resistance. *For more details, please refer to the PDF document or feel free to contact us.

• others

At the food factory, it was pointed out that the outdoor CO2 circulation tank only had a ladder, raising concerns about safety during operations, and they sought advice on countermeasures. We proposed the "Escort I-Rail," a fall prevention device that can be installed in extremely small spaces. As a result, they were pleased that a long-standing issue had been resolved. During actual operations, simply moving the Iris allows for safe work, which was also evaluated as an improvement in work efficiency. 【Case Study】 ■Issues - They want to replace the back basket ladder, but there is no installation space. - There is no place to attach a safety harness during tank top inspections, posing a high risk. ■Proposal - We proposed the fall prevention device "Escort I-Rail." *For more details, please refer to the PDF document or feel free to contact us.

• tank

We would like to introduce a case study of solving our customer's problem. In the process of moving transmissions in the automotive industry several times, the customer was struggling because they had to attach nuts to bolts and then suspend and move them, followed by manual tightening and loosening, which took a significant amount of time and effort. We proposed the "FF type" one-touch coupler hanging hardware that can be connected easily with one touch, tailored to the shape of the bolts used by the customer. As a result, the tasks that were previously done manually could now be moved easily with one touch, significantly reducing the work time, and the customer was very satisfied. [Case Study] ■ Issues - Manually attaching nuts to two bolts on the transmission for movement. ■ Proposal - Proposed the "FF type" one-touch coupler hanging hardware. *For more details, please refer to the PDF document or feel free to contact us.

• Coupler

We would like to introduce a case study on solving the problems faced by our customers who manufacture electronic components. Although production is carried out in a clean room operating at Class 1,000 (ISO Class 6), they were struggling with the inability to eliminate contamination. We proposed the "ViEST" fine particle visualization system manufactured by Shin Nippon Air Technologies Co., Ltd. As a result, after implementation, we captured images of several suspicious areas, clearly confirming the presence of dust. [Case Study] ■ Issues - There are multiple operations and locations within the clean room where dust generation is suspected, but they cannot be identified. ■ Proposal - We proposed the "ViEST" fine particle visualization system manufactured by Shin Nippon Air Technologies Co., Ltd. *For more details, please refer to the PDF document or feel free to contact us.

• others

We would like to introduce a case study of solving a customer's problem. We received a request to investigate whether the PVC drainage pipes buried underground are deteriorating or if there are any cracks. Our company proposed to perform a cleaning operation before the investigation, and then insert a fiberscope (industrial endoscope) through the inspection opening to observe the interior and take photographs. The cleaning and investigation of the 150m section in question were completed in two days, and we were able to create a very detailed investigation report with numerous photographs. [Case Study] ■ Issues - The inner diameter of the pipes is approximately 150mm, so it is not possible for a person to enter for inspection. ■ Proposal - Conduct internal observation and photography using a fiberscope. *For more details, please refer to the PDF document or feel free to contact us.

• Other contract services

At the food factory, the chilled water coil of the air conditioning unit has corroded and started leaking, necessitating urgent repairs. Our company had a custom chilled water coil manufactured by the air conditioning unit manufacturer to fit within the main unit. As a result, we were able to utilize the main unit and ducts as they were, significantly reducing costs compared to a complete replacement. 【Case Study】 ■Issues - The corrosion of the coil has progressed to a point where partial repairs such as welding are not feasible. ■Proposal - Custom manufacturing of a chilled water coil by the air conditioning unit manufacturer to fit within the main unit. - Conducted multiple simulations of the loading and unloading process through discussions with the customer. *For more details, please refer to the PDF document or feel free to contact us.

• Inductor Coil

We would like to introduce a case study of solving customer issues at an automobile manufacturer. The company faced frequent connection errors due to the similar diameters and connection shapes of hoses. Although they attempted to differentiate using paint and tape, these quickly peeled off and were not effective solutions. Recently, a connection error occurred that could potentially lead to a serious disaster, prompting the need for connection fittings that could be easily distinguished at a glance. In response, we proposed a one-touch coupler with colored hard anodized treatment on the nut section. [Issues] - Even with color coding using paint or tape, it quickly peels off. - The diameters and shapes are similar, making it difficult to distinguish at a glance. - Mistaking fluids could lead to serious accidents such as explosions. - There have been instances of electrolysis occurring at the connection points. *For more details, please refer to the PDF document or feel free to contact us.

