蒲田工業 List of Products and Services

This is an example of installing a mobile clean booth in a rubber roll lathe processing work environment under clean conditions. A large opening was necessary to accommodate the task of removing the rubber rolls from the lathe, and a design that allows for smooth operation was required. Therefore, we proposed a method to maintain a sealed space during lathe processing and to move the clean booth itself when removing the rubber rolls. As a result, by customizing the clean booth design to fit the customer's work environment, we were able to contribute to the improvement of efficiency and safety in the work environment. [Challenges and Customer Requests] - We want to perform the rubber roll removal operation smoothly. - The required cleanliness level is Class 10,000. - We want to block external light during rubber roll inspection. - We want to be able to see the working conditions inside the clean booth. *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
• Clean Booth

This is a case study from a food company. They had previously introduced air showers and adhesive rollers to address foreign matter contamination, but they were struggling to reduce hair contamination. Therefore, we proposed the introduction of an ionizing blade that can instantly eliminate static electricity just by passing through. As a result, they evaluated that hair contamination had significantly decreased after installation. 【Issues】 ■ Hair attached to clothing may not be removed by the air shower due to static electricity. ■ They were looking for a highly effective solution that requires minimal effort. *For more details, please refer to the PDF document or feel free to contact us.

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

You were having trouble with the cutting work of rubber conveyor belts being manufactured. Using a utility knife for this task presented issues such as "the width and thickness vary by type, making it difficult to introduce a guillotine-style fixed cutting machine." Therefore, we proposed the introduction of the Flexico electric belt cutter. When testing the demo unit for adoption, we received feedback that the cutter body tilted during cutting, causing the cutting direction to deviate. In response, we independently designed and manufactured a support plate and requested another round of testing. As a result, once the support plate was installed, it was highly praised for allowing anyone to cut easily, safely, and quickly. [Issues] ■ Difficult to cut easily with a utility knife ■ Using a utility knife requires multiple passes for cutting, which is labor-intensive and poses a risk of injury ■ The cutting surface does not finish neatly ■ The width and thickness vary by type, making it difficult to introduce a guillotine-style fixed cutting machine *For more details, please refer to the PDF document or feel free to contact us.

• cutter

This is a case study from a powder conveying line. There was a challenge where powder adhered to the inner surface of the hopper, causing bridging. Although the "Z-1 liner," a super high molecular weight polyethylene lining material, had been used traditionally, there were complaints about the quality of the installation. Therefore, we proposed to take the base material and have it installed at a specialized lining factory with extensive experience. As a result, we received feedback that "the quality of the finish is remarkably superior compared to the conventional method." [Issues] - Customers are satisfied with the performance of the "Z-1 liner" itself. - The finish at the corners and joints of the hopper is not good. There is a lot of jointing, which leads to adhesion issues. *For more details, please refer to the PDF document or feel free to contact us.

• Surface treatment contract service

This is a case study from a food company. In the process of plating side dishes, they were using a large table with a "bento box" filled with ingredients, but they were struggling with constraints in their workspace. Therefore, we proposed the creation of a dedicated "bento box" cart using the FS Erector from Yazaki Chemical. Since they can perform the plating work while the cart is loaded, they can effectively utilize the workspace. As a result, they evaluated that the flexibility of the layout increased, allowing them to work efficiently according to the product types and production volumes. [Issues] - They wanted to change the number of workers according to production volume, but the table was too large, preventing them from adding more than a certain number of people. - The task of placing the "bento box" on the table was labor-intensive depending on the ingredients. - The table was large and heavy, making it difficult to change the layout easily. *For more details, please refer to the PDF document or feel free to contact us.*

• Contract manufacturing
• furniture

This is a case study from a food company. They were struggling with the burden of cleaning due to product adhesion on the molds and transport guides used in the manufacturing process. Among several surface treatment options we proposed, they showed interest in a ceramic coating that excels in heat resistance and non-stick properties. After conducting a test evaluation, we achieved good results in terms of non-stick performance. As a result, even after several months of use, there was no degradation in performance, and they were pleased to find that cleaning tasks had become significantly easier than before. [Issues] - Excessive material adhesion can lead to defects where products do not meet the specified weight. - They had previously adopted fluoropolymer coatings, but these wore out quickly, resulting in low cost-effectiveness. *For more details, please refer to the PDF document or feel free to contact us.*

• Surface treatment contract service

The customer, engaged in food manufacturing, is sequentially updating the air conditioning units in their factory for the purpose of addressing global warming and energy conservation. The air conditioning unit targeted for this update is installed within the grille (lattice-like fence) on the building's wall rather than on the rooftop, making the removal and installation process extremely difficult. As a result, the existing outdoor unit was disassembled on-site, and the ducts to be replaced were cut before the removal work was carried out. The new outdoor unit was also disassembled once and brought in using a high-altitude work vehicle from the wall. The grille was temporarily removed and restored after the unit was brought in. Despite the limited space and numerous obstructions such as beams that needed to be navigated for piping, we were able to complete the work as scheduled. [Issues] ■ The removal and installation route is limited, preventing the new outdoor unit from being brought in through the factory. ■ The existing outdoor unit cannot be removed as is. *For more details, please refer to the PDF document or feel free to contact us.

