蒲田工業 List of Products and Services

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 bending 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.

• others

We received an inquiry from a lime manufacturing company regarding their desire to reduce the replacement work caused by 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 lead to a decrease in production volume.

• Water and sewerage pipe fittings
• stone

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

• others

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

• stone

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

• others

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

• others

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

• others

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

• others

In the line producing powder for a chemical company, there are two bag filter dust collectors for drying and cooling. Various countermeasures have been used, but none have resulted in satisfactory products, leading to concerns about maintenance effort, costs, and safety. Issues: 1. The filter media for drying is at high temperatures and low humidity, creating a risk of static electricity causing sparks and fires. 2. Even when using static electricity countermeasure filter media, the charge level is high, and there have been near-fire incidents. 3. The filters for cooling become wet due to condensation of the powder, and even with pulse cleaning, clogging of the filter media is not resolved, necessitating frequent replacements. 4. Although high water-repellent filter media has been used, while it performs well when newly replaced, its lifespan does not extend as much as expected.

• others

You were using soft PVC sheets processed into a tubular shape at the joint section of the line that transports dry powders from the filling machine of a food processing factory to the bagging process, but you were experiencing many troubles. Issues and Points: 1. Due to the need for flexibility, you are using 0.8mm soft PVC sheets, but they wear out quickly and develop holes in a short time. 2. The joints frequently come apart. 3. You want to avoid using soft PVC sheets due to concerns about environmental hormones and dioxins. 4. Since there are areas where food ingredients flow directly, you want products that comply with food sanitation laws. 5. You want to confirm the flow of materials inside.

• others

We received information that a hygiene products manufacturer is reviewing the costs of various purchases and is making efforts for environmental conservation. Issues: We have decided to consider whether we can contribute to cost reduction and the reduction of industrial waste with the wide timing belts that Kamata Industries supplies, which have sponge attachment and silicone coating processing. Currently, the timing belts themselves show almost no visible wear, but the surface sponge and coating have been damaged and replaced with new ones. 1. Is it possible to reuse the main body of the used belt based on its residual strength? 2. Can the main body of the belt be reused and reprocessed to restore the surface to like-new condition? 3. Is it possible to reduce the unit price through reprocessing?

• others

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

• others

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

• others

We received a consultation from a paper processing company regarding their plan to change the manufacturing line due to an increase in product production. Issues: 1. They would like us to handle everything from listening to their requests to planning, design, construction, project management, and trial operation. 2. There is only one cutter (processing machine) for two manufacturing machines, making it impossible to produce with both machines simultaneously. 3. The packaging machine is only able to operate at less than half of its capacity. 4. There are no solid blueprints for the current building.

• others

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

• others

There is a ventilation opening in the upper wall above the entrance door of the laboratory, through which outdoor air mixed with soot and dust from black smoke generated on the rooftop was entering the room. A filter-equipped outlet was installed at the ventilation opening, but since the outlet was fixed to the wall and could not be removed, the filter had been used for many years and was no longer functioning at all. Additionally, there were gaps between the outlet and the filter, allowing dust to enter, so we received a request to improve these issues in a simple manner without extensive construction. Issues: 1. Improve the system to allow for filter replacement. 2. Eliminate gaps to prevent dust intrusion. 3. Complete the installation work without incurring costs or taking much time.

• others

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

• others

When cleaning the resin material that adheres to the screw of the extrusion molding machine, it is done manually using a hand brush, which takes a considerable amount of time for cleaning. Issues: 1. The adhered resin material is very hard, and the cleaning work takes about a day. 2. I borrowed a regular high-pressure washer from another department to try, but it could not remove the adhered dirt.

• others

When cleaning the inner surface of the raw material underground tank, it was being washed with factory water pressure, but there was a problem with poor dirt removal, making cleaning difficult. Additionally, due to the acidic nature of the raw materials, the existing resin coating was prone to peeling, which could lead to the underlying concrete corroding. Issues: 1. Generally, using a high-pressure washer can apply too much pressure, causing the resin coating to peel off. 2. It takes a considerable amount of time to clean (over 2 hours). *Neglecting cleaning can lead to corrosion and aging of the underground pit tank due to hydrogen sulfide and other factors. If left unattended, this can result in the leakage of hazardous materials, leading to serious environmental issues.

