Our company is making efforts to market not only our main product, industrial heaters, but also the insulated covers introduced in the previous issue. These activities extend not only throughout various regions in Japan but also to countries in Southeast Asia. In November last year, we exhibited at an international exhibition related to metal processing in Thailand and promoted the insulated covers as a useful tool for cost reduction.
In this final installment of our series on the current state of plastics processing in Southeast Asia, we will delve into the current state of plastics processing in the region and the challenges it faces. Additionally, we will cover the business development of insulation covers, for which demand is expected to increase in the future.
Plastics processing mainly occurs in Southeast Asia. Major countries include Thailand, Vietnam, the Philippines, Malaysia, and Indonesia. According to a report by market research firm Mordor Intelligence, Indonesia’s plastics market accounts for more than 25% of the total Southeast Asian market. Furthermore, over the five-year period 2024-2029, the Southeast Asian plastics market is projected to increase at an average growth rate of 6%.
The thriving plastics processing industry in Southeast Asia is facing a major challenge. Due to the relatively high electricity and other energy costs in Southeast Asia, local factories are always conscious of the cost-effectiveness of expenses and prices in the production of plastic products. Therefore, they are actively introducing injection molding machines with low power consumption and efficient heating and cooling.
Reference: Market Trends of Plastic Processing Machines in Southeast Asia (Alibaba.com)
Any factory would naturally consider the adoption of cost-effective injection molding machines that can produce reliable and high quality plastic products. However, focusing solely on injection molding machines would result in parity between competitors, leading to a plateau being reached. Consequently, efforts are being made to discover new ways to reduce costs.
Our insulation covers are used at plastics processing sites in Japan and have been praised for their usefulness in saving electricity costs and improving the working environment. This track record has led us to focus our efforts on the sales of insulation covers overseas, with the aim of addressing the cost-saving challenges faced by plastics processing sites in Southeast Asia.
We had the opportunity to showcase our products at METALEX 2023, an international exhibition related to machine tools and metalworking, in Bangkok, Thailand.
The event was held for four days from November 22nd to 25th, 2023. The venue was Bangkok International Trade and Exhibition Centre. Our company had previously exhibited at PROPAK ASIA as well, an international exhibition focusing on packaging for food and other products.
First overseas exhibition at PROPAK ASIA 2022, Aiming to Create a New Base in Thailand
To get as many people as possible to see our featured product, the insulation cover, we displayed it in a prominent place at our booth and eagerly awaited visitors.
However, visitors did not pay much attention to the insulated cover. Instead, we were asked more about heaters in general. Despite our enthusiasm to promote the insulation cover, things did not go as we had hoped.
The insulation covers did not attract much attention at the exhibition booth due to the gap in awareness of insulation covers and their use. In Southeast Asia, insulation covers are not as widely known as they are in Japan. From interactions with visitors, we learned that they focus on selecting machines that consume less power to save on electricity costs and achieve efficient production. In other words, there seems to be less attention paid to the utilization of additional tools. In fact, many visitors at our booth said that they were seeing insulation covers for the first time.
Another challenge emerged when promoting the insulation covers. Despite emphasizing the usefulness of insulation covers for saving on electricity costs, we received many responses expressing uncertainty about how much electricity consumption could be reduced. We found ourselves unable to provide sufficient explanations. We realized the need to present not only product explanations but also concrete measurement results of how much electricity consumption could be reduced using insulation covers.
While our booth at METALEX 2023 did not produce the results we had hoped for in terms of sales for our insulation covers, we were able to gain valuable insights on how to market our products to plastics factories in Southeast Asia. Using the lessons learned from the exhibition, we are now more determined than ever to the spread the use of insulated covers to plastics processing sites in Southeast Asia.
Over the course of three issues, we have addressed the challenges faced by plastics processing sites in Japan and internationally from the perspective of heat. The heat emitted from injection molding machines, which is essential to produce plastic products, is pushing domestic factories to save electricity and improve work environment temperatures in summer. Furthermore, it is pushing Southeast Asian factories to reduce electricity costs in order to gain customers. To meet this challenge, our company wants to propose insulated covers to the industry.
Our company’s mission is to solve the “heat problems” faced by factories. Until now, we have solved heat problems by generating heat with our heaters. Moving forward, we intend to add to our mission not only to create heat, but also to find solutions to prevent its escape.
We do not lose the heat that we have created. That is also the mission of ThreeHigh.
With this in mind, we are determined to take on new challenges in Japan and internationally.
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Our insulation jacket is crafted using glass cloth, which is a fabric made from woven glass fibers. Glass cloth is a commonly used material for insulation.
This insulation jacket consists of two layers: an inner jacket for attachment and an outer jacket that covers it.
The outer jacket is equipped with a belt, hook-and-loop fasteners (Velcro), and adjustable strings to facilitate easy attachment and allow for precise tightening.
We have recorded a demonstration video on how to install it by yourself. Please take a look at the video, which shows the process of attaching an insulation jacket to a cylinder with an internal diameter of 200 millimeters, resembling pipes or cylinders.
The size of the insulation jacket used in the video is as follows.
For long cylinders, install insulating jackets about the size above in a row. You can use a larger size jacket, but if it gets damaged it will be expensive to replace. If you keep it small, you can keep costs down because you only need to replace part of it.
Wearing two layers, an inner jacket and an outer jacket, has advantages over a single layer. One is that it suppresses the release of heat to the outside and increases the effectiveness of trapping it inside. It's the same as layering two layers of futon to make the inside warmer. Another issue is maintenance. The insulation jacket will eventually need to be replaced after long-term use. Depending on the situation, either the inner or outer jacket can be replaced. Maintenance costs can be reduced while maintaining the insulation effect that only two layers can provide.
When wrapping an insulating jacket around the cylinder of an injection molding machine, you need to be concerned about plug connections and cable wiring. If cables are connected to the cylinder, you must take measures to prevent the wiring from running around. If possible, I would like to cut a hole for the wiring in part of the jacket.
The insulation jacket can be cut and processed freely, so holes for wiring can be easily drilled.
You can make the holes yourself, but it is better to use a product that has been pre-processed to your specifications, as it will trap the internal heat more efficiently. We design and process the most suitable insulation jacket based on the cylinder size and the presence or absence of connection cables. We keep the design specifications, so we can manufacture and deliver the same product at any time if requested.
Measures to prevent heat release from injection molding machines by using heat insulating jackets are attracting attention at plastic processing sites in Japan, and we are also receiving inquiries about them. Consultations regarding heat release from industrial machinery are sometimes received from industries other than plastic processing. I believe that insulation jackets will be widely used in manufacturing sites in the future.
Furthermore, this insulation jacket is attracting interest not only in Japan but also overseas. In particular, there is interest in insulation jackets at plastic processing sites in Southeast Asia to prevent heat from injection molding machines from being released into the work site.
In Part 3, we will discuss the current state of heat release, which is occurring at plastic processing sites in Southeast Asia such as Thailand, and the expectations for heat insulating jackets.
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Currently, in the facilities where plastic is processed or assembled, there is a concern about the heat generated from the injection molding machines. According to reports, this issue is significantly impacting profitability and the working environment in these facilities.
In this series of three articles, we will address the challenges faced in plastic processing facilities while highlighting the initiatives our company is taking to address them. In the first part, we will discuss the impact of the heat released from injection molding machines, which is essential for plastic processing.
First, for those not familiar with the field of plastic products, let me provide a brief overview of the basics of plastic processing.
To create plastic products, a technique called injection molding is employed. In simple terms, this involves melting solid materials, such as synthetic resins, which serve as the raw material for plastic, heating them, and then injecting the molten material into a mold. Once it solidifies, the finished product is removed from the mold.
Rather than explaining in text, it's often clearer to understand through CGI animations.
The injection molding machine is responsible for managing this entire process. The basic mechanism involves placing pelletized plastic raw materials and solid coloring materials into an inverted cone-shaped container called a hopper. These materials are then fed into a cylindrical barrel. Inside this barrel, the two materials are melted and transformed into a liquid state before being injected into a mold. Once solidified, the finished plastic product is removed from the mold.
While the following video is dated, it provides a comprehensive explanation of the entire process carried out by an injection molding machine. Watching it helps to understand the workflow clearly.
Currently, systems are automated to streamline tasks such as retrieving finished products with robotic arms and packing them into boxes, reducing the manual effort required by workers. However, injection molding remains a sophisticated craft that demands skilled expertise.
In operational settings like local factories, where plastic products are processed using injection molding machines, a specific challenge arises – the heat released from these machines.
During the plastic processing in injection molding machines, there are two heating stages using heaters. One involves drying the raw materials in the hopper, and the other involves melting the raw materials inside the cylinder. The former is for removing moisture and doesn't require extremely high temperatures. The latter, however, involves heating to high temperatures ranging from 200 to 240 degrees Celsius within the cylinder.
The heat generated during these two processes is released externally, and currently, this released heat has become a significant issue.
One problem is the electricity cost associated with the operation of injection molding machines. The consecutive increases in electricity rates are impacting the financial management of factories. Particularly, the high-temperature heating of the cylinder's heaters consumes a significant amount of electricity, leading to increased expenses. Due to the inability to transfer these costs to product prices, maintaining profitability requires controlling production expenses. The ongoing rise in electricity costs is expected to affect the overall profitability.
Another issue is the rise in indoor temperatures and its impact on the health of workers due to the heat dissipation. With recent climate changes, summer days with temperatures exceeding 30 degrees Celsius have become more frequent. Consequently, heatstroke prevention measures are emphasized not only outdoors but also indoors. In workplaces with injection molding machines, the heat released by the heaters significantly increases indoor temperatures during the summer. This not only compromises the health of workers due to the heat but also increases the risk of heatstroke. To address this, it becomes necessary to lower the air conditioning temperature to cool the indoor environment. Naturally, this incurs additional electricity costs for air conditioning. Despite the associated electricity expenses, the use of air conditioning is essential for maintaining the health of workers and the working environment. This creates a practical dilemma, as cutting costs conflicts with the goal of preserving the working environment.
In this way, the released heat poses a challenge to balancing cost reduction and maintaining the working environment. Factories operating multiple injection molding machines are reported to be grappling with a significant dilemma.
At our company, we are deeply committed to addressing the challenge of heat released from injection molding machines in plastic processing facilities. As a solution, we believe that the best approach is to prevent the heat generated by heaters from escaping.
By containing the heat internally, the following benefits can be achieved:
Reduced Power Consumption for Heating:
By trapping the heat internally, the operation of heaters can be mitigated. Consequently, this results in lower power consumption for heating, leading to cost savings in electricity.
Suppressed Increase in Indoor Temperature, Reducing Air Conditioning Power Consumption:
Preventing the release of heat from the heaters can help suppress the rise in indoor temperature. This, in turn, prevents situations where workers might be at risk of heatstroke during the summer. Additionally, it allows for a relaxation of the air conditioning set temperature, reducing electricity consumption for cooling.
The savior to realize these benefits is the insulation jacket.
The insulation jacket is an insulating material that can be placed over or wrapped around the heated portions to prevent the release of heat to the external environment. By installing this on hoppers and cylinders, it helps to minimize heat dissipation to the surroundings. When actually attached to the cylinder, it looks like this.