• Machinery and equipment installation/dismantling/relocation
• air conditioning

A large case cleaning device has been newly introduced for a customer engaged in food manufacturing. The cleaning inside the device is performed by opening the ceiling hatch, but there are no access stairs or fall prevention handrails to the ceiling, making it a dangerous task, and measures were required. Therefore, we proposed the installation of a walkway with safety rails to match the height of the cleaning device's top surface. As a result, safety has been ensured, allowing for cleaning operations to be carried out with peace of mind. [Issues] ■ There is no means to access the top of the cleaning device (currently, personnel are walking on top of the equipment to climb up) ■ Currently, high-pressure cleaning is being performed while standing on the device's top surface ■ The top surface of the device has no walkway or safety rails, making the task quite dangerous *For more details, please refer to the PDF document or feel free to contact us.

• Machinery and equipment installation/dismantling/relocation

This is a case study from a paper manufacturing company. We reviewed the safety measures on the production line and decided to implement all possible measures within a limited period of one year. At Kamata Industries, we carry out many safety improvement projects. We proposed to explain our achievements and experience, and to conduct a comprehensive process from site surveys, formulation of countermeasures, measurements, design, and production of drawings to construction. Additionally, since there are numerous target areas, we suggested leveraging our network of partner companies to simultaneously advance multiple countermeasures. As a result, we designed and prototyped a rubber bellows for the movable parts of the lifter and installed it to prevent entrapment of hands and feet. [Issues] - It is estimated that there are hundreds of locations requiring countermeasures. - It is impossible for the responsible personnel to devise and verify countermeasures for all locations due to time constraints. - For some equipment, detailed drawings and materials have been lost. - We want to minimize the time required for meetings and the effort related to work instructions as much as possible. *For more details, please refer to the PDF document or feel free to contact us.*

• Machinery and equipment installation/dismantling/relocation

This is a case where we solved problems related to foreign object contamination measures at a food manufacturing site. We decided to thoroughly implement measures against foreign object contamination to further improve quality. Despite the absence of visible dust, there were issues with foreign object contamination, leading the client to consult with Kamata Industries without finding a solution. We proposed a specialized light to visualize and make dust visible. We delivered a user-friendly size of the specialized light, allowing the client to confirm the visualization of dust themselves, identify the causes of foreign object contamination, and achieve their goal of quality improvement (measures against foreign object contamination). [Issues] - There are suspicions of foreign object contamination in the clean room. - There is no visible dust of significant size. - They were searching for a method to visualize dust. *For more details, please refer to the PDF document or feel free to contact us.

• Other clean room equipment and facilities
• Other lighting equipment

This is an inquiry from a customer who was using a custom tank with a mixer at a food factory. They were considering replacing it due to aging, but were troubled to find that the renovation costs would be nearly double what they were before. In response, Kamata Industries proposed designing and manufacturing an original tank, providing one-stop solutions for mixer installation, renovation, delivery to the site, quality assurance, and maintenance. As a result, we achieved lower costs and shorter delivery times compared to purchasing and renovating off-the-shelf products. Furthermore, by gaining a detailed understanding of the customer's site, we contributed to improving the efficiency of detailed tasks such as attaching and detaching the mixer and opening and closing the lid. [Issues] - The delivery time was extended because the mixer had to be installed after purchasing an off-the-shelf tank. - A special design was necessary to allow for easy attachment and detachment of the mixer. - Short delivery times were required for the development of new products. *For more details, please refer to the PDF document or feel free to contact us.*

• Machinery and equipment installation/dismantling/relocation
• Contract manufacturing
• tank

