サンエス工業 List of Products and Services

As a case study for the introduction of the "Micro Separator MSR-200 model," we will introduce an example of hydraulic oil purification in injection molding machines. Before the introduction, small sedimentary contaminants that could not be removed by filters or oil purifiers would rise due to turbulence in the oil during startup and remain suspended chronically, leading to issues such as control malfunctions in pumps and system circuits. After the introduction, the amount of contaminants was reduced from 74.2 mg/100ml before improvement to 35.9 mg/100ml one month after improvement. Additionally, improvements were observed, including the elimination of abnormal sounds from the pump, resolution of valve operation failures, and a decrease in floating contaminants. For more details, please contact us or download the catalog.

We would like to introduce a case study of the Mag Bar implemented by San-Ei Industrial Co., Ltd. In the gear manufacturing industry, there was a frequent occurrence of defects due to scratch marks on grinding machines. As a solution, we introduced two sets of five Mag Bars. As a result, the defect rate caused by scratch marks and the accumulation of chips in the tank decreased. Our company develops, manufactures, and sells filtration devices for working machine hydraulic oils, lubricants, and coolant liquids. Please feel free to consult us when needed. 【Case Overview】 ■Industry: Gear Manufacturing ■Processing Machine: Grinding Machine ■Problem: Frequent defects due to scratch marks ■Solution: Introduced two sets of five Mag Bars *For more details, please refer to the PDF document or feel free to contact us.

We would like to introduce a case study regarding the testing and adoption of a cleaning tank system in conjunction with the tank opening inspection during oil replacement, using a device called "Swimming Roll" that provides a glossy finish to paper at a paper mill. The machine has been in operation for three years without any significant issues. According to internal standards, oil replacement is scheduled every three years, but the used oil has shown noticeable NAS 11 level contamination and sediment. In this test adoption, we intentionally did not perform the oil replacement in the third year, allowing users to experience the purification capabilities of the cleaning tank system. As a result, the cleanliness of the hydraulic and lubrication oil for the Swimming Roll has maintained a high level of cleanliness, measured at below 1 mg using the gravimetric method, six months after the test adoption. 【Case Overview】 ■ User: K Paper Mill ■ Machine: Swimming Roll ■ Tank: 400L (for hydraulic and lubrication use) ■ Used Oil: Idemitsu Daphne Mechanic 100 ■ Adopted Product: MSJ-400*280 (custom-made unit) *For more details, please refer to the PDF document or feel free to contact us.

This time, we would like to introduce a report stating that the process capability index (Cp value) of lathe machining has dramatically improved due to the purification of hydraulic operating oil. The single-spindle lathe is a type of automatic lathe that rotates bar stock to cut its outer shape. It automatically chucks the bar stock processed to a specified length, performs rough cutting of the outer shape, and then carries out finishing cuts. The cleanliness of the hydraulic operating oil was classified as "outside grade" according to the NAS standard, and the equipment's Cp value was 0.65 (estimated defect rate: 22%), indicating that rework on the processed products was necessary. A partition plate was installed using the mounting bolts of a microseparator. The drain from the pump was also modified to return to the oil return side. As a result, after three months, the cleanliness of the hydraulic operating oil improved to grade 9 according to the NAS standard, and the equipment's Cp value increased to 0.96. After nine months, it reached grade 8, and the equipment's Cp value improved to 1.33. 【Case Summary】 ■ User: X Parts Manufacturer ■ Machine: Single-Spindle Automatic Lathe (Roll Forming Diameter Processing) ■ Tank: 60L ■ Products Used: Two units of MSR-200 model *For more details, please refer to the PDF document or feel free to contact us.

At Company N, the vane pump operating at 140 kg/cm² was emitting abnormal sounds, and the solenoid valves frequently malfunctioned, necessitating weekly inspections and solenoid valve replacements every six months. Additionally, tank cleaning and oil replacement with new oil were conducted annually, but oil degradation due to contamination progressed within about six months. To address this, the tank structure was transformed into a cleaning tank that allows the oil to flow calmly, and to supplement the tank capacity with a QC ratio of 4, a microseparator was installed at a ratio of one unit per 50 liters. Before the measures were implemented, the oil used for one year was extremely contaminated and outside the NAS grade. However, analysis one year after the measures showed a NAS grade of 8, and the weight analysis indicated that the contamination weight in 100 ml was 1.25 mg, maintaining a state of "almost no contamination from new oil." 【Case Summary】 ■ User: Company N (Spring Manufacturer) ■ Machine: Rolling Mill (Auxiliary Hydraulic) ■ Tank: 2,000L ■ Pump: 500L/min ■ Adopted Product: MSR-200 model, 32 units *For more details, please refer to the PDF document or feel free to contact us.