When using our company's insulation jackets, it is reported that the perceived heat released into the indoor environment is significantly reduced, resulting in cost savings on electricity.
In the next installment, we will provide a detailed explanation of the insulation jacket.
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In the food and beverage industry, there is a growing interest in food waste disposal machines from an environmental and SDGs perspective.
A food waste disposal machine is a device designed to process and reduce the waste from perishable food items and scraps, commonly referred to as "food waste." This technology involves mixing with microorganisms or enzymes to break down waste into compost, or applying heat to evaporate moisture and reduce the volume of the food waste itself.
The processed compost can be reused for cultivating plants and agricultural produce. Additionally, dehydrated food waste, after undergoing proper treatment, can also be buried underground. In either case, this contributes to reducing municipal waste collection for combustible materials.
Businesses operating in the food and beverage industry, including restaurants and food processing establishments, handle a substantial amount of ingredients on a daily basis. In doing so, they inevitably generate a significant volume of food waste that requires disposal.
Recently, there has been a growing focus on efforts by companies to reduce waste and engage in environmental recycling. Furthermore, an increasing number of companies are becoming aware of the Sustainable Development Goals (SDGs). Within these SDGs, there is an emphasis on "ensuring sustainable consumption and production patterns," and this has led to heightened interest among businesses in food waste disposal.
Heaters play a significant role in commercial food waste disposal machines.
There are three primary types of commercial food waste disposal machines: bio-type, drying-type, and carbonization-type. Heaters are utilized in each of these methods. Let's delve into the different types of commercial food waste disposal machines and the role of heaters.
Bio-type: The bio-type involves breaking down food waste using microorganisms to transform it into water, carbon dioxide, and organic compost. By placing a mixture of waste and a substrate containing decomposing microorganisms (referred to as a biochip) into a container and stirring, water and carbon dioxide are produced, while the remaining material turns into organic compost.
One drawback of the bio-type is that it's challenging for microorganisms to proliferate when dealing with high moisture content in the waste. To address this limitation, some machines come equipped with heaters. When handling moisture-rich waste, the container can be heated using the heater to reduce the moisture content, creating a more favorable environment for microorganism growth.
Drying-type: The drying-type method involves using hot air to dry the food waste, evaporating its moisture content and reducing its size. The resulting waste can be transformed into compost, although in smaller quantities compared to the bio-type. The primary goal here is waste reduction and disposal; reuse of the processed material is secondary.
Heaters are used to generate the hot air required for the drying process. The heated air not only aids in moisture removal but also plays a role in sterilizing or deactivating bacteria and pathogens.
Carbonization-type: This method is unique to commercial food waste disposal machines and involves transforming food waste into charcoal through high-temperature carbonization. It's similar to the process of converting wood into charcoal through pyrolysis. Unlike incineration, which involves burning waste, this process uses steam and heat treatment. The carbonization-type offers greater waste reduction compared to the drying-type. The resulting charcoal can be reused as fuel.
Heaters serve as the heat source for the carbonization process. Given the need for high temperatures, high-temperature heaters are used.
In conclusion, each type of commercial food waste disposal machine - bio-type, drying-type, and carbonization-type - employs heaters to facilitate its unique waste processing method. These heaters play a crucial role in creating optimal conditions for waste breakdown, moisture removal, and thermal treatment, contributing to efficient waste management and sustainable practices.
Designing suitable heaters for various types of food waste disposal machines, contributing to the SDGs.
Our company has been dedicated to the design and manufacturing of heaters for commercial food waste disposal machines. With our track record, we aim to continue accepting orders in this domain. Drawing from our past achievements, we take pride in our ability to meet the demands for custom-designed heaters that are optimal for specialized food waste disposal machines.
Our range of heater products covers various needs, ranging from medium to high-temperature heaters for moisture removal, to high-temperature heaters required for carbonization. Moreover, we handle the entire process from understanding specifications to heater design, fabrication, and delivery, all within our own facilities. We are well-equipped to accommodate not only bulk orders but also individual requests. Our adaptability allows us to effectively address the unique requirements of commercial applications.
In parallel, our company is actively committed to the Sustainable Development Goals (SDGs) within our organization. As part of our efforts, we are also dedicated to promoting our engagement with the SDGs.
Reference: ThreeHigh's Initiatives towards SDGs
One of the goals within the SDGs is "Responsible Consumption and Production," which aims to prevent, reduce, and recycle/reuse waste to significantly decrease the amount of waste generated by 2030. With a commitment to achieving this SDGs goal, all of our employees in the local factory are eager to take action. In addition to managing organic waste, we also utilize biomass energy in the heating sector. If you are interested in heaters designed with eco-friendly and environmentally recyclable materials, please feel free to reach out to us for inquiries.
From June 6th to 9th, 2023, the prestigious food industry trade show, "FOOMA JAPAN 2023," took place at Tokyo Big Sight. It was our company's first time participating as an exhibitor at this event. Despite being overwhelmed by the sheer number of exhibitors and attendees, we were thrilled to sense unprecedented business opportunities when visitors expressed their keen interest in heaters.
Here is an introduction to our booth at FOOMA JAPAN 2023.
FOOMA JAPAN is a business exhibition event focused on food manufacturing, organized by the Japan Food Machinery Manufacturers' Association (JFMA). It brings together companies involved in the food industry, ranging from major corporations to small factories and startups. The event serves as a platform for these companies to showcase their products, technologies, and services specifically tailored for the food manufacturing sector, utilizing their unique expertise. FOOMA JAPAN facilitates fruitful business negotiations and networking opportunities among industry professionals.
FOOMA JAPAN 2023 Special Website
FOOMA JAPAN is proud to be one of the world's largest exhibitions in the food industry. The event occupies the entire East Exhibition Halls 1-8 at Tokyo Big Sight, showcasing its grand scale. In its 46th edition, this year's event featured an impressive participation of 969 exhibitors, and the total number of visitors reached an all-time high of 106,104, making it the largest in history.
The exhibited contents of the participating companies cover a wide range of areas. It is truly impressive to see the utilization of AI and robotics technology in food processing, as well as automated systems that can mass-produce processed food simply by inputting the ingredients.
In addition, you can also explore various technologies and products related to food lifestyle, such as hygiene supplies, packaging technology, cooking utensils, and pest control solutions.
Our heater products are also utilized for applications such as heating, insulation, and prevention of solidification in food ingredients. Last year, we exhibited at PROPACK ASIA 2022, an international exhibition focused on packaging for food and related industries, held in Bangkok, Thailand. It provided us with valuable connections within the food industry.
Reference: First overseas exhibition at PROPAK ASIA 2022, aiming to create a new base in Thailand!
Building on this achievement, we have decided to take on a new challenge by participating in domestic food-related exhibitions this year. As a result, we eagerly embraced the opportunity to exhibit at FOOMA JAPAN, one of the leading food industry trade shows in Japan.
As a food-related exhibition, our booth primarily featured products that received inquiries and orders from food processing companies and restaurants.
Firstly, we showcased pipe heaters. Pipe heaters are utilized to heat materials such as melted chocolate or other liquids, ensuring they remain in a fluid state as they flow through the processing line via pipes. To cater to different needs, we displayed two types of user-friendly products: pipe heaters using silicone rubber and a new addition to our lineup, the TechHeater.
Secondly, we presented insulation materials, which are used for heat retention and preventing heat loss. In this exhibition, we showcased two products: "KINZO," a new material capable of metal detection, and silicone sponge. These materials offer excellent insulation properties and provide effective solutions for various applications.
KINZO is not only an effective insulation material but also a new material capable of detection by metal detectors. By using KINZO to create gaskets or seals, even if a fragment of the gasket falls off due to corrosion or aging on the production line, it can be easily identified and detected by metal detectors. This feature plays a crucial role in preventing foreign object contamination in food production lines and ensuring food safety.
Silicone sponge is a product that we have been manufacturing and selling for many years. It is used to provide insulation by covering heating devices and components or placing it beneath containers to ensure heat retention and prevent burns when touched by human hands. Its ability to be processed into customized shapes according to specific requirements is also a notable feature.
Reference:Electricity cost savings technique utilizing heat retention cover and silicone sponge!
Furthermore, we also showcased a prototype of a container jacket heater that is currently under development. This heater is designed to provide insulation and prevent freezing or solidification of liquids during transportation. We have been advancing its development with the aim of offering a solution for transporting food materials in a liquid state. We presented it as a reference exhibit to demonstrate its potential benefits in maintaining the desired consistency of food ingredients during transit.
We are also considering the application of this jacket heater for IBC containers. IBC containers are rectangular-shaped transportable polytanks with a capacity of 1,000 liters (equivalent to five drums). We have been conducting prototypes for a transportable insulation heater that can be used for carrying solvents and other liquids, not limited to food ingredients, in their liquid state.
Over the years, our company has participated in various domestic and international exhibitions such as Smart Factory Japan and PROPACK ASIA. However, at this year's FOOMA JAPAN, we encountered something unprecedented compared to our previous exhibition experiences. It was the following remark from the visitors:
Many of the visitors came to our booth with the specific intention of seeing the heaters right from the start. They didn't simply stop by to greet us in order; their primary focus was to explore our heaters by visiting our booth.
With nearly 1,000 participating companies and booths spread across eight halls, FOOMA JAPAN is a large-scale event where it becomes challenging for representatives to visit every single booth, even when dividing the tasks among all team members. Therefore, prior to attending the exhibition, company representatives review the exhibiting companies' offerings to narrow down the booths they want to visit. In our booth, we had a significant number of visitors who were representatives from the food manufacturing industry with a keen interest in heaters. Many of them expressed concerns about food insulation and heating. It was a remarkable achievement for us to be able to engage with these individuals, understand their specific needs, and provide on-the-spot product recommendations based on their requirements. This outcome was something we had not experienced in our previous booth displays.
According to the event organizers, the next FOOMA JAPAN in 2024 is scheduled to take place from June 4th to June 7th, 2024. After experiencing such a positive response and outcome from our inaugural participation, we are eagerly looking forward to the possibility of exhibiting again next year. We have a strong desire to set up a larger booth and showcase a wide range of products to welcome even more visitors. The anticipation and enthusiasm within us are already building up for this opportunity.
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When you pull out aluminum foil from the box, there is a white discoloration in the center.
Aluminum foil is a common household item that we often use in our daily lives. At home or in the office, you'll likely find a box of it stored on the kitchen shelf as a cooking accessory.
Additionally, it is also useful for storing materials and heating machines in factories or laboratories."
Although aluminum foil is a common and convenient item, when you take out a piece that has been left unused for a long time, you may notice a white discoloration in the center that does not go away no matter how much you try to smooth it out. Additionally, the foil may become stuck together, making it difficult to separate, and pulling too hard may cause it to tear, leading to frustration.
The cause of the white discoloration on aluminum foil and the difficulty in separating it may be closely related to condensation.
The cause is corrosion of the aluminum due to condensation during long-term storage.
The reason why the center of aluminum foil turns white in a band shape is because the surface has undergone significant corrosion. This is the same phenomenon that occurs when a one yen coin is used and its surface becomes dull and white.
A one yen coin is made of a substance called aluminum oxide (alumina), and when moisture or humidity comes into contact with the surface, the alumina corrodes further. Both aluminum foil and one yen coins start out shiny and silver-colored, but when the surface is eroded due to corrosion, the luster disappears and eventually turns white in color.
The cause of rust formation on aluminum foil is condensation. When a box of aluminum foil is left unopened in a humid room for a long time, moisture enters the inside of the box and adheres to the aluminum foil. In other words, it is condensation. If this state continues for several months, the aluminum foil will oxidize and rust. As it progresses further, the rust peels off from the surface and turns into white powder.
The reason why white rust does not form on both ends of aluminum foil is that the indoor air easily enters and the humidity eventually dries out, suppressing moisture adhesion. On the other hand, the central part is less ventilated and less prone to drying out, making aluminum oxidation and rust formation more likely. As a result, the central part of the aluminum foil is the only place where a strip-shaped rust forms.
Another problem caused by condensation is that moisture can seep into the gaps of aluminum foil, causing the foil to stick together. Even if you try to pull it apart, it may become impossible to remove, and if you pull too hard, it may tear, making it impossible to extract the necessary length of foil. Even if you cut it with a cutter, it may tear in the middle, leaving you at a loss.
The biggest enemy when using aluminum foil is arguably condensation.
Use it up early in rooms with high humidity.
To protect aluminum foil from condensation, it is best to store it in a dry place. However, when using it in a room with high humidity such as a kitchen, it is necessary to store it with a drying agent in the cabinet. This can become cumbersome over time, as the drying agent may need to be replaced. In factory workspaces, aluminum foil is often placed on work shelves and left exposed to the elements.
When using aluminum foil in a humid room, it is best to use it up as soon as possible. It is also recommended to not prepare too much in advance and replenish as needed when the amount being used starts to run low.
If white streaks of rust have formed on the aluminum foil and you cannot remove them, it is recommended to use a new one. The surface of the aluminum foil is already oxidized, meaning that it is already slightly rusted. While this rust is not a major concern from a hygiene perspective, the streaks can be greatly affected by condensation, and trying to remove them can be a waste of effort. It is better to simply use a new one in this situation.
When we hear the term "condensation," we tend to think it only occurs in conditions with a large temperature difference. However, it can also occur in our daily lives. We shouldn't underestimate the effects of condensation.
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( Electricity cost savings technique utilizing heat retention cover and silicone sponge! )
Actually, we heard from a business partner that heating with a thermal cover or silicon sponge can save electricity. Our company was not aware of how much money could actually be saved.
There was a lot of interest within the company in using insulation to save on electricity costs, so we decided to verify it through experimentation. And the results showed that insulation really does save money on electricity.
Here is the whole story of the experiment.
Assuming heating with a heater attached to the piping to verify whether there is a difference in electricity rates with and without insulation.
This experiment is based on the assumption that piping for industrial machinery is warmed by an electric heater. The objective is to find out how much money can be saved on electricity with and without insulation.
Since we do not have piping for industrial machinery, we substituted it with a vertical metal pot used for cooking. The substitute metal pot is made of molybdenum, which is a different material from the aluminum and stainless steel used for piping. They also differ in thermal conductivity. The thermal conductivity of molybdenum at room temperature is 138 W/(m-K), which is about halfway between aluminum's 237 W/(m-K) and stainless steel's (SUS 304) 16 W/(m-K). Please take this into account when comparing electricity savings in actual pipe heating.
Heating was performed for 8 hours and heater operating time was measured with and without silicone sponge
The experiment consists of wrapping a silicone rubber heater around an empty metal pot and operating the heater for 8 hours under two conditions: with and without a silicone sponge attached as insulation. The total time the heater is active, the electricity rate, and the power consumption are then measured using a commercially available eco-checker. The 8 hours set as the experimental time is assumed to be the daily operating time.
The experimental apparatus and procedure are as follows;
Equipment used...
-Metal pot: molybdenum, outer diameter 24 cm, height 22 cm, with closed lid
-Heater: silicone rubber heater (made by ThreeHigh, width 10 cm)
-Insulation: Caterpillar silicone sponge, sheet silicone sponge (both made by ThreeHigh, width 10 cm)
-Fixing tape: Glass tape
-Heating and energizing control: Thermostat attached to the silicone rubber heater. When the heating temperature exceeds 60 degrees Celsius, the power is automatically shut off.
-Measuring instrument: Eco-checker (used to measure the energization time and power consumption of the heater)
Procedure...
1.Cover the empty metal pot and wrap the silicone rubber heater around the sides. If insulation is used, cover and wrap with a caterpillar-shaped silicone sponge, and finally secure with glass tape. If insulation is not used, wrap the silicone rubber heater and then secure it with glass tape.
2.To prevent heat from escaping under the floor, place a metal pot on top of the silicone sponge sheet.
1.Connect the silicone rubber heater and the EcoChecker to a 100-volt AC power outlet to start heating. When the heating temperature exceeds 60°C, the thermostat on the silicone rubber heater automatically turns off the power and stops heating.
2.Confirm that the EcoChecker is working and record the time of the start of the experiment.
3.Continue this for 8 hours.
4.After 8 hours, the accumulated electricity usage time recorded in the EcoChecker is recorded as the active running time. In addition, electricity rates, power consumption, and CO2 emissions are also recorded.
Because the measurement time spanned 8 hours, the experiment was conducted on two separate days. The indoor temperature during the experiment was 23°C on the first day and 21°C on the second day, which is considered almost the same environment.
Silicone sponge reduces heater run time and electricity usage
The following table shows the power-on time, electricity rates, and power consumption of silicone rubber heaters operated for 8 hours each under two conditions, with and without silicone sponge, and measured with an EcoChecker. Electricity rates are based on Tokyo Electric Power Company's rate structure.
Of the 8 hours of experimental measurements, the energized time is in the 2-hour range in both cases. This is because the thermostat stops heating the silicone rubber heater when the heating time exceeds 60 degrees Celsius, and no electricity is used until it is reheated when the temperature drops. Because this action was repeated during the measurement time, the energized time was much shorter than 8 hours.
It is noteworthy that the time with insulation was 30 minutes shorter than without insulation. This is thought to be due to the fact that the use of insulation improves the heat-retention effect and shortens the time from when the heater stops heating to when it starts heating again. In other words, the use of insulation reduces the amount of time that electricity is used.
The electricity cost for the total time with insulation was 5.40 yen and without insulation was 7.83 yen. The difference between the two was 2.43 yen, or approximately a 30% savings when heating is done with insulation.
Assuming that the daily operating hours are 8 hours, the same as the experimental hours, and that the number of operating days in winter is 70 days (5 days per week x 14 weeks), a savings of ¥170.10 (¥2.43 x 70 days) is expected for the electricity bill in winter. Assuming an annual operating period of 225 days (5 days per week x 45 weeks), the annual electricity bill will save 546.75 yen (2.43 yen x 225 days). During spring and fall, temperatures are higher than in winter, so less electricity is used for heating with heaters. Therefore, electricity bills are expected to be saved even more.
For reference, we also looked at CO2 emissions relative to electricity consumption, and found that CO2 emissions were 0.11 kilograms when insulation was used, 0.05 kilograms (50 grams) less than the 0.16 kilograms when it was not used. Using the 225 days of annual operation assumed in the electricity cost calculation, this translates into an annual reduction of 11.25 kilograms in CO2 emissions. This is equivalent to the amount of CO2 emitted when driving a standard car from Tokyo Station to Tsukuba City. However, since the conversion is based on the amount of electricity consumed in winter, the actual annual CO2 emissions are expected to be a little lower.
Heater heating with insulation saves on electricity costs.
In this experiment, we found that heating with heaters using silicone sponge as insulation material saves about 30% of electricity costs compared to heating without insulation. Although the amount of electricity saved may vary depending on the size and number of heaters, we were able to demonstrate that using heaters together with insulation at production sites can lead to electricity cost savings.
With the weak yen, high prices, and rising utility costs, the situation in the manufacturing field continues to be fragile. We hope that the results of this experiment will help you save money.
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Due to increasing energy prices and recent extreme cold weather, the demand for heat retention and anti-freezing measures have increased significantly.
In recent years, electricity companies have repeatedly raised electricity prices due to soaring fuel prices.
For manufactures energy costs are one of the main and biggest expenses. Some companies are having difficulties charging the increased costs to the customers, resulting in decreased margins and profit.
This winter was especially cold in the Tokyo area, with prolonged freezing temperatures occurring in the night and early mornings. Freezing temperatures can damage certain water systems outdoors and indoors, and the repair costs are significantly higher than preemptive measures.
Heating using electricity is an effective way to prevent freezing, but due to rise in utility costs it is becoming more burdensome to use.
There has been a rapid increase in requests for products that can keep warm and prevent freezing while also saving on electricity bills. We offer various solutions to these issues, from electric silicone heaters to thermal insulation.
Thermal insulation cover and silicone sponge that can reduce power consumption and keep warm to prevent freezing.
Electric heaters are often used to keep the equipment and piping used in production lines warm. It is a good idea to use materials with heat insulation effect in order to reduce electricity bills and maintain the desired temperature. For inquiries about heat retention and anti-freezing, we recommend heat insulation covers and silicone sponges. Let's take a closer look at each.
▼ Heat insulation cover ▼
The glass fiber cover can withstand heat of about 200 degrees. This heat insulation cover is used for mantle heaters that can heat at high temperatures.
Our mantle heater
We also manufacture and sell only the heat insulation cover that covers the mantle heater. Because it is a fiber material, it can cover and insulate parts with complex shapes such as elbow-type pipes, valves, and robot arm joints. As it is a custom-made product, it can be designed and processed according to your request.
Example of the production of our company manufactured by our company
Strong Points
Depending on the material, it can be used at high temperatures of around 200 degrees or even higher.
It can cover square and complicated shaped parts to keep them heated.
**Important point**
The price is slightly higher because it is made up of glass fiber.
▼ Silicone sponge ▼
This product is made of silicone material. Heat dissipation can be decreased by attaching it closely to linear parts such as straight pipes or box-shaped cases. It is cheaper than the heat insulation cover mentioned above, and it is useful when you want to keep a lot of parts warm. In addition, the silicone material is flexible and elastic. Easy to process and easy to cut. It is also highly resistant to chemicals and is suitable for use in equipment that handles chemicals.
We offer a variety of silicone sponges that match the application, such as a sheet type, caterpillar type, tube type, square string, as well as a cracked round tube that is easy to attach and remove.
Compared to the heat insulation cover, the heat resistance temperature is up to about 200 degrees. When using it on top of the heater, it is necessary to pay attention to temperature control.
Please contact us in advance before installing.
Strong Points
Useful for straight piping, flat plates, and box-shaped containers.
Cheaper than a thermal cover.
It can be easily processed.
Resistant to adhesion of chemicals, etc.
**Important point**
Heat resistant up to 200 degrees.
How to use to save on utility costs.
If you use the heat insulating cover and silicone sponge as follows, you will be able to save electricity.
Cover the heater to increase heat retention and reduce electricity usage.
When using an electric heater in an industrial facility, it must be set to a specified temperature with a temperature controller (thermostat) to maintain a constant temperature.