• Coupler
• Other electronic parts

We would like to introduce a case study on solving customer issues at a paper mill. In the drying process, the surface of the dryer rolls tends to accumulate paper fibers, which can reduce drying efficiency if left attached. To address this, we proposed a method called "Flowglass," which uses adhesive tape made from glass cloth impregnated with fluororesin. During installation, it is essential to perform thorough surface preparation to prevent peeling, and to carefully work to ensure that no air gets trapped between the tape and the roll. The finished work done by our experienced veteran workers has received high praise from customers. [Issues] - Large rolls with a width of over 2000mm and a diameter exceeding 1500mm require significant labor and costs for removal and reinstallation. - Heat-shrink fluororesin is not available in standard sizes, making it unsuitable for this application. *For more details, please refer to the PDF document or feel free to contact us.

• Adhesive tape

We would like to introduce a case study of solving customer issues at a paper processing company. In order to receive OEM contracts from a major manufacturer, it was necessary to improve the production environment. This involved renovating aging buildings and infrastructure such as piping, as well as reviewing the complex layout of equipment to enhance production efficiency. As a result, existing steel frames and beams were reused as much as possible after confirming their strength, achieving a reduction in construction time and costs. Consequently, without causing any foreign matter contamination incidents, a clear flow line was established, which shortened the distance for movement and improved productivity. 【Proposal Details】 ■ Ceiling replacement, floor painting, wall painting ■ Various piping updates and partial rewiring ■ After removing existing walls, new partition walls were installed to optimize area division ■ Relocation and installation of air showers, handwashing stations, and sheet shutters ■ Efficient flow line construction through the relocation of chemical tanks, various manufacturing equipment, and transport devices ■ Removal of existing liquid barriers and installation of new liquid barriers *For more details, please refer to the PDF document or feel free to contact us.

• tank
• Machinery and equipment installation/dismantling/relocation

"We want to remove foreign substances mixed in the raw materials to improve quality. We would like to process them before they are put into the raw material tank." Here is a case study that addresses these customer concerns. We selected and installed an auto-strainer, modified the piping, and undertook bypass construction, as well as manufactured and constructed maintenance platforms based on site sketches, all in one order. As a result, we received feedback saying, "We were able to remove large foreign substances and are very satisfied. Furthermore, maintenance is user-friendly since we can set the number of cleaning cycles on the control panel." [Issues] ■ Large foreign substances are mixed in the raw materials in various places. ■ The equipment is located at a high position, requiring piping modifications and staging platforms. ■ We also want maintenance scaffolding for cleaning and replacing filters. *For more details, please refer to the PDF document or feel free to contact us.

• valve
• Piping Materials

This is a case study of solving customer issues in the pet bottle transportation process at a beverage company. In recent years, the company has been facing problems with the increasingly complex and diverse shapes of bottles, which tend to get caught on the conveyor's guide plates and fall over. To address this, we obtained information that applying a V-groove processing to the surface of the guide would reduce the contact area and resolve similar troubles, and we proposed this solution to the customer. As a result, instead of a temporary measure like applying slip-resistant tape, a permanent solution was achieved. [Key Points] - Multiple types were prototyped to find the optimal depth and pitch for the V-groove. - CAD drawings were submitted to facilitate easy ordering upon formal adoption. - The guide was manufactured at a length of 2 meters, considering the constraints of the processing machine and handling during installation. *For more details, please refer to the PDF document or feel free to contact us.*

• Transport and handling robots
• Other conveying machines

We would like to introduce a case study of solving customer issues at a chemical plant. We received a consultation regarding signs of aging in the drainage lines within the factory. Although there are currently no leaks, the customer expressed a desire to carry out thorough repairs to ensure safe operations in the future. As a solution, we updated the existing piping to PVC HT pipes. We also proposed applying a "polyurea resin" coating to the interior of the catch basin at the same time as its renewal. As a result, the coating had very little odor and could be applied in a very short time. [Issues] - The repair targets are the pipes and catch basin buried underground. - The drainage contains strongly alkaline components, and any leakage could lead to significant problems. - The concrete parts are showing noticeable deterioration. - The catch basin should not only be renewed but also coated with a durable finish. - Since this area is used for raw material delivery, we would like the work to be completed as quickly as possible. *For more details, please refer to the PDF document or feel free to contact us.

