EMANAK Group's EMANAK East Japan Yashio Plant, the core of Emanac, a heat treatment manufacturer based in Moriguchi City, Osaka, commenced operations of its new No. 2 furnace in October of this year. The implementation of a high-performance continuous furnace system, enhanced for environmental performance, aims to reduce energy consumption by 30%. The furnace's ignition ceremony took place on September 1.
The newly introduced mesh belt-type next-generation high-performance continuous furnace, manufactured by Toyo Ro Kogyo, incorporates proprietary ceramic tubes and a new burner system, achieving significant energy savings in the heat treatment process. This product received the Energy Conservation Award (Special Prize of the 2017 Review Committee, Energy Conservation Center, Japan) from Toyo Ro Kogyo and Tanaka Netsuko Co., Ltd. It marks the sixth installation within the entire Emanac Group.
At the Yashio Plant, which conducts carburizing processes, the original No. 1 furnace, operational since the company's founding, underwent renewal in October of the previous year. Subsequently, the renovation work for the older No. 2 furnace was progressing. To ensure uninterrupted supply to users, the Yashio Plant operated the new No. 1 furnace and the old No. 3 furnace during the construction period. The removal of the old No. 3 furnace is scheduled for October, following the completion of the installation of the new No. 2 furnace. The shift to a dual-system of new furnaces maintains a production capacity of 500 to 600 tons per month, almost unchanged from previous levels. Simultaneously, energy consumption, including electricity and gas, is expected to be reduced by 30%. The quick start-up time also allows for improvements in the scheduling process.
The new furnaces incorporate Yashio Plant's unique quality know-how. The dipping method is employed in the intermediate cleaning process to remove soot that tends to accumulate in cross holes generated during carburizing. With high cleaning capability, it accommodates workpieces prone to soot adhesion, such as nuts and bag-shaped components. Additionally, through proprietary specifications, the system prevents foreign material contamination caused by snags, which is common in precision products.
The next phase after the completion of the three-year construction is the automation of the process with the dual-furnace system. Settings such as temperature, speed, and atmosphere, previously managed item by item, are shifting from semi-automation to full automation by reading information from barcodes attached to work instructions. Moreover, the surplus space created by the dual-system setup is being considered for the introduction of automated equipment.
Sixty percent of the products processed at the Yashio Plant are for the automotive industry, with a particular emphasis on micro-precision screws, where increased demand is expected in response to the rise of electric vehicles (EVs) and electronic control. Additionally, there is anticipation of increased demand due to the recent resurgence of domestic production by air conditioner manufacturers. To meet these demands, the company aims to accelerate its enhancement efforts under the new system.