Our temperature controller monoOne+B (left) and monoOne+W (right)
In winter when the temperature is low, the heating time with the heater will be longer, and therefore more electricity will be used. Also, even if the heating stops automatically when the set temperature is reached, the heat will cool down immediately. Then the temperature controller will detect the drop in temperature and heat again. If this behavior is repeated frequently, electricity is wasted.
Therefore, by covering the heater with a heat insulating cover or silicone sponge the heating time of the heater can be shortened. The heat insulating effect reduces the reheating process of the temperature controller and lowers power consumption.
A company that adopted this method was able to reduce the use of a 1-kilowatt heater from 6 hours to about 3 hours, saving electricity costs. Although it depends on the usage environment and power consumption, it can be said that the use of thermal insulation products will significantly decrease the power consumption.
Prevents freezing by insulating the object and blocking outside air.
Prevents freezing at night by directly attaching heat insulating covers and silicone sponges to pipes and indoor water pipes without the use of electric heating. Both the heat insulating cover and the silicone sponge have the effect of blocking the outside air.
The insulation cover and silicone sponge alone are enough to prevent freezing. Not only can you save electricity bills, but you can also prevent freezing problems on the production line.
Reliable products are recommended for heat insulation of industrial equipment.
Even if you don't have to buy a heat-retaining cover or silicone sponge to save electricity and prevent freezing, you can save money by using heat-insulating materials and heat-insulating sheets sold at home centers.
However, it is not always possible to obtain a sufficient heat retention effect for use in industrial equipment. If you buy heat insulation products from a home center and process them yourself, the adhesion may be loose or there may be gaps, which make it easier for heat dissipation and cold air to enter. As a result, heat retention and insulation may be inadequate.
If you cover it with a heater, you need a silicone material that can withstand temperatures of about 200 degrees. Moreover, silicone materials are resistant to chemicals. Some of the heat insulation products available at home centers have low heat resistance and are not guaranteed to be chemical resistant, so they are not suitable for commercial use.
At our company, we process and deliver heat insulating covers and silicone sponges to meet your needs. As a result, it is possible to reduce the loss of heat and the intake of outside air when attached to a pipe. This not only contributes to saving electricity bills, but also gives a sense of security that the production line can be operated reliably at all times. At first, it may feel expensive, but I am confident that you will feel the benefits when you apply it.
Electricity cost savings at manufacturing sites are expected to continue for the time being.
It is important to take measures to save electricity bills now. We will propose the best thermal insulation and anti-freezing products for your production line, so please feel free to contact us for a free consultation.
I often visit plating factories to conduct sales. When I talk about a certain topic, the person in charge of the project will often confide in me and said, "We have this kind of case”. That topic is that the plating has hardened in the pipes, and when you try to unclog the plating, you end up breaking the pipes by hitting them from the outside with force. Moreover, it is said that the problem occurs more frequently in pipes located on the north side of the building, which receives less sunlight. According to the story, the cause of the broken pipes seems to be the method of heating the pipes.
We have the know-how to solve "certain problems" that plating factories face. The trump card is an electric heater made of silicone rubber. This time, we will introduce how to install the heater to avoid hitting the piping.
Metal plating can cause clogging in pipes when cold.
Plating is used in a wide range of fields. For example, industrial products include screws, automotive parts, electrical equipment, and tools, just to name a few.
There are various methods for applying plating treatment. One of them is hot-dip plating. The metal used as the plating material is heated to melt it, and the part is dipped into the melted metal to form a film on the surface. This method is called "hot dipping," and is used in the plating process of automotive parts.
At a plating factory, when hot-dip plating a large number of parts, the molten metal is sent by piping to a container where the parts are immersed in the molten metal for the plating process. The piping must be kept warm at all times. As the molten metal cools, it solidifies at the bottom of the piping and accumulates as sediment. As this precipitation grows, it clogs the piping.
Floodlighting to prevent coagulation is inefficient and unsafe
One of the most common methods of preventing coagulation of hot-dip plating that we see in the places we visit is to warm the piping by shining an incandescent floodlight on it. This method is especially used in plating factories in snowy regions. When the temperature is low due to cold weather, they use incandescent floodlights to prevent water pipes from freezing, which is probably applied to pipes as well.
However, it is not a good idea to shine an incandescent floodlight on the piping where the plating is sent. The reason is that the entire piping cannot be heated evenly, resulting in uneven heating. In areas that are not adequately heated, the molten metal will cool and solidify, causing a gradual accumulation of precipitates. On the other hand, in areas that are heated intensively, the piping becomes hot and may cause burns if touched during operations. In addition, incandescent floodlights are being replaced by LED bulb types, and in the future, consumable incandescent bulbs will be difficult to obtain.
A vicious cycle of hitting clogged plating and then breaking and replacing the piping.
When piping is heated by incandescent floodlights, one thing that is inevitable is the treatment of molten metal that is clogging the piping. When we talked to them, they surprisingly said that they repair the blockage by hitting the piping with a blunt instrument to break up the sediment.
If this forceful method is repeated, the piping will be damaged. When young workers with strong arms hit the pipes without knowing how much to hit, they often damage the pipes and have no choice but to replace them.
In the case of using incandescent lamps to heat the pipes to prevent the plating from solidifying, the uneven heating causes sediment to accumulate, resulting in a vicious cycle of hitting the pipes with a blunt instrument, breaking them, and replacing them with new ones. This not only reduces the plant's operating efficiency, but also increases the cost of replacing the piping. It is necessary to consider some improvement measures.
Best to install an electric heater for even heating.
What we propose is to heat the piping with an electric heater.
Electric heaters have products that can heat cylindrical components. For piping, silicone belt heaters and rubber piping heaters are recommended. Silicone rubber is a polymeric material that is flexible and bendable. It is favorable for attaching piping.
Silicone belt heaters are heaters that are wrapped around and are suitable for heating straight piping. Heat-resistant tape is used for fixing. We offer three types according to belt width: slim (10 mm wide), regular (20 mm wide), and wide (40 mm wide).
Silicone belt heaters
Rubber piping heaters are heaters that are attached to piping to heat it. In straight piping, it can heat the entire pipe more uniformly than wrapping it around the pipe. It can also reliably heat elbow-type piping that changes its angle by 90 degrees, preventing an increase in sediment that accumulates in bent sections.
Rubber piping heaters
The heater is an electrical product. Do not strike the piping to which the heater is attached. It will break inside and become unusable.
Support including insulation is also available.
We not only deliver heaters, but also provide various types of support for different purposes. One such example is when we receive inquiries about piping heaters, we suggest introductions that include insulation.
Heaters can be maintained at a constant temperature using a temperature controller. Nevertheless, depending on the temperature setting, piping surfaces may become hot and workers may get burned if they accidentally touch the piping. For safety reasons, insulation is a good idea to give workers peace of mind.
Insulation can also be added to further uniform temperature distribution in the piping, as well as help retain heat for extended periods of time. This is especially effective when installing silicone belt heaters.
We, who work with electric heaters, cannot turn a blind eye to heating that could knock the piping and break it. Please contact us. We will propose a piping heater that meets your requirements.
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Large Parabolic Antenna Essential for Space Exploration and Astronomical Observation
From last year to this year, a lot of news about space has been reported. Among them, the Japanese asteroid probe "Hayabusa 2" has attracted a lot of attention. The news that it arrived at the asteroid "Ryugu", landed a small exploration robot, fired a bullet to create a crater, and collected the rock inside the surface, made us feel the high level of Japanese space technology.
On the other hand, the news that Voyager 2 has left the solar system after more than 40 years has become a hot topic. It is amazing that Voyager 1, which left the solar system earlier, is still sending signals to the Earth.
The news that Mt. Fuji and the monster Godzilla that was named after constellations also attracted attention. The two constellations named Fujisan and Godzilla are different from the constellations shining in the starry sky, and are constellations that connect celestial bodies that emit a type of electromagnetic wave called gamma rays. Japanese research institutes have been working to collect data by observing gamma rays from distant space with artificial satellites. His achievements were highly evaluated, and constellations named after Japan were adopted.
Parabolic antennas play an active role in capturing signals from such probes and observation satellites. In particular, many large parabolic antennas with diameters of dozens of meters are used to exchange data with probes flying in distant space and to observe electromagnetic waves emitted from distant stars. . You may have seen the sight of a large dish-like antenna rising up into the sky in TV programs and movies.
A heater is essential for catching weak signals from space
In fact, a heater is essential for capturing signals from space. The reason lies in the principle of parabolic antennas.
A parabolic antenna consists of a round dish-shaped reflector that reflects radio waves, and a receiver that is installed at a distance from the reflector. To capture radio waves coming from space, point the parabolic antenna in the direction of the observation satellite or probe, and receive and reflect the radio waves sent from the satellite on the concave surface of the reflector. There is a place where the reflected radio waves gather at a certain point. There is a receiver at that location, which collects the reflected radio waves and transmits them to the observation center. And by analyzing the signals delivered by radio waves, we can obtain various information from space.
Radio waves from distant space are extremely weak. Therefore, the parabolic antenna for observation is installed in a high-altitude place where there is no electrical noise generated in the city. It may snow in such places, and snow adheres to the reflective surface of the parabolic antenna. The snow then prevents the reflection of the incoming radio waves, making it impossible for the receiver to collect radio waves efficiently.
A heater comes into play here. As shown in the figure below, attach a heater to the back of the reflector (orange part). When it snows, a heater warms the reflective part to prevent snow from adhering.
Thanks to the usage of the heater, we can always catch radio waves from space regardless of the season.
Heaters are also useful when receiving satellite broadcasts in snow country
Parabolic antennas are used in everyday life. This is an antenna for satellite broadcasting reception for receiving BS digital broadcasting and paid CS broadcasting of TV. Satellite broadcasting is evolving more and more with the start of 4K and 8K broadcasts, which provide a clearer picture of programs.
If the antenna for satellite broadcasting is covered with snow, the image may be disturbed and the image may not be seen clearly. For this reason, some parabolic antennas for receiving satellite broadcasts in snowy areas have a heater built into the reflector.
Satellite parabolic antennas with heaters come in handy in public facilities in areas with heavy snowfall. For example, a community center that serves as an evacuation center in the event of a disaster. Residents huddle together at evacuation shelters when record heavy snowfall is expected. Broadcasts from televisions installed in shelters can be a reliable source of information. Most shelters will have terrestrial digital broadcasts turned on. However, in the unlikely event that the digital terrestrial antenna collapses under the weight of the snow and terrestrial digital broadcasting becomes unwatchable, satellite broadcasting would become reliable. Antennas for satellite broadcasting are small and strong against snowfall, but when snow piles up on the parabolic antenna, the reception capability declines. A parabolic antenna with a heater can melt accumulated snow, so weather information and local damage information can be reliably communicated to people in evacuation shelters.
From astrophysics to everyday life, parabolic antennas are now indispensable. Unbeknownst to us, heaters help parabolic antennas to catch signals from space.