• Steel
• Renovation and repair methods
• others

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

• others

There was equipment for transporting toilet paper to customers that are manufacturing it, using a resin belt (conveyor system) as a transport line to wrap paper around the "core." To add "fragrance" to the "core" as added value for the product, a new "sprayer" was installed to spray that fragrance. The fragrance contains trace amounts of oil, which has caused the following issues: Issue details: - The transport belt (resin belt) generally has joints that are bonded with adhesive, but the oil seeps into those areas and causes delamination. - Since several types of fragrance are used, the previously used fragrance remains on the transport belt, leading to a mixing issue between the new and old fragrances.

• glue
• others

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

• others

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

• Weighing scale
• others

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

• others

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

• others

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

• others

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

• others

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

• others

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

• others

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

• others

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

• others

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

• others

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

• others

We received an inquiry from a machinery manufacturer regarding the nozzles (cast φ50×300L) in their cleaning line, which are experiencing wear due to fluid pressure loads on the inner surface, causing them trouble. Issues: 1. Every time a leak occurs due to erosion wear, they have to replace the nozzles as consumables, resulting in labor and costs. 2. They were considering applying a thick layer of hard chrome plating (approximately 150μ).

• others

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

• others

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

• others

Customers using a large number of carrier rollers in pipe conveyors and shuttle conveyors have been troubled by roller wear for many years. The conveyed items adhered to the rollers, causing surface wear due to friction with the conveyor belt. This led to issues such as the edges of the conveyor belt contacting the worn rollers, causing fraying, and the belt tearing vertically due to burrs. The worn rollers also became a cause of belt misalignment. Points: 1. Standard rollers do not have specific wear-resistant measures on their surfaces. 2. When problems occur, the line must be stopped for recovery work to be carried out. 3. In some cases, the torn belt must be replaced. 4. The conveyed items contain moisture and are prone to adhesion.

• others

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

• others

At a steel manufacturing company, a cylinder valve was installed for flow adjustment in the factory's piping system. However, it has been reported that fine-tuning the valve opening is difficult, leading to the occurrence of water hammer, which damages the piping. They consulted us to see if there is a valve that can reduce the hammer. Issues: 1. The current cylinder valve makes it difficult to finely adjust the valve opening. (It goes from fully open to fully closed suddenly.) 2. They want to reduce water hammer and extend the lifespan of the piping. *Water hammer refers to a phenomenon, also known as water shock, that occurs when the flow of water in a pressurized pipe is suddenly stopped, causing a shock and high pressure to develop within the pipe due to the inertia of the water. When the water or steam in the piping is instantaneously halted, the kinetic energy of the fluid has nowhere to go and is converted into pressure energy, resulting in a rapid increase in pressure within the piping (pressure fluctuation) and the generation of a "high-pressure wave" (shock wave). This pressure wave can propagate instantaneously over long distances through the piping and fluid (in water, at speeds exceeding 1,400 meters per second), causing unusual noises (such as knocking sounds) in locations far from the source of the problem and potentially damaging the piping or valve body.

• others

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

• others

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

• others

In the cooling process using water, to prevent the splashing of the rebound cooling water, it is necessary to cover the surroundings with iron plates each time. Since the iron plates are large and heavy, installing and removing them requires significant effort, and there is also a risk of falling. It seems that fabric curtains have not been implemented so far due to issues such as heat resistance. Issues: 1. The temperature of the rebound cooling water and steam is very high, so ordinary fabric curtains cannot withstand it. 2. Simple fabric absorbs water, which poses a risk of falling off the curtain rail. 3. It is necessary to devise a method of installation that does not require large-scale modifications to the equipment.

• Cloth
• others

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

• others

It is a fixture that clamps and seals objects of all shapes with a single touch, without the need for tools.

• Joints between components
• Water heater Cooker IH
• others

About wear resistance Ceramic lining Ceramic thermal spraying Ceramic fired products Ceramic hoses

• others