• Surface treatment contract service
• Coating Agent
• Repair Agent

We would like to introduce a case study of solving customer issues at a food factory. We received a consultation regarding a line that uses hot water, where the flooring material at the junction with the drainage was peeling off quickly, causing problems. In response, we proposed a floor coating that can withstand high temperatures. As a result, we were able to prevent the peeling of the base material and achieve heat resistance and high durability for the flooring material. Although improving the base material took time due to the need for concrete polishing, we focused on careful work and were able to integrate the new base material effectively. [Issues] - The junction with the drainage is prone to peeling of the flooring material. - Common epoxy resin flooring materials peel off quickly. *For more details, please refer to the PDF document or feel free to contact us.

• paint

We would like to introduce a case study of solving customer issues at a pharmaceutical company. The company regularly sterilizes and cleans sanitary silicone hoses, but they were struggling with drying and storage after cleaning, and could not find a suitable existing drying cabinet, so they reached out for consultation. We listened to their needs and proposed the design and manufacturing of a dedicated drying and storage cabinet. As a result, this equipment can dry and store eight hoses, has a quick drying time, and allows for hygienic management even when not in use. [Issues] - Since we need to dry sanitary hoses, we want to blow clean air into the cabinet. - We want a function to maintain the internal temperature between 30-40°C and adjust the operating time with a timer. - We would like a structure that allows for easy storage and retrieval of the hoses. *For more details, please refer to the PDF document or feel free to contact us.

• Drying Equipment
• Contract manufacturing

This is a case where Kamata Kogyo centralized the construction management of a large-scale renovation and thoroughly managed the schedule to complete the project according to the customer's requests. The delivery date for the new equipment to be introduced was already set, and we were struggling to find a way to complete the renovation work, including partition work and other ancillary construction, by the deadline. Therefore, we proposed to centralize the construction management of all works to ensure completion by the deadline. As a result, we were able to complete all the construction before the introduction of the new equipment. [Issues] - The delivery date for the new equipment was already determined, and all construction had to be completed by that date. - The types of construction were diverse, including partition work, air shower installation, floor coating, and sheet shutter installation. Selecting contractors and coordinating for each type of work would not allow for completion by the deadline. *For more details, please refer to the PDF document or feel free to contact us.*

• Other contract services

We would like to introduce a case study of solving customer issues at a chemical plant. The company faced a problem where raw material storage silos were shared among multiple production lines. When switching production, if raw materials from the previous product remained in the silo, it would lower the purity and lead to a decline in quality. To address this, we proposed an "Air Knocker" that is installed on the exterior of the silo to provide impact and dislodge any adhered materials. As a result, we received feedback stating, "We can remove the adhered materials in a short time. All air knockers can be operated from a single control panel, which reduces management effort." [Issues] ■ Raw material storage silos are shared among multiple production lines. ■ Residual raw materials mix, leading to a decline in product quality. ■ The large capacity of the silos makes it impractical to wash them out each time due to operational and cost concerns. ■ There are limits to the range of impact that can be applied by human effort, resulting in inefficient dislodging. *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements

We would like to introduce a case study on solving customer issues related to the working environment. In an outdoor piping line carrying dilute hydrochloric acid, a valve was installed right next to a walkway, at face height. There was a risk of a serious accident if the chemical were to spray out from the valve joint and hit a person. To address this, we proposed installing a transparent PVC "safety cover for the valve" to contain any potential chemical spray and to physically make it more difficult to operate the valve. As a result, the installation work could be completed in a short time, and the measures taken became clear to everyone. [Issues] - Installing partitions or similar structures to prevent spray would incur significant costs, and typhoon measures would also be necessary. - Even with a "Always Open" sign to prevent incorrect operation, there is still a possibility of misreading it. - We want to keep costs down by using off-the-shelf products as much as possible. *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements
• Other safety equipment

We would like to introduce a case study on solving customer issues. When introducing new production equipment, there was a need to enclose the installation area. In the planned installation space, dust and debris were falling from the upper floors, leading to contamination of the products, which meant that the ceiling also needed to be covered. Therefore, we proposed an enclosure structure using lightweight steel frames and calcium silicate boards, tailored to the shape of the equipment. As a result, by conducting final adjustments on-site, we were able to assemble a booth that ensured the required clearance with the equipment. [Issues] - The equipment has a complex shape, but we want to enclose it in the minimum space possible while matching its shape. - The floor where the installation is planned has unevenness and has not been leveled. *For more details, please refer to the PDF document or feel free to contact us.