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Patients feel uneasy when medical chairs and beds are cold
We believe that many of the owners and medical practitioners of community-based clinics and otolaryngology, dentistry, obstetrics and gynecology medical centers want to make their patients feel relaxed during treatment. There are many places that try to make people feel less anxious about their illness, such as brightening up the lighting and interior decorations in the waiting room and treatment room and playing background music. And these efforts are effective in putting the patient's mind at rest.
Now, there is one more thing to consider for the patient and they will really appreciate it. If the chair or bed they sit on during treatment is warm, they will feel even more relaxed.
The chairs and beds used for treatment are made of materials that are firm and cool to the touch. After a consultation with the doctor, the patient is often asked to sit in a special chair or lie on a bed while waiting for treatment. At that time, the coldness of the chair and bed is transmitted, which makes them feel uncomfortable. It doesn't bother much if they keep the clothes on, but if they are only wearing underwear, they are somewhat worried about getting sick.
Furthermore, when a diagnosis is made using medical equipment such as an ultrasound diagnostic device or a fiberscope, the patient must remain still for about 10 minutes. If you are undressed and undergoing a diagnosis on the bed, your body will gradually cool down and you may feel cold. Even if you are in an air-conditioned room, your body will feel cold during the treatment due to anxiety. Especially if you're undressed.
A slight warmth in the back can soothe the patient
Patients will feel more comfortable if the treatment chair or bed is warm enough to not get hot.
When a patient comes to the hospital with a sudden illness, they are worried about what kind of treatment they will receive. If you are visiting a hospital for the first time, you will have to undergo a medical examination without knowing the right or left.
Warmth is effective in alleviating the patient's anxiety. It's neither hot nor cold, and when the right amount of warmth is transmitted through your skin, you feel calm. In large-scale treatments such as surgery, BGM is played in the operating room and the operating table is heated by a heater to eliminate the patient's mental anxiety.
Touching the patient's body with warm heat during treatment can soothe the patient and make them feel at ease.
A thin, soft-feel heater reduces patient anxiety
How should I warm the chair and bed for treatment? There are chairs and beds with heaters, but they are quite expensive. It would be a second thought to buy a new one. If you can cover it with an affordable heater, it's better than that.
The first thing that comes to mind when it comes to cheap heating equipment is an electric foot warmer. However, commercially available electric foot warmers cannot fix the chair well even if you try to warm your back. Also, if you try to use it on the bed, there will be a step. Recently, there are flat mat-type products, but they are small and cannot heat the entire chair or bed.
As a solution, although it costs more than commercial products, there is a method to have a special heating appliance made using a silicone rubber heater. Silicone rubber heaters are thin and flat. It can be attached to the back of a chair, or it can be used to cover the entire bed. In addition, since it is made of soft material, it does not feel uncomfortable even if it touches the body. It can be used as a heater by combining with a controller that can adjust the temperature to an appropriate level.
Silicone rubber heaters Digital temperature controller
Warmth can also be an opportunity to build a relationship of trust with patients
Concern for treatment is very appreciated by patients, and it is also an opportunity to deepen trusting relationships with doctors and nurses. The warmth of the heater serves as an intermediary between the doctor and the patient.
In addition, it helps to improve the reputation of hospitals and clinics. Recently, word-of-mouth sites that allow you to post reviews of medical institutions are gaining popularity. And there is a strong tendency to select a hospital based on written reviews. The introduction of heaters as part of patient care may add to the positive publicity.
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ThreeHigh's digital temperature controller "monoone series" also has an instruction manual that explains in detail how to deal with errors. Even if a sudden error or abnormality occurs, it can be quickly resolved in most cases by referring to the instruction manual. I often receive inquiries over the phone because, just like setting problems with smartphones, it would be quicker to ask directly over the phone than to read the instruction manual.
Of course, such inquiries are always welcome, but in order to save you the trouble of calling, this time we will explain common problems with the monoone series.
Digital Temperature Controller monoOne-120 (monoOne-120)
Basic error code lists of monoOne-120
There are 7 types of monoOne-120 errors in total.
(*1) A priority is given to the conditions of "control output is off" or "alarm output is on" resulting from other errors.
There are so many errors that you may be confused, but there are very few cases where "Er 0", "Er 5", or "LoC" appears. Most of them are "Er 3" for heater failure, "Er 1" and "Er 4" for temperature sensor failure.
*The difference between "Er 1" and "Er 4" is the position (photo below) of the terminal block of the connected sensor. In this case, check if the heater or temperature sensor is disconnected, and if the cable is properly connected to the terminal block.
If you connect only the power supply and forget to connect the heater or sensor and turn on the monoOne-120, an error will appear.
In the photo below, electricity is flowing to monoOne-120. If you try to connect the heater in this way, it will short out. In the past, I have also set up and led to short-circuited and burned the terminal block. Moreover, not only the main unit but also the breaker in the room has fallen.
It is very dangerous and can even cause a fire, so please be sure to check that it is not connected to the power supply before starting the operation when you connect a heater or temperature sensor.
The displayed temperature does not rise even though the heater gets hotter and hotter!!
This case has happened in the past.
Originally, when the temperature detected by the sensor reaches the control temperature, monoone's normal operation is to stop powering the heater.
However, there were several cases where the temperature displayed by monoOne-120 showed 20°C or 30°C, which was close to normal temperature, even though the heater was too hot to touch. Since the control of the heater was not effective, there should be some kind of error. However, at this moment, the heater was as energized as it was, and the temperature was extremely high.
Why did this case happen?
The cause is a sensor malfunction! But no errors! ?
In order to control temperature, a temperature sensor senses the temperature and will transmit that temperature controller, monoOne-120. However, in the following two cases, it didn't sense the temperature very well.
Case 1: The temperature sensor is disconnected from the heater!
This is simple.
As shown in the photo below, the temperature sensor is not in contact with the heater.
The rod-shaped one is the temperature sensor (K-type thermocouple sheath type) and the orange (red) is our silicone rubber heater.
The temperature sensor cannot accurately measure the temperature unless it is in contact with the heater. The temperature decreases as heat move away from the heat source.
Especially in the case of silicone rubber heaters, they are designed to be brought into close contact with the object to be heated to conduct heat. Therefore, if you do not make proper contact, you will end up measuring the temperature at a position slightly above the heater instead of the heater temperature. As a result, the temperature is lower than the actual heater temperature.
In order to prevent such troubles, we have also produced a sensor pocket so that the temperature sensor does not come off.
The sensor pocket is a simple fixture that creates a tunnel above the heater and inserts the temperature sensor into it. By installing this sensor pocket, you can prevent the temperature sensor from falling out.
Case 2 : Temperature sensor is twisted!
In fact, if the temperature sensor is twisted, the measured temperature may not be displayed properly.
Normally, if the temperature sensor is disconnected, the electricity will not flow, and the error function will work and the electricity will stop. However, even if the temperature sensor is twisted, if the wires do not break and the metals come into contact with each other, a new circuit may be created and electricity may flow.
A thermocouple (temperature sensor) measures temperature at the junction of two metals.
The temperature sensor is an insulator to prevent metal-to-metal contact. However, if the metal is exposed when connecting to the connector as shown in the photo below, the twisted part of the connector may come into contact. At that time, if the contact part is close to monoone, the temperature will be measured.
When I realized the cause, I had no idea that the temperature of the connector was detected. Since the part that detects the temperature was not working properly, the heater was sending more and more electricity, and the heater continued to heat up to the limit of its capacity. This case is very dangerous for heaters.
Other cases of malfunction
There are also other patterns that sometimes cause problems.
●The control temperature cannot be set above 300°C.
---The initial setting of monoOne-120 prevents the temperature from rising.
●The display temperature of the heater is decreasing.
---You may have connected the positive and negative terminals of the sensor in reverse.
●The heater does not heat up.
---The monoOne-120 has been installed a 20A fuse. A fuse may have blown. In this case, electricity flows to the main body, but electricity does not flow to the heater.
Finally...
This blog will be able to prevent any unforeseen accidents by presenting examples that happened before.
Please take a look at this promotional video for monoOne-120.
ThreeHigh has various know-how. If you have any questions about heaters, temperature control, etc., feel free to contact us anytime!
You can easily contact us at any time from the URL below.
https://www.threehigh.com/contact/
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Reference: First overseas exhibition at PROPAK ASIA 2022, aiming to create a new base in Thailand
After returning to Japan, I sent a message to the person in charge of the company I met at the exhibition, showing appreciation for their visit. Then, we received the following request from two factories in Thailand.
"I am interested in your heater. Would you like to come to our factory?"
With an unexpected business opportunity from overseas, I went to Thailand again in early August.
A snack factory requested a new heater to prevent chocolate from solidifying.
The first place I visited was the confectionery factory. Here, they make biscuits from flour and produce snacks that combine cream and chocolate.
At the front gate of the candy factory.
Mrs. Bee, who helped us as an interpreter at PROPAK ASIA 2022, also accompanied us this time (right of the photo).
According to employees, preventing the chocolate from solidifying is essential for the snack production line. The chocolate is liquefied and piped to be placed on or dipped into the biscuit. At that time, it is necessary to warm the pipes in order to prevent the chocolate from solidifying and clogging the pipes.
This factory introduced a system to heat the pipes with hot water to prevent chocolate from solidifying. Using a double pipe made of metal, liquid chocolate is poured into the central cavity, and warm water is poured into the cavity surrounding it to heat it. However, when hot water flows through a double pipe, the metal where the hot water flows corrode over time, and when it reaches the central cavity, there is a risk that the hot water will mix into the chocolate. Because of this concern, they decided to replace the hot water system with an electric heater.
To meet this demand, we proposed a cable-type electric heater. This is a special product that can self-regulate the amount of heat generated according to the ambient temperature without using a temperature controller or temperature sensor. Since it can be wrapped around, it is ideal for heaters for warming pipes.
An example of winding a cable heater (orange) on a pipe.
The piping system is different from the one in the factory this time.
By introducing this heater, it seems that we can play an essential role in rebuilding the chocolate solidification prevention system used in the factory.
Requested replacement of heaters to prevent solidification of salad oil and sauces at a tuna can factory
Next, we visited a factory that manufactures canned tuna.
On the way to the tuna can factory. Unfortunately, the weather was rainy.
This cannery uses tuna and edible oil (salad oil) as well as a sauce for seasoning. Salad oil and sauce are in individual containers and are injected into the can through a pipe. Since both salad oil and sauce are oils and fats, it is necessary to warm them with heaters so that they do not solidify inside the piping while the production line is in operation.
Electric heaters were used in this factory to prevent solidification. However, they have a problem with the electric heater they are using. The heater they are currently using is a cheap product made in China, and although it is wrapped around the outside of the pipe, it is said that the heating was uneven. As a result, solidified oil accumulated in unheated spots in the pipework, requiring periodic dismantling and cleaning of the pipework. To solve this problem, they learned about our heaters at PROPAK ASIA 2022 and became very interested in them.
Therefore, we proposed the same cable-shaped heater as the confectionery factory mentioned above. Since the purpose is to warm the pipes, a cable heater is best.
At PROPAK ASIA 2022, we vigorously appealed the quality of Japanese products. The results are already bearing fruit.
I want to sell more heaters by setting up an office and representatives in Thailand.