The tank used before the MS system had a poor structure of "a straight line from return to suction," and due to the low position of the suction strainer, it easily sucked in sediments, resulting in an oil cleanliness level of class 11. To enhance the purification effect by calming the oil, an elbow was installed at the cut of the return pipe when setting up the micro-separator. Additionally, a partition plate A for circulating the oil and a partition plate B for trapping sediments immediately after the return were bolted to the outer plate of the tank. As a result, the deterioration of the oil was prevented by implementing a cleaning tank system, allowing the oil to be used continuously for about 4 years, achieving a cleanliness level of class 8 according to NAS standards. Furthermore, there were no equipment failures, and filter clogging was resolved. [Case Summary] ■ User: Company A (bearing parts manufacturer) ■ Machine: Single-purpose machine (cutting inner and outer rings of bearings) ■ Tank: 100L ■ Operating Oil: Shell Teras Oil #25 ■ Adopted Product: 1 unit of MSR-200 *For more details, please refer to the PDF document or feel free to contact us.

Company C has begun specific investigations into whether contaminants in lubricating oil can be removed using filters and micro-separators, and they have requested oil analysis from our company. In horizontal injection molding machines, there is a high incidence of moisture contamination, making the recycling of lubricating oil difficult. However, in the case of vertical machines, it has been determined that purification with a micro-separator is possible, and testing has commenced. Analysis of the lubricating oil in use revealed that most of the contaminants were minute metal particles. As a result of the analysis, it was demonstrated that the oil in the lubrication section was in a condition close to that of new oil, with no issues regarding viscosity. [Case Summary] ■ User: Company C (Injection Molding Machine Manufacturer) ■ Machine: Vertical Injection Molding Machine ■ Tank: 25L ■ Pump: Drip Lubrication ■ Product Used: MSR-200 Type, 1 unit *For more details, please refer to the PDF document or feel free to contact us.

We are using water-glycol hydraulic fluid, and issues have arisen due to its characteristics; however, I report that these are gradually being resolved after the installation of the microseparator. To confirm the effectiveness, we conducted a monitoring of the hydraulic fluid, comparing machines with and without the microseparator over a six-month follow-up period. When comparing the condition of the oil after six months through microscopic observation, machine A, which does not have the microseparator installed, showed floating contaminants (scum) specific to water-glycol and foreign contaminants, indicating a high level of contamination and unstable oil properties. In contrast, machine B, which has the microseparator installed, demonstrated its effectiveness, maintaining a low level of contamination and a stable condition. [Case Summary] ■ User: Company H (automotive parts manufacturer) ■ Machine: Cylinder head casting machine ■ Tank: 400L ■ Pump: (approximately 80L/min) ■ Products used: 5 units of MSR-200 type ■ Oil used: Swafluid HQ (water-glycol) *For more details, please refer to the PDF document or feel free to contact us.

This time, we would like to introduce a case where a surface grinding machine uses both hydraulic oil and lubricating oil. At Company T's G factory, there was no previous experience with micro-separators, so this surface grinding machine was chosen as a trial. The tank structure of the surface grinding machine is not of the long flow type, but the return and suction parts of the oil are separated, and it was installed without modifying it to a circulating type to observe its performance. After the installation of the micro-separator, an oil analysis conducted two and a half years later showed that everything was progressing smoothly without any issues, and it is expected to continue being used in the future. [Case Study] ■ User: Company T (Bearing Manufacturer) ■ Machine: Surface Grinding Machine ■ Tank: 120L ■ Pump: 25L/min ■ Product Used: One unit of MSR-200 type *For more details, please refer to the PDF document or feel free to contact us.