• Other contract services

We would like to introduce a case study that addresses the issues faced by our customer in glass manufacturing. They were troubled by the problem of rust forming on the cast parts used to protect the furnace heaters, which caused rust to fall and adhere to the products. In response, we proposed on-site work using a "sponge jet," which involves blasting a media that contains aluminum oxide particles, a polishing material, encapsulated in a special urethane sponge. As a result, since there was almost no dust generated, it was possible to work without affecting the surrounding area by simply enclosing the workspace, and all processing was completed in one day without damaging the parts. [Issues] - There are over 200 parts, leading to the possibility of loss or mixing of parts. - The target parts are cast components that are prone to cracking. - The downtime of the furnace is short, requiring all rust removal work to be completed in one and a half days. - Since the work is done in the customer's factory using available space, sandblasting, which generates a lot of dust, cannot be used. - There are concerns that sandblasting may leave abrasive materials trapped in the gaps of the parts, causing defects. *For more details, please refer to the PDF document or feel free to contact us.*

• Other cleaning tools
• Other cleaning machines

We would like to introduce a case study of solving customer problems. We received an inquiry about wanting to automate the sealing and printing after manually packing products into boxes. It was taking a lot of time and effort, and there were concerns about the occurrence of human errors. Therefore, we proposed combining the Everroll sealing machine "IL-703" with the Kishu Giken Kogyo printing machine "PC Coder." As a result, they were able to handle various sizes of cardboard boxes without any issues while producing different product varieties, and the tape application and printing were evaluated to be neater than when done manually. [Issues] ■ Performing sealing and printing manually can lead to human errors. ■ The current takt time (working time) is not a problem, so they cannot invest much in improvements. ■ There are concerns about whether the sealing machine and printing machine will match well if purchased separately. *For more details, please refer to the PDF document or feel free to contact us.

• Sealing
• Other processing machines

We would like to introduce a case study on solving customer issues for a confectionery manufacturer. The company encountered a problem during the production of a new baked goods product. The dough was sticking to the mold, making it difficult to release it cleanly. Upon examining the molds manufactured by the oven manufacturer, it was found that they were surface-treated with PTFE. Therefore, we proposed a PFA coating, which has superior non-stick properties. As a result, they were surprised to learn that even among fluoropolymer coatings, there can be performance differences. With the use of PFA-treated molds, production went smoothly, and the new product was successfully launched. [Issues] - The molds were requested to be manufactured with a non-stick coating specification by the oven manufacturer. - The dough was sticking to the molds during baking in the oven. *For more details, please refer to the PDF document or feel free to contact us.

• Surface treatment contract service

The company Daikishisystem, which we have entrusted with the molding of the original components for clean booths, "KAMATA Aluminum Frame," is embarking on a new business venture in plant factories. In this context, a small hydroponic cultivation unit called "Vege Seller" has been developed, and they consulted us about wanting to adopt the "KAMATA Aluminum Frame" for this unit. As a result, we created a prototype showcase that leverages the various features of our product. Consequently, they recognized the beauty of the finish, and it was officially adopted. [Issues] ■ We want to minimize the space taken up. ■ It is important to have excellent design. ■ It should be easy to change dimensions according to requirements. *For more details, please refer to the PDF document or feel free to contact us.

• Other safety equipment
• Other clean room equipment and facilities

We would like to introduce a case study that addresses the concerns of customers engaged in resin cutting processing. In a workspace equipped with 10 processing machines, temperature management was insufficient, leading to variations in dimensional accuracy for each machine. We received a request to improve yield by thoroughly managing the temperature. In response, we proposed the installation of a booth using insulation panels, taking into account the layout of the processing machines and the workflow. As a result, temperature management in the cutting area was optimized, improving processing accuracy and significantly reducing the defect rate, achieving the intended goals of the installation. [Issues] ■ High dimensional accuracy is required for the resin cutting products being produced. ■ The temperature during processing affects dimensional accuracy. ■ We want to collect the shavings generated during cutting and keep the processing room clean. *For more details, please refer to the PDF document or feel free to contact us.