Thailand is a country with high temperatures throughout the year. At the factory I visited, the temperature was 40 degrees indoors and nearly 70 degrees inside the pipes. At first, I thought that in such a hot environment, the production line would not be affected even without a heater. However, in reality, I felt that heating and keeping warm with a heater were indispensable.
In addition, the market for electric heaters is still underdeveloped in Thailand. Since the places we visited this time have adopted hot water circulation heating and heat retention systems, it seems that there are many factories that have introduced similar systems. I also learned that even in places where electric heaters have already been introduced, frequent maintenance is required due to the introduction of inexpensive products. In either case, we are confident that our heater products will meet your needs. For this reason, we would like to focus on selling heaters in Thailand.
We also visited a company that maintains food machinery and explained our heaters.
During my revisit to Thailand this time, I got a big response to the local business development. We have set up an office in Thailand, stationed representatives there, and have the ambition to sell more products.
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Vacuum is indispensable for advanced technology research
In addition to information devices such as personal computers and smartphones that we use every day, the latest electronic products such as televisions and washing machines use many electronic components that use semiconductors such as memories, image sensors, and solar cells. . When researching these electronic components or producing them in a factory, it is necessary to create a vacuum environment using special machines. Why should it be a vacuum?
In order to create high-performance electronic parts by combining electronic materials such as semiconductors and rare metals, it is necessary to maximize the properties of the constituent atoms and molecules. For that reason, if other substances are mixed in during the manufacturing or synthesis process, the expected performance cannot be obtained and good parts cannot be produced. Therefore, it is necessary to create a vacuum space that is free of unnecessary molecules in the air such as oxygen and nitrogen, as well as impurities floating in the gaseous state, and we need to conduct experiments and manufacturing within that space. It also requires a much higher degree of vacuum than vacuum packs used for long-term food storage.
It takes time to create a high vacuum
The method used to create a vacuum in as short a time as possible is to hit a metal vacuum container (called a chamber).
A high vacuum for testing electronic components is created step by step. First, a low-vacuum pump, which is a machine that is similar to a vacuum cleaner, is used to create a vacuum that is about 1/1000th of the atmosphere, which is said to be about the same level as in outer space, slightly farther than the Earth's atmosphere.
A low-vacuum pump cannot create a higher vacuum. Next, a special vacuum pump is operated to create a high vacuum of 1/1,000,000 or less. By the way, even with such an extreme vacuum, there are still countless gas molecules remaining.
It takes a long time to create a high vacuum. If you start exhausted from the atmosphere, it can take from one day to several days. Therefore, it is necessary to devise ways to shorten the time and reach the target degree of vacuum.
High vacuum in a short time by heating with a heater
This is the method that heats a metal vacuum vessel (called a chamber).
The inner surface of the vacuum vessel is covered with gas molecules and oils and fats that stick to your hands during maintenance. These particles do not easily leave the surface and continue to be released gradually, which hinders the creation of a high vacuum in a short period of time. Therefore, a heater is wrapped around the outside of the vacuum vessel to warm the entire vacuum vessel. Then, the inside of the vacuum vessel is also warmed up, and the gas molecules and oils adhering to the inner surface are activated by the heat of the heater and released in large quantities, making it possible to efficiently ventilate them with a high vacuum pump. If the heating of the heater is stopped and the vacuum vessel is allowed to cool before the start of the experiment, the activation due to the heat will subside, which also reduces the amount of gas molecules, oils and fats that have adhered to the internal surfaces, allowing the vessel to be placed in a high vacuum.
A belt-shaped heater that can be easily wrapped around is used to heat the vacuum vessel. Examples include silicone belt heaters and glass cloth ribbon heaters (tape heaters). For use in cleanrooms, ribbon heaters are also available made from polytetrafluoroethylenePTFE).
Silicone Belt Heater
Ribbon heater (tape heater)
When installing, cover the vacuum vessel with aluminum foil after winding the heater so that the heat can be easily transferred throughout the container.
Please leave heater for the vacuum equipment that is difficult to wind to us
In the case of experimental high-vacuum equipment, various additional devices may be attached to the side of the vacuum vessel. Then, it is difficult to wind a standard heater because the width does not match, and there is no choice but to create a high vacuum without a heater. In such cases, please contact us.
Our heaters are handmade. Therefore, heaters of any length and width can be adapted to your needs. We accept orders from 1 piece. Our strength is that we can make custom-made heaters.
Vacuums and heaters, which are indispensable for the research and development of advanced technology, play a modest but significant role in creating a vacuum. Heaters are still used today to heat vacuum equipment in laboratories and factories, in an effort to bring future information equipment and new products to the world.
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What is a silicone sponge?
What exactly is a silicone sponge?
As the name suggests, the material is silicone.
Characteristics of silicone
-Resistant to both high heat and low temperature
-Excellent water repellency
-Strong electrical insulation
These characteristics make it one of the essential materials for industrial products.
A silicone sponge is made by adding a foaming agent to this silicone material.
Since foaming agents are added, there will be some air bubbles inside. However, the silicone sponges have a structure in which each air bubble is independent called closed cells.
By the way, the structure in which the cells are connected without being independent is called "continuous cells".
Three characteristics of silicone sponge. The great attention is its excellent heat insulation!
Silicone sponge has the following three characteristics.
1. Light and easy to process!
Silicone sponges are attractive because they are light weight. (depending on length...)
And it can be cut freely, so it can be easily arranged.
Because it is easy to process, it can be used for various purposes such as cushioning and packing.
2. Almost impervious to gases and liquids!
The silicone sponge has a structure called "closed cell" that we mentioned earlier.
The properties of closed cells are
-Impermeable to gases and liquids
-Float on water
-It has a heat insulating and heat retaining effect
For this reason, this characteristic is also utilized in silicone sponges.
In particular, the characteristic of "difficult to pass gases and liquids" is perfect for industrial products, so it is used for various products such as packing and sealing materials.
3. Excellent heat insulation!
As heater manufacturer, we should pay attention to silicone rubber, which has excellent heat resistance compared to general organic rubber.
If the temperature exceeds 100°C for natural rubber and 150°C for general synthetic rubber, it will deteriorate in a short time and become unusable, but silicone rubber can be used continuously even at temperatures exceeding 180°C.
Depending on the degree of compression, it can generally be used from -60°C to 200°C.
So, what is the reason behind this excellent thermal insulation effect?
The reason why it has excellent heat insulation is in the air bubbles!
The reason why it has excellent heat insulation is because there are air bubbles inside.
In fact, air bubbles have the greatest insulating effect.
Whether a duvet is warm or not depends on how much air is trapped between the feathers.
In addition to the air bubbles in the silicone sponge blocking the passage of heat, the highly insulating "closed-cell" structure of the sponge also provides outstanding heat insulation.
Strong against freezing! Recommended usage environment
Despite the fact that there is a great heat insulation effect , it also has an opposite high anti-freezing effect as well
In cold regions and northern countries, depending on the weather, the temperature may drop below freezing, and pipes and tubes may freeze.
Silicone sponges can be used up to -60°C, so they are highly recommended for freezing pipes and tubes in cold regions and northern countries.
I just talked about the merits of silicone sponges and the secret of excellent heat insulation. I believe it is really convenient to have a "silicone sponge" that is excellent in heat insulation and heat retention.
Because it is excellent in heat insulation, it prevents heat dissipation and helps the heating effect, so it is an excellent helper that supports the power of the heater to the maximum.
Three High offers a wide range of silicone sponges.
We can also change the size according to your request, such as silicone sponge sheets, silicone sponge tubes, and silicone sponge square cords.
If you want to keep the temperature, prevent the heater temperature from dropping, prevent burns, or use it as a cushion material, please feel free to contact us!
Click here for the lineup of silicone sponges
(If you have a chance, please take a close look at the air bubbles inside the silicone sponge. There are a lot of air bubbles (lol).
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* The above photo is a display in Bangkok International Airport.
Booth at PROPAK ASIA 2022 held in Thailand
This time, we exhibited at an exhibition called PROPAK ASIA 2022. This is an international business event where Asian companies involved in the packaging of food and sanitary goods gather to introduce their own products. It was held for four days from June 15th to 18th, 2022 at the "Bangkok International Trade and Exhibition Center (BITEC)" in the eastern part of Bangkok.
PROPAK ASIA official website (English)
Venue Bangkok International Trade & Exhibition Center (BITEC)
Most of the exhibitors are Asian companies. If we take a look by country, there are many local Thais, and in addition to Thailand's neighboring countries such as Singapore and Indonesia, we also saw participants from India and Taiwan. Chinese companies had a small number of exhibitors, partly due to the lockdown measures taken in Shanghai to prevent the spread of the new coronavirus infection. Japanese companies exhibited independently, but the Japan Food Machinery Manufacturers Association (FOOMA) also participated and provided booth space for Japanese companies that wanted to exhibit. Our company rented the booth prepared by FOOMA and was able to exhibit for the first time overseas.
Desperately appealing in English while interweaving gestures
At exhibitions in Japan, opening ceremonies such as ribbon cutting are held at the entrance of the venue on the first day of the exhibition, but here the exhibition started quietly without any events. After the start time, visitors began to visit the booths of each company little by little. Many of them are in their 30s and 40s, and the relatively young lineup stands out.
PROPAK ASIA 2022 venue entrance
We also arranged our own products in a designated booth and made preparations to welcome visitors. Since it was a food-related exhibition, we exhibited mainly silicone rubber heaters that are excellent in terms of hygiene.
Our booth in corner of FOOMA
For the booth exhibition, we hired two local business interpreters. They are excellent people who can speak three languages, Japanese, English and Thai. However, we could not just leave it all to them. We actively tried to sell our products to visitors, making full use of the English conversation skills we had practiced.
Appeal actively despite being nervous
Many of the visitors are local Thais, and most of the other Asians do not speak English as their native language. Therefore, I was able to communicate quite well even in English while mixing gestures. I was happy that they understood what I was talking about even when I just said "We make heaters!". After that, with the help of interpreter, I focused on promoting our company's products while showing them the actual products. When Thai people came to visit, I called out to them by calling out “สวัสดีครับ (Sawasdee Klap),” which I learned for this occasion.
The senior staff explains products to visitors without being scared.
In addition, the five companies exhibiting at the FOOMA booth took turns introducing themselves and the products they were developing for 15 minutes. At our company, Matsumoto and I introduced our company and various usage examples using heaters, and gave a presentation showing the actual product.
Presentation while actually showing the heater
The presentation in English was hard. Still, I was able to complete it successfully, and I played an important role!
Introducing business activities in English
Business opportunities in the current situation where electric heaters are NOT well known
The number of visitors to the exhibition increased with each passing day. Before we knew it, we had become accustomed to communicating in English, and were able to quickly answer questions from visitors. Then I realized that there was a difference in the recognition of heaters in Japan.
In Thailand, steam heaters are the mainstream when it comes to heaters, and electric heaters are not well known.
Even in Thailand, where the climate is warm, heaters are used for industrial purposes. However, it is said that only steam heaters are used. Perhaps because of that, some people said it was the first time they had seen an electric heater. When I explained the benefits of electric heaters, such as safe heating and accurate temperature control, they seems to be interested.