This is a case study that addresses the issue of foreign matter contamination occurring during the process of filling resin raw materials in powder and granular form into container bags. There were multiple challenges to solve, including measures to minimize the influence of outside air, avoiding complex structures around the filling machine, and resolving issues within a limited budget. To tackle this, we enclosed the area around the filling machine with a vinyl booth and a Fan Filter Unit (FFU), creating positive pressure only in the manufacturing environment. As a result, the construction of the vinyl booth and FFU reduced foreign matter contamination, achieving a certain level of effectiveness. Additionally, the floor renovation work carried out to seek further improvements also helped to suppress dust generation, and we were able to confirm a reduction in foreign matter contamination through measurement data. [Issues] - Adjacent to a shutter connected to the outdoors, making it susceptible to outside air influence. - The upper part of the filling machine has a complex structure with hoppers and piping installed. - Cracks have developed in the concrete foundation and the warehouse floor. - There is no budget available for fundamental measures such as overall air conditioning improvements in the warehouse. *For more details, please refer to the PDF document or feel free to contact us.*

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

The emergency shower booth is a device designed to quickly wash off harmful chemicals, such as organic solvents, from the body in case of accidental exposure. It is enclosed to prevent water from splashing around. While it is not needed during normal circumstances, it can minimize damage in the event of an accident. *After thoroughly rinsing with water from this product, please ensure to receive appropriate medical treatment at a healthcare facility. ■Specifications *Product specifications and values may change without notice for quality improvement. - Weight: Approximately 200 kg - Body size: W880 × D880 × H2,230 mm

• others

■Excellent Characteristics 1. Good Wear Resistance Dykron has a hardness of around Vickers hardness HV1000. 2. Strong Adhesion to the Base Material Using a unique mixed catalyst for Dykron coating that has strong adhesion to the material, we have enhanced the adhesion to the base material. As a result, it forms a coating with a high intermolecular bonding force with the base material. There is almost no visible cracking or peeling even when subjected to bending after treatment, which is impossible with ceramic or metal thermal spraying and hard chrome plating. However, it may be affected by repeated bending exceeding several dozen times. 3. Good Heat Resistance By diffusing non-metallic elements into the material and electrically depositing the coating layer, it exhibits excellent performance against heat shock from rapid heating and cooling, and the treated material maintains a hardness of HV800 even at temperatures of 400°C, so its performance is hardly reduced at high temperatures. *It also has properties that make it difficult to experience seizure. 4. High Dimensional Accuracy of the Surface Compared to hard chrome plating, there is less variation in film thickness due to ingenuity in jigs and other tools. Due to its high hardness, it depends on the condition of the surface preparation, but a mirror finish (a smooth surface like a mirror) is also possible. Post-processing such as polishing and grinding is also possible.

• others

■Excellent Characteristics 1. Slip Resistance By creating unevenness on the surface, the contact area with the object is reduced, resulting in outstanding slip resistance. 2. Wear Resistance Not only does the treated material itself reduce wear on the object, but selecting the appropriate surface roughness also makes it less prone to scratches. 3. Adhesion to the Base Material Like Dyneon, it excels in adhesion to the base material as well as heat resistance.

• others

■Excellent Characteristics 1) Thin film treatment is possible without compromising the surface roughness or dimensional accuracy of the material. 2) Corrosion resistance, slip resistance, release properties, and dirt resistance are improved. 3) Wear resistance is significantly enhanced, contributing to a longer lifespan.

• others

■Excellent Characteristics 1. Release (Non-adhesive) Property It is particularly outstanding. While it is not completely non-adhesive, the release property is good, and adhesion can be easily wiped off. 2. Corrosion Resistance It is not affected by strong acids, strong alkalis, or solvents. 3. Slipperiness It has low friction resistance and is very excellent, similar to other fluoropolymer-treated materials. 4. Heat Resistance It can be used continuously up to 180°C.

• others

■Excellent Characteristics The wear resistance (due to the sintered nature of the chips) is very high (equivalent to ceramic molded products). On-site construction is possible. It can be applied to various material shapes. *In cases where the shape is extremely complex, it may be used in conjunction with some ceramic putty lining. Compared to ceramic molded products, it can significantly reduce costs.

• others

■Outstanding Features We use fine ceramics with a very dense structure as the inner pipe material, which provides excellent wear resistance. Compared to plating and thermal spraying, it has a thicker wall (5mm to 15mm) and boasts a very long lifespan. The ceramic sleeve is also shaped and fired to match the curvature of the bend pipe. There are almost no joints or steps, allowing for smooth transport without causing turbulence. There is no concern about peeling, which is often a worry with chip lining.

• others

αESG is an energy-saving product that can strongly agitate refrigerants and reduce the burden on compressors. By simply installing the fluid agitation device αESG, you can expect an annual energy-saving effect of approximately 10% to 30% (reduction in electricity costs).

• others