• Other temperature and humidity measuring instruments

We would like to introduce a case study of solving customer problems. In a production line manufacturing medical devices, there was an issue with insect contamination in the products. Although the entire factory was managed under positive pressure and certain pest control measures were in place, they were struggling with the fact that these measures were not completely effective. Therefore, we proposed enclosing the manufacturing area, where contamination was possible, with a clean booth and implementing double positive pressure management in conjunction with the entire factory. As a result, we received feedback stating, "We have traps for flying and crawling insects in the manufacturing area, but after the implementation, there have been almost no insect intrusions. The positive pressure in the area is also being maintained consistently, which has improved cleanliness." [Key Points] - The manufacturing area with potential contamination is doubly isolated from the outdoors. - Control of airflow is linked to the opening and closing of the sheet shutter. - When the shutter is open, airflow is increased to maintain pressure within the booth. - The sheet shutter is also doubled, with an interlock mechanism to prevent simultaneous opening. - A horizontal airflow air curtain is adopted. *For more details, please refer to the PDF document or feel free to contact us.

• Clean Booth
• curtain

This is a case study on the cleaning of resin molding processes at a customer manufacturing medical devices. There was a concern about the possibility of foreign substances adhering to products manufactured by injection molding, necessitating countermeasures. However, simply enclosing the entire molding machine was problematic and raised various issues. Therefore, we proposed a bellows-type clean booth tailored to the shape of the injection molding machine. Based on the cleanliness requirements needed for this project, we believed that this portable and storable bellows-type clean booth could meet the customer's needs. [Issues] - Enclosing the molding machine with a fixed booth would worsen the operability for mold changes and product retrieval. - Some products do not require cleaning. - The molding machine is equipped with a product retrieval arm, and including the arm, the machine height is nearly 5 meters. - There is a desire to share the booth among multiple molding machines in operation. *For more details, please refer to the PDF document or feel free to contact us.*

• Clean Booth

A new beverage filling process will be established within the existing factory. Initially, it was considered to enclose the filling machine in a booth for cleanliness; however, due to the limited ceiling height of the factory, there was no space available for the installation of air conditioning units or FFUs, which was a concern. Therefore, part of the existing ceiling wall material was coated with thick dust paint to create clean panels, which were then incorporated into the booth structure. Additionally, clean panels with partition specifications were added to shut out dust intrusion by forming a booth structure. We proposed a construction method that would complete the work, including painting, within three weeks. The project was completed two months after the initial meeting, allowing us to meet the operational start date for the line. [Issues] - The ceiling height at the planned location for the filling machine is 3,000mm, with gypsum board. - The height of the filling machine is 2,800mm. - There is not much time left until the planned start date for operations. *For more details, please refer to the PDF document or feel free to contact us.*

• Other clean room equipment and facilities
• Machinery and equipment installation/dismantling/relocation

A customer who has recently started manufacturing health foods consulted us about establishing a clean manufacturing environment. In the area where installation is planned, there is a ceiling cassette-type air conditioner, and they expressed a desire to utilize it as is. Therefore, we proposed constructing the entire clean room using antibacterial clean panels, with a double structure that includes a KAMATA clean booth in the filling process area. As a result, by attaching a high-performance filter to the ceiling cassette-type air conditioner, we were able to change it to quasi-clean room specifications, and by using a floor-mounted FFU in conjunction, we successfully established a clean environment at a low cost. [Issues] ■ They want to establish a clean environment as soon as possible, considering the market entry timing and subsidy application schedule. ■ They want to utilize the existing air conditioner. ■ They want the filling process area, which requires high cleanliness, to be Class 1,000. *For more details, please refer to the PDF document or feel free to contact us.

• Other clean room equipment and facilities
• Machinery and equipment installation/dismantling/relocation

This is a case study from a chemical company. They were facing the problem of product scattering during the filling process of powdered products. Although the filling area was temperature-controlled, they were also struggling with poor balance in the intake and exhaust, leading to low air conditioning efficiency. In response, we proposed a distribution air conditioning system by installing a large air conditioning unit with sufficient capacity and supplying air to each room through a Fan Filter Unit (FFU). As a result, we designed an automatic linkage system that allows for appropriate intake based on the exhaust volume, achieving stable room pressure management. [Issues] ■ A dust collector is installed, but it only functions near the intake area. ■ A cleanliness level of Class 10000 is required. ■ Air conditioning is ineffective. ■ There are five separate rooms, each requiring individual room pressure control. *For more details, please refer to the PDF document or feel free to contact us.