Example of our electric heaters
When we asked about the types of industries of the visitors, we found that they ranged from food manufacturers and food equipment manufacturers to restaurant managers, trading company agents, and sushi restaurants. People from all industries showed a strong interest in our heaters. I realized that there is a business opportunity in developing in Asia, given the high level of interest in electric heaters.
I want to build a foothold for overseas expansion in Thailand
On the last day of the event, the number of business discussions increased. Something big happened here too. that is,
"Where do you sell your company's electric heaters?"
"Is it possible to buy it at a store in Thailand?"
It is a purchase consultation.
Sometimes intrusive exchanges
Our products can be ordered and purchased online for domestic use. In addition, we have opened an English online shop for overseas customers. In addition to getting people to use it, if we can sell our products locally, we will be able to expand overseas business in earnest.
By participating in PROPAK ASIA 2022 this time, in addition to our first overseas exhibition, we want to build a foothold for our overseas expansion. It is a great achievement to get a definite response to fulfilling that desire.
After returning to Japan, we sent a message from our company to the person with whom we had a business meeting. We have received many replies stating that their interest in our heaters has not changed and that they would like to maintain the relationship in the future.
Everything from harvest to reflection is a first-time experience
During the four days of the event, I met a lot of people during the exhibition. In particular, I am happy to have made many acquaintances from Thailand. The two interpreters worked very hard every day. I would like to say thank you in Thai, ``koob kun''.
Commemorative photo after finishing the booth exhibition.
Interpreters Bee (front left) and Tip (back center), Threehigh Matsumoto (back left) and Nakayama (back right)
For me, this trip to Thailand was a first-time experience for me. In addition to overseas business trips, product explanations and presentations in English were a great experience. And I am keenly aware that I must study English more.
There is also a reflection point. It took me a while to go through the procedure when bringing in exhibits such as heaters at the airport when I entered Thailand. It took me two hours to complete the procedure because I was unfamiliar with the procedures for industrial products. I was able to learn the difference between overseas travel and business trips, and I would like to take this as a lesson for next time.
By the way, I was bad at eating spicy food. But it became possible for me to eat it on this business trip to Thailand. I got used Pak Chi (Cilantro) as well.
Stir-fried crab curry (left) and green curry (right) at a local restaurant
It would be an exaggeration to say that my participation in PROPAK ASIA 2022 was my first step towards becoming a global businessman, but that thought grew in my heart. I would like to make use of this experience to achieve better results.
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In the previous article, we introduced contact heating, in which silicone rubber heaters and mantle heaters are brought into close contact with the container. This time, we will take up bottom heating, which is heating from the bottom of the container with a bottom heater.
Bottom heating and bottom heater
Bottom heating is a heating method in which the container is placed on a heater stand and the contents are heated from the bottom. The advantage is that there is no need to attach the heater to the container, unlike contact heating. In addition, there is no need to custom order a dedicated heater that matches the shape of the container. You can easily heat it by simply placing the container containing the food you want to warm on the stand.
A bottom heater (Hot plate) is representative equipment for heating the bottom surface. Industrial bottom heaters are designed to be easy to use for commercial purposes, such as being able to heat many containers at once.
Bottom heater is one of our main products
Bottom heaters are in demand in many areas of business. We are also focusing on bottom heaters, and we sell a product called "GOEMON-150". GOEMON-150 is available in two types: a normal type with a raised projection on the base on which the container is placed, and a flat type with a flat base as a made-to-order product.
The features of GOEMON-150 are as follows.
●It is possible to heat 4 cans of 18 L cans and pail cans at once.
●It can be easily heated just by placing it.
●Consumes less power than large electric furnaces.
The structure is the same as cooking heaters and electric stoves. Heaters are placed around the back of the table so that it can be heated evenly. The photo below is the back side of the flat type.
For more information about GOEMON-150, please visit the product introduction page.
The bottom heater plays an active part in these sites
What kind of sites are bottom heaters used for? Let us introduce you some examples based on our GOEMON implementation results.
Heating of rust preventives used for surface treatment of metal parts
At the site where metal parts are processed, there is a task of applying antirust coating to the surface of the parts. However, there are the following problems when dealing with rust inhibitors.
●At room temperature, the rust inhibitor is uneven, and the quality cannot be maintained evenly without stirring.
●Rust inhibitors are highly viscous and difficult to handle at room temperature. Stirring at room temperature imposes a heavy labor burden on the operator.
●Therefore, it is necessary to heat to soften the viscosity.
●Since a large amount of rust inhibitors are used, it is inefficient unless many cans are heated at once.
To solve these problems, we introduced the normal type GOEMON-150.
The normal type GOEMON-150 has a raised base for placing the container. The size of this raised bottom is designed to match the size of 18-liter cans and pail cans.
If the bottom is raised, the bottom of the can and the heating surface will touch without any gap. As a result, heat is easily transferred to the liquid in the container, and it can be heated efficiently. Moreover, there is no uneven heating. Therefore, the viscosity and quality of the rust inhibitor can be kept uniform.
After actually using the GOEMON-150, it was well received that it solved the problem they were having. Currently, they have introduced several GOEMON-150 units to warm up a large amount of containers containing rust inhibitors, and are working to improve work efficiency.
Viscosity reduction of edible fats and oils in food processing
Edible oils and fats such as lard and sesame oil are sometimes used at food processing sites such as food factories. When handling edible oils and fats, there are the following issues.
●Edible fats and oils are highly viscous and must be heated to reduce their viscosity before starting operation.
●If the viscosity remains high, the oil will become uneven and affect the taste of the food.
●There is also a method of warming a can containing edible oil in boiling water, but this is not preferable from the standpoint of food hygiene because the can rusts.
●Since a large amount of edible oil is used, work efficiency is poor unless the cans are heated together.
Therefore, I decided to introduce GOEMON-150 to heat cans containing edible oil. GOEMON uses flat type. The flat type is used because cans containing edible oils come in various shapes, so it is convenient to put them together on the table. From a hygienic point of view, stainless steel is used because it is desirable to use a material that does not rust on the stand where the cans are placed.
By using a flat-type bottom heater, it is possible to heat multiple cans with different shapes at once, making it possible to reduce the viscosity of edible oils and fats evenly. Since we use a large amount of various edible oils and fats on site, we have introduced several flat bottom heaters to help with food processing.
Not only can multiple containers be heated at the same time, but it is also effective in reducing the viscosity of liquids.
Industrial bottom heaters with bottom heating are useful for heating many large containers at once. In addition to that, from the results of introduction so far, we found that it is often used for the purpose of lowering the viscosity of liquids. Therefore, it can be said that it is also useful for warming liquids containing fats and oils. In addition to the industrial fields covered in this article, bottom heaters can be used to great effect in fields related to chemicals, cosmetics, and coatings.
When choosing a bottom heater, it is best to use the bottom-up type if you are heating containers of the same size, and the flat type if you are considering containers of different sizes and versatility.
In two installments, we have discussed how to heat industrial vessels and which heaters are suitable for each. When you want to use a heater for your business, but you can't figure out which one to choose even if I look at the website or catalog. In the end, I think that there may be times when you get stuck without coming to a conclusion. In such cases, please contact us. Based on the experience we have gained so far, we will propose products that meet your needs.
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Well, people involved in the rice milling industry have a certain difficult problem in their daily work. This is a rice bran remover that adheres to the inside of the rice mill. Adhered rice bran must be cleaned manually on a regular basis, which is time-consuming and labor-intensive. Although they want to change this cleaning works, but they cannot find a good method. Eventually, they end up doing manual works as usual.
Heating with a heater is effective in removing adhering rice bran. Therefore, we will introduce the removal of rice bran in the rice mill using a heater, which can be said to be good news for rice millers.
Adhesion of rice bran inside the rice mill is a cause of concern
The white rice we eat on a daily basis is made by removing the bran (rice bran) and the germ from the raw material, brown rice. The process of turning brown rice into white rice is called rice polishing. To polish the rice, a special machine called a rice polishing machine is used.
↑commercial rice milling machine
When you put brown rice into the rice milling machine and operate it, the machine takes in air and creates a strong air current inside. When the brown rice collides with each other due to the air current, the rice bran and germ on the surface of the brown rice are peeled off. The grains that are left after these are peeled off are white rice. The white rice is collected in the built-in rice polishing tank.
On the other hand, the rice bran is separated from the brown rice in the rice milling machine, turned into powder, and sent to the tank where the rice bran is collected. Some of the powdered rice bran adheres to the piping in the middle of this process. Approximately 20% of rice bran is oil and fat, and it is sticky rather than smooth. Therefore, the rice bran sticks to the inside of the piping due to the stickiness of the oil.
↑Inside of piping
If the rice bran that has accumulated in the piping is left as it is, the rice bran will be exposed to air and oxidized, resulting in a darkening of the color. This is unhygienic. This is because part of the blackened rice bran may fall off during the rice polishing process and mix into the rice container. If products are shipped without noticing contamination, consumers and business partners will question hygiene management. For rice millers, it can be a credibility problem, so they are very concerned about the adhesion of rice bran.
The cleaning work of adhering rice bran is a large task
In order not to mix the blackened rice bran with the white rice, the rice mill must be cleaned regularly to remove the attached rice bran.
Rice bran mainly adheres to the piping of the rice mill. Stop rice milling machine for cleaning. After that, the cleaning door inside the pipe is opened and the rice bran is removed by air pressure washing.
When it comes to cleaning a large commercial rice milling machine, is a large-scale job that consumes time and manpower. Depending on the season, it is said that cleaning must be done twice a month. For rice millers, they want the cleaning work of the rice bran that has accumulated in the rice milling machine becomes more efficient.
Rice bran can be efficiently removed by heating with a heater
Adhesion of rice bran to pipes is more likely to occur in winter than in summer. Humidity is the main factor. In many cases, the heater is not turned on in the building where the rice milling machine is installed during winter, and when the temperature is low, moisture adheres inside of the piping due to condensation. This moisture makes it easier for rice bran to stick to the rice during polishing.
To prevent rice bran adhesion, it is effective to reduce the humidity inside the piping. As a method, the piping is warmed from the outside to prevent moisture from getting inside. Some rice millers place an incandescent bulb near the pipes and heat the pipes with the heat (radiant heat) emitted from the incandescent bulbs. However, this method has the disadvantage of uneven heating. In addition, LED light bulbs, which emit almost no radiant heat, are used for floodlights, and there is no prospect of long-term use.
We would like to propose solution for rice bran adhesion for rice millers by heating the piping with a heater. By attaching a silicone rubber heater to the pipe and heating it, you can remove the moisture condensed inside the pipe. Since silicone rubber is flexible, it can adhere to the piping, enabling even heating. Therefore, the moisture inside the pipe can be uniformly removed.
↑Example of attaching a heater to the piping of a large rice milling machine
Our silicone spiral heater is one of our products suitable for heating pipes. A silicone spiral heater is a spiral heater that looks like a curled cord that you see on telephones. The feature is that it is easy to wrap around the pipe, and it is fixed with heat-resistant tape when wrapping. The maximum temperature that can be heated is 80 degrees.
↑Silicone Spiral Heater
To use a pipe heater, you also need a controller to control the temperature and a sensor to measure it.
At our company, we have prepared a product "Pipes Heater" which is a set of these.
