蒲田工業 List of Products and Services

At Company A, which manufactures car lamps, dust was adhering due to static electricity during the painting of resin molded products, causing uneven paint application. 1. We want to eliminate static electricity from the products. 2. We want to reduce defects caused by uneven paint application.

• others

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

• Grating
• others

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

• Water Treatment Plant
• Unit and other construction
• others

At the steelworks, a belt cleaner has been installed as a measure against material spillage from the raw material transport belt. However, the previously used cleaner utilized ultra-steel for the scraping part (chip). While ultra-steel chips are efficient in scraping, they can damage the belt if there are partial repairs or uneven wear on the belt, leading to issues such as gouging into the belt or causing significant damage like longitudinal tearing. They were looking for a good solution to achieve the conflicting goals of cleaning the belt surface (scraping) and preventing damage to the belt. Additionally, poor scraping effectiveness on the belt surface can lead to spillage of the transported raw materials, resulting in increased labor and costs for cleaning up spills in the factory. 1. Measures against material spillage from the conveyor belt. 2. Measures to prevent damage to the belt from the belt cleaner.

• others

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

• others

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

• others

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

• others

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

• glue
• others

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

• others

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

• others

At the A Steelworks, you were troubled by dust generation and spillage issues with the powder raw material transport conveyor line. In the transition areas of the steep belt conveyor, spillage and dust generation are likely to occur. As a countermeasure, skirt rubber has been installed to address spillage and dust from the sides of the belt. This skirt rubber was made from cut pieces of old belt conveyors. When the skirt rubber from the old belt is pressed against the surface of the belt, it causes uneven wear in the areas where the skirt rubber makes contact, and the belt can slip due to the pressure applied. As a result, it was used with gaps, leading to an inability to control spillage and dust generation. Issues: 1. Uneven wear on the belt occurs. 2. The belt slips due to the pressure applied. 3. Using it with gaps prevents spillage and dust generation from stopping.

• others

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

• others

Due to the presence of delamination and cracks between the substrate and the corrosion-resistant lining inside the exhaust gas treatment device chimney, we have received inquiries regarding the investigation of the delamination causes of the existing lining and consultations for extending its lifespan during the renewal process. 1. The existing lining was installed by the plant manufacturer at the time of equipment introduction, so the details such as the construction method, components, and film thickness are unknown. 2. Since the existing lining became unusable in about 6 years, we would like to ensure a durability of over 10 years for the renewal. 3. It is necessary to extend the lifespan while staying within the specified budget and construction period.

• others

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

• others

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

• Paper cloth
• others

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

• others

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

• Air conditioning
• others

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

• others

At the factory of a food manufacturer, the floor coating had started to peel, and there were the following issues: Issues: 1. Since products are supplied to convenience stores, there is hardly any time available for repairs. 2. Because the manufacturing area and the construction site are close together, we want to avoid the use of organic solvents that could affect the products and materials that may transfer odors. 3. We hope for repairs that have a long lifespan and good heat resistance.

• Mural
• Reinforcement and repair materials

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

• others

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

• others

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

• others

The safety cover surrounding the manufacturing line is deteriorating, and we would like to update it. Due to multiple modifications made in the past to accommodate changes in the line, there is a lack of overall cohesion, and the appearance is poor. Some of the resin panels are also showing signs of damage. Issues: 1. Instead of enclosing the entire manufacturing line broadly, we want to cover it compactly in accordance with the equipment's contours. 2. Using commercially available aluminum frames for customers to design and fabricate the cover themselves is very labor-intensive. 3. The existing product uses resin panels, which are prone to cracking and pose a risk of foreign object contamination, so we would like to use expanded metal, which has proven effective in other locations, as the material for the panels.

• others

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

• Scaffolding and Support Materials
• others

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

• others

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

• others

We received a consultation from a resin film manufacturing company regarding their high-performance resin film inspection process, where dust is adhering to the film, causing them trouble. 1. Dust is adhering to the film, and it must be removed each time with adhesive rollers, which is time-consuming and labor-intensive. 2. Due to the process, it is also difficult to separate the inspection workspace with clean booths or similar measures.