• Other clean room equipment and facilities
• Machinery and equipment installation/dismantling/relocation

A waterproof test for the product will be conducted within the company, and a dedicated large testing room will be established. Since this test corresponds to the ISO 20653 standard, it will be designed to allow continuous sprinkling, and because the drainage will also contain oil, an efficient drainage and treatment system is necessary. Therefore, a testing room with high airtightness and water resistance was designed using non-combustible clean panels as the main material. To address waterproofing and water-repellent measures, the inner wall surface of the clean panels was changed from color steel plates to stainless steel. As a result, a system that can handle the process without issues was established, and the design, which considered smooth loading and unloading of products, received high praise. [Issues] - A system that can properly sprinkle and spray is required. - Oil-water separation treatment must be conducted. - Due to the large volume of drainage, the structure must prevent overflow within the testing room. - Since the weight of the products being tested is close to 8 tons, the floor must have high load-bearing performance. *For more details, please refer to the PDF document or feel free to contact us.

• Other clean room equipment and facilities
• Machinery and equipment installation/dismantling/relocation

At the research institute, we are advancing the development of therapeutic drugs for difficult diseases in the central nervous system, such as ALS and Parkinson's disease, as well as congenital metabolic disorders. However, the manufacturing of formulations used after clinical trials requires facilities managed under GCTP (Good Cell and Tissue Practice). It is essential that the experimental area for development and the manufacturing area are separated to prevent the mixing of research reagents and materials with manufacturing reagents and materials. Therefore, we constructed the room based on antibacterial panels and antibacterial floor sheets as a cell culture processing facility compliant with GCTP. As a result, the facility has also been adapted to the new regenerative medicine law, ensuring very high safety and satisfactory quality control and operational aspects. [Issues] ■ There was no manufacturing environment for formulations that could be used after clinical trials. ■ The current laboratory does not have cleanliness grade management. ■ Facilities compliant with GCTP regulations, the Cartagena Act, and guidelines for sterile formulations are necessary. ■ It is a prerequisite that the experimental area for development and the manufacturing area are separated. *For more details, please refer to the PDF document or feel free to contact us.

• Other clean room equipment and facilities
• Machinery and equipment installation/dismantling/relocation

This is a case study from a chemical company. Antimony trioxide, used as a flame retardant and pigment, was designated as a specific chemical substance due to legal amendments, requiring measures in accordance with regulations during operations. Specifically, it became necessary to implement emission suppression measures during the process of removing it from bags and weighing it. Therefore, we proposed not only installing exhaust equipment but also enclosing the work area with a localized booth, creating a dedicated weighing exhaust booth for antimony trioxide to achieve dispersion suppression measures. As a result, we were able to comply with the legal dispersion prevention measures and conduct regular measurements. [Issues] ■ Antimony trioxide, which affects human health, requires emission suppression measures. ■ Although dust masks are worn during operations, there is a possibility of inhalation by workers. ■ Other raw materials are also present in the factory, increasing the risk of mixing during weighing. *For more details, please refer to the PDF document or feel free to contact us.

• Other clean room equipment and facilities
• Machinery and equipment installation/dismantling/relocation

This is a case where a new clean room was constructed at the request of a cosmetics manufacturer. It was necessary to design and build it under the condition of cleanliness level 100,000, in accordance with the general cosmetics manufacturing industry permit. Before constructing the clean room, the existing ceiling was opened up to utilize the ceiling space and ensure effective height. To achieve the cleanliness and pest control measures required by the client, it was necessary to overcome various challenges, but through collaboration with the design team, we were able to construct a clean room that exceeded their expectations. [Issues] - There was a concern about insufficient effective height due to the construction location being on the mezzanine of a gable warehouse. - High cooling capacity was required. - Floor-mounted air conditioning units and ceiling line ducts were not desirable. - Management of internal pressure, dust control from inside, and pest control measures against flying and crawling insects were also necessary. *For more details, please refer to the PDF document or feel free to contact us.

• Other clean room equipment and facilities
• Machinery and equipment installation/dismantling/relocation