We will introduce the case of Company F, which promoted TPM activities and received the "PM Business Site Award." When a magnetized needle was inserted into the oil, it was determined that contaminants were adhering to the surrounding area, making magnetic contamination management possible. Furthermore, upon investigating the relationship between the level of contamination and the variation in the stroke of the work drive cylinder, it was found that higher levels of contamination corresponded to greater variation. As a countermeasure, the Suness cleaning tank system was adopted, and additional measures were implemented to prevent the intrusion of fine cutting chips generated during grinding. As a result, in just half a month, the cleanliness of the oil reached NAS grade 8, and the processing accuracy of the products, which had been forced to slow down to 63% of the standard cycle time, was able to speed up to 110%, thereby increasing overall equipment efficiency. [Case Overview] ■ User: Company F (Tool Manufacturer) ■ Target Equipment: Tooth Profile Grinding Machine ■ Tank: 80L ■ Pump: 34L/min (Constant Discharge Type) ■ Adopted Product: 1 unit of MSR-200 *For more details, please refer to the PDF document or feel free to contact us.

This is a case study of hydraulic operating oil for a medium-sized injection machine. The target machine is a molding machine manufactured by Company A with a clamping force of 450 tons, and the tank has a capacity of 1600L, using a direct pressure surge type stirring system, producing household plastic products. Coincidentally, the oil gear pump of this machine broke down, necessitating a replacement, and along with the oil change, a micro-separator was installed. Even after three months, the effects of the micro-separator have been fully realized, and concerns about trouble occurrences have disappeared. Additionally, even after one year, there are hardly any residues observed, and the cleanliness has been maintained without further oil changes. [Case Summary] ■ User: Company S (Resin Product Manufacturer) ■ Machine: Injection Molding Machine ■ Tank: 1600L ■ Pump: Direct Pressure Surge Type ■ Adopted Product: MSR-200 Type, 16 units *For more details, please refer to the PDF document or feel free to contact us.

Until around 1975, Company T frequently experienced seizure issues with the fluid bearing section connecting the automatic grinding machine and grinding wheel in the crankshaft processing line, requiring long repair times each time. To address this, two units of the micro separator (model MSR-200) were installed, and a two-month trial was conducted. As a result, it was confirmed that the cleanliness of the oil was improved, eliminating troubles. Company T planned to systematize the cleaning tank along with its unique machine function improvements. 【Case Overview】 ■ User: Company T (automobile manufacturer) ■ Target Equipment: Automatic grinding machine ■ Tank: 250L (overflow type) ■ Pump: 129L/min (constant discharge type) ■ Adopted Product: 10 units of MSR-200 model *For more details, please refer to the PDF document or feel free to contact us.

In the bearing industry, the first issue that is often raised is the grinding machine. Particularly, the processing fluid often becomes a problem, but in this case, we will explain the purification of hydraulic oil. The machine is a PSG-52A from Company 0, and the oil used is Nippon Oil's Uniway D32. The high oil temperature, the tank retaining heat, excessive air intake, valve burning, filter clogging, and rapid oil degradation were the main issues. To address this, we first attached an elbow to the opening of the return pipe to prevent the return oil from blowing up settled contaminants towards the tank's side wall. Additionally, we modified the structure by adding a partition plate between the oil return and suction to create a recirculating cleaning tank. As a result, the oil temperature dropped to about 40°C, there were no valve troubles, filter clogging was resolved, and the oil's lifespan was extended. [Case Summary] ■ User: Company K (Bearing Manufacturer) ■ Machine: Surface Grinding Machine ■ Tank: 50L ■ Pump: 20L/min. ■ Product Used: One unit of MSR-200 type *For more details, please refer to the PDF document or feel free to contact us.

At Company N, lubrication management of oil was conducted using filters and oil purifiers. In the case of this injection molding machine, there were issues with abnormal sounds from the pump and malfunctioning valves, and a large amount of sludge had accumulated at the bottom of the tank and in the filter. Therefore, a microseparator was introduced. According to the analysis results of contaminants using emission spectrometry, the amount of contaminants decreased from 74.2 mg before the installation of the microseparator to 35.9 mg in just one month, effectively halving the amount. Improvements were observed in the elimination of abnormal sounds from the pump, the resolution of valve malfunctions, and the prevention of the spread of sedimentary contaminants. [Case Overview] ■ User: N Automobile ■ Machine: Injection Molding Machine ■ Tank: 3200L ■ Oil Used: Wear-resistant Hydraulic Oil ■ Product Adopted: 15 units of MSR-200 *For more details, please refer to the PDF document or feel free to contact us.