• others

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

• others

I received the following inquiry from a representative of the research department that conducts tests on printing performance and equipment: they are looking for a gantry crane that can lift a special resin sheet printed in a clean room while remaining on a frame (approximately 2m x 2m). 1. They have searched for ready-made gantry cranes suitable for clean room specifications, but the prices exceed their budget significantly. They are wondering if there are any options that fit within their budget. 2. Due to the limited space around the machinery, they are looking for a more compact option. 3. Since the crane may need to be fine-tuned or moved to other machines, they are seeking one with casters that remains stable during movement.

• Crane and others

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

• Steel
• others

In the raw materials and products warehousing and logistics department, measures to prevent the falling of transported items when using forklifts were being discussed. There is a possibility of sudden braking or sharp turning to avoid accidents, which could pose a danger to workers and those nearby due to the collapse of transported items. Therefore, safety measures were necessary. Furthermore, such collapses can lead to losses of raw materials and products. Issues: 1. Since switching from wooden pallets to resin and metal pallets, the risk has increased significantly, especially as the pallets have become more slippery (the danger increases particularly in rainy conditions). 2. When sudden braking occurs, metal pallets can slip, causing items to fall from the forks and potentially leading to accidents. 3. In the case of sharp turns, balance can be lost, increasing the likelihood of items falling or mistakes in steering. 4. As a countermeasure, anti-slip rubber mats with magnets are being used, but there are issues as outlined below.

• others

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

• others

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

• shutter
• others

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

• others

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

• Grating
• others

We received a consultation from the manufacturing technology department of a paper company regarding a section of the production line where shower rings are used. They were previously circulating water using a strainer (washing machine), but now they have switched to disposable use, leading to a significant increase in water consumption, which has become a problem for them. 1. When using circulating water, dirty water frequently clogged the hundreds of shower nozzles, requiring regular cleaning and replacement. 2. As a countermeasure, they used an auto strainer to reduce nozzle clogging, but the maintenance of the strainer was quite challenging. 3. To reduce strainer maintenance, they increased the mesh size of the filter, but this led to frequent clogging of the shower nozzles, creating a cycle of increased cleaning effort. Ultimately, they gave up on using circulating water and resorted to disposable use, which increased consumption. They want to find a way to reduce the waste of water resources.

• others

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

• others

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

• others

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

• others

You were having trouble with the contamination of metal wear powder and debris in the conveying pipes for feed ingredients. Issues: 1. The metal detector is located at the final stage, causing delays in detection and reducing production efficiency. 2. There is almost no available space around the piping line, so we want to implement measures without changing the piping. 3. Since the unit price of the product is not high, we want to keep costs to a minimum.

• others

The chemical manufacturer requested to install a fence to make the emergency exit (in case of disaster) safer. There were several requests to enhance safety that needed to be addressed. Issues: 1. Since there are rotating equipment such as dust collectors and blowers inside the fence, we want to ensure safe walking even in dim light. 2. To prevent tripping, we want to anchor the fence securely to the floor without creating any steps. 3. The fence should be made of wire mesh with a diameter of φ3 or more instead of board materials, to avoid affecting the equipment inside the fence and to withstand heat and fire. 4. The equipment inside the fence requires maintenance, so we would like to install a door. 5. To ensure safety, we want the side of the passage to be as smooth as possible, making it difficult for clothing and other items to get caught on the fence.

• Air compressors, blowers and pumps
• others

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

• others

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

• others

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

• others

A manufacturer of sanitary products was having trouble with hot melt (solid monomer/adhesive that melts with heat) adhering to rollers. 1. The hot melt hardens when the temperature drops, making cleaning tasks very difficult. 2. They had previously tried fluororesin coatings and fluororesin shrink tube coverings, but the non-stick effect was not as effective as they had hoped, and they sought advice on finding a better solution.

• glue
• others