In order to suppress the adhesion of rice bran like this time, the desired effect cannot be obtained unless the size of the heater is matched to the thickness and shape of the pipe. In other words, it is best made as a special-order item. Our company also sells the "Nukadama Buster" as a made-to-order heater for rice millers to prevent rice bran adhesion. We will make a dedicated heater that is perfect for your own rice milling machine. Please consider it.
We want to contribute to Japanese food culture through heaters.
Rice is an essential ingredient in our diet. Dishes using rice can be said to be a symbol of Japanese food culture. The menu, which combines rice, miso soup, and fish and meat dishes, makes you feel the Japanese food culture itself.
Providing consumers with safe and secure rice that is free from contamination is an important social contribution that will lead to the development of Japanese food culture. We believe that it is meaningful for our company to work on this social contribution. The heater plays an important role in cooking delicious rice with a rice cooker. In addition, it is a great honor to be able to contribute to Japanese food culture by contributing to rice polishing. We put our hearts into Japanese food culture, and are dedicating ourselves to making heaters.
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There are three methods of heating and keeping warm inside the container.
There are three general ways to heat the contents of a container.
1. Wrap the heater around the body of the container (heating with close contact)
2.Place the container on the hot plate (heat from the bottom)
3.Place the heater in the liquid (direct heating)
Of these, we handle heaters using methods 1 and 2.
This time, we will explain method 1 while introducing our products.
What kind of heater should I choose to heat from the body of the container?
If you want to heat from the outside of the container, use a silicone rubber heater or mantle heater. Let's explain each of them.
Silicone rubber heaterThe most representative type of electric heater is the sheet silicone rubber heater. It is made of silicone, a synthetic chemical material, so it is flexible and can be tightly attached to the container. The degree of adhesion is very important in order to transfer the heat of the heater firmly. Looking at the thermography image when heating with the silicone rubber heater wrapped around it, the parts that are in close contact are uniformly colored orange, and you can see the good heating efficiency.
In order to heat safely, in addition to the silicone rubber heater, a temperature sensor and a temperature controller are used in combination. Specifically, a temperature sensor is attached to the surface of the heater, and the temperature of the heater is controlled by a temperature controller.
The silicone rubber heater tailored for the hopper tank maximizes the degree of adhesion. The photo below shows a hopper tank with an orange silicone rubber heater installed over its entire surface. Taking advantage of the unique flexibility of silicone rubber heaters, it fits perfectly in a conical shape like this. If necessary, we can also perform irregular shapes, notches, and drilling.
There is also a silicone rubber heater wrapped with silicone sponge as a heat insulator. Silicone rubber heaters generate heat from both sides. In addition to this, the heat insulation effect is added, and the heat of the heater can be effectively heated without escaping. Insulation also plays a role in preventing burns if accidentally touched.
Mantle heater (jacket heater)The mantle heater is a heater that can heat and keep warm up to 700°C. Suitable for tanks, tubes, pipes, pumps, etc.
Mantle heaters are suitable for:
• For complex shapes
• When you want to use it at a high temperature
• When you want to use it in a clean room
We have a factory that designs and manufactures mantle heaters according to the usages, and we can manufacture even one product that meets the customer's request.
We hope we can be of some help to you in your heater selection process.
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The guitar must be maintained on a regular basis. According to a professional craftsman who handles repairs, disassembly work may be necessary depending on the condition, and in that case, it will be a great help if there is equipment that can work efficiently. A heating device called a neck iron helps to do this.
We also often receive inquiries and orders for heaters that can be used to repair acoustic guitars. Therefore, I would like to introduce a neck iron (neck heater) that is useful for repairing and maintaining guitars.
Guitars need to be repaired for warpage caused by aging
There might be people who are not familiar with guitar reading this blog as well. First, I will briefly explain the names of each part of the guitar and the need for its maintenance.
A guitar is a stringed instrument that plays sound by plucking (pinch) the strings with your fingertips. A typical one is an acoustic guitar. It might be hard to imagine an acoustic guitar, but it's a typical guitar that everyone has seen.
From now on, the acoustic guitar will be referred simply as a guitar.
The guitar consists of three parts: the body, the neck, and the head (the head may also be referred as a part of the neck in some cases).
"Reference": Names of each part of the guitar (Guitar introductory course for super beginners)
Most of the guitar is made of wood. Over the years, wood becomes moist due to humidity. This will cause the guitar body to become deformed or distorted.
These distortions occur at the neck of the guitar. When the distortion becomes noticeable, it warps in an upper or lower arc perpendicular to the stringed surface. This warp is called "neck warp". Neck warpage can also occur depending on how you store it and how you handle your guitar.
Reference: Understand by using illustration! ~ Neck warp ~ (Repair of Shimamura Music)
The neck is an essential part of keeping the strings constant. If the neck warps, the tension of the strings will change and the correct temperament will not be produced, or the tone unique to the guitar will not be produced. In addition, the neck also acts as a handle, which can make it difficult for the guitar to play and can cause bad playing habits.
Regular maintenance is essential to make the guitar last longer and maintain good sound. Especially for vintage items that have just been obtained through online auctions.
Neck iron used to repair warpage of the neck
Guitar maintenance can be a difficult task for an amateur, so it's best to ask a professional contractor or a professional craftsman who runs a workshop. Maintenance can be time-consuming even for professional craftsmen. In particular, it takes time and effort to repair the neck warp.
To fix the neck warp, we need to adjust the string tension or move a rod called a truss rod built in the neck body. In some cases, the distorted area may be scraped off to make it flat.
Reference: Check the warp of the neck, Let's adjust it: YG TUNE-UP FACTORY 4th Maintenance (YOUNG GUITAR)
However, depending on the condition of the guitar, it is often the case that the warp cannot be fixed as expected. In that case, the neck must be disassembled before repair. A device with a built-in heater is used to disassemble and repair the warp of this neck. A heating device called a neck iron or neck heater.
The neck iron plays two roles in repairing the guitar. The first is heating to remove the wood that makes up the neck. On the surface of the neck, a part called a fingerboard is attached with an adhesive such as glue. The fingerboard must be carefully peeled off to repair warped parts. For that purpose, it is easier to peel off by heating the neck and warming the part with the adhesive.
The second is to heat and evaporate the water contained in the wood to flatten it. Moisture is removed by drying with a heater, to straighten and to eliminate warpage.
The mechanics of the neck iron are not complicated. We prepared an aluminum square lumber with the same length and width as the neck, and put a silicone rubber heater inside.
To fix the warp, place a neck iron on the neck, clamp it and apply a straightening force to flatten the warp. After that, water will be removed while slowly drying over time.
According to a craftsman who repairs neck warpage with a neck iron using our silicone rubber, he used to work with a household electric iron to remove wrinkles from clothing. The electric iron had a small heating area and could not be heated uniformly. After starting to use a neck iron, he said that he would be able to apply heat evenly by attaching it directly to the entire neck. Thanks to this, not only was it easier to remove the adhesive, but it was also easier to fix the warp, and the work time was shortened.
To use a neck iron that utilizes a silicone rubber heater, you need a temperature controller that can control the temperature. Failure to control the heating temperature can burn the lacquer on the guitar and, above all, damage the wood. When using a neck iron to repair a guitar entrusted to you by a customer, we strongly recommend that you always use it as a set with a temperature controller.
I want to contribute to work that can play good sounds for a long time based on past achievements
Neck warpage also occurs on various guitars such as electric guitars and bass guitars. And the same for other stringed instruments such as violins and cellos.
The neck iron using our silicone rubber heater introduced this time has been ordered for many years and is featured in the blog.
Reference: About self-made neck heater (neck iron) (neck origin, warp correction device)
Thankfully, we are still receiving new orders.
We pride ourselves on being able to contribute to the maintenance of instruments that produce good sounds, which is a very significant task for us. Based on the order record so far, we would like to manufacture silicone rubber heaters for neck irons suitable for various stringed instruments, and propose and sell products that include related equipment such as temperature controllers. If you are involved in the repair of various stringed instruments such as guitars and are interested in neck irons that use silicone rubber heaters, please feel free to contact us.
* Please note that our company only manufactures and sells heaters. We do not accept repairs for musical instruments.
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Silicon sponge, a new material that can be detected by a metal detector
A new silicone sponge called MDSR (Metal Detecting Silicone Rubber) has been launched. Metal is contained in the silicon sponge, and it has the property of detecting a metal reaction when a metal detector is brought close to it. We sell under the brand name "KINZO".
Please see the next page for product description and technical specifications.
KIN in KINZO is from the word ‘metal (Kinzoku)’, and we named it KINZO with a sense of humanity. You might imagine the talent of Kinzo Sakura, but it has nothing to do with it. Below, we will proceed with the introduction by calling the new material silicon sponge KINZO.
Applicable to packing used in food production lines
KINZO can be used as a packing to connect processed foods to a valve that flows into a container on a production line in a food factory. The material complies with the Food Sanitation Law (Ministry of Health and Welfare Notification No. 370).
The packing is a consumable item, and the material deteriorates over the years. Therefore, it must be replaced with a new one regularly. If you neglect to replace the packing due to improper maintenance, the silicone sponge may become debris and chip off from the attached valve. Since the debris is small, it cannot be visually confirmed if it enters the container together with the ingredients. As a result, foods containing contamination are shipped without knowing.
Therefore, if you make the packing with KINZO, you will be able to prevent contamination from entering. Suppose the packing made with KINZO is chipped off and the debris enters the food container. At this time, if a metal detector is installed and operated in the middle of the production line, it will react and sound an alarm when a container containing KINZO debris passes through. After that, if you find the corresponding container, you can eliminatet.
When using KINZO to prevent contamination from entering, metal food containers such as canned foods cannot be used. This is because the metal detector installed on the line will always react. Please keep in mind that it can be used only for containers such as plastic and Styrofoam.
We often see news that more than 10,000 shipped foods have been voluntarily collected due to contamination. When such a situation occurs for the food company of the manufacturer, not only the manufacturing cost and the financial burden of the collection work, but also the credit loss due to food loss and inadequate manufacturing process is immeasurable. KINZO can play a useful role in preventing foreign substances from entering the food manufacturing process.
Sold as a set with a heater processed into the desired shape
So far, we have talked about the use of KINZO alone. Our main product is heaters. Therefore, we are considering product development that combines a heater and KINZO.
For example, KINZO has the same flexibility and heat insulation as a conventional silicone sponge. Flexible materials allow you to process into complex shapes according to your desire. Therefore, taking advantage of heat resistance, we can manufacture an original heat-insulating jacket-integrated heater made by processing our silicone rubber heater and KINZO into the desired shape.
When heating from the side using a large heat-resistant plastic container on a production line that requires strict hygiene control such as food, an insulating jacket is used to prevent burns during transport and transfer. At this time, if the insulation jacket is damaged, the small pieces may get mixed in other containers. We believe that a heater with an integrated heat insulating jacket that can solve these problems is significant in development and manufacturing.
This time, I have described the possibilities of KINZO, focusing on its utilization in the food field. For hygiene-oriented utilization, it can be applied not only to food products but also to products used for skin care such as cosmetics. We will continue to explore the possibilities of KINZO, which we have newly started handling.
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