With the help of Maeda Shell Services compressed air quality measurements and the resulting installation of air filters a broad variety of problems in several industries could be solved. We introduce some cases where energy and cost savings could be realized, because defects disappeared and machine malfunctions were significantly reduced.


3 in1 Multi Dry Filter

– It combines three filter functions in one filter body
– It reduces all forms of particles and oil mist larger than 0.01μm by 99.99% – Its auto-drain function drains the filter automatically
– HACCP, FSSC22000, ISO8573-1 compliant

Case-studies

AIR FILTER DEMO MOVIE

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Case 1: Coating

The production line of Japans largest car manufacturer’s premium models
Coating of car body
A coating defect occurred and additional work such as re-painting was necessary

1. Issue: Coating Process
Coating defect occurred in around 15% of the cases. Even after 0.01μm filter was installed
additional work such as re-painting was necessary on a regular basis.
2. Investigating the root cause by measuring air quality
When the air quality was measured with a laser particle counter, impurity particles of over 0.3μm could be found at quantities of around 1,200 pcs/l.
It became clear that the impurities in the air were one cause of the coating defects.on a regular basis.
3. Improvement Installation of air filters
3 in1 MULTI DRY FILTERS were in installed at important positions and the problems were solved.
Installation locations: Air supply for drying, overcoating, and clear coating
4. Result Defect reduction,
quality improvement, process improvement
– The count of impure particles of over 0.3μm in the compressed
air was reduced from 1,200 pcs/l to 0 pcs/l.
– Painting defects due to compressed air → Zero

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Case 2: Food Industry

Bread production
Mold was found in products within shelf-life.

1. Issue Packaging Process
Mold grew in products within shelf-life time.
In the packaging process the package was inflated with air. However,
there was no high performance air filter installed and the manufacturer was looking for a solution.
2. Investigating the root cause
by measuring air quality
When the air quality was measured with a laser particle counter, impurity particles of over 0.3μm could be found at quantities of around 10,000 pcs/l.
It became clear that there was the possibility that bacteria in the air could have caused the issue.
3. Improvement Installation of air filters
3 in 1 Multi Dry Filters were not only installed in the packaging process, but also at the depanner, the airblow, and any location where air could directly or indirectly could contact the product.
4. Result Installation of a safe
and secure food production process
– The count of impure particles of over 0.3μm in the compressed air was reduced from 10,000 pcs/l to 0 pcs/l.
A virtually sterile air supply was realized
– The occurrence of mold within shelf-life time caused by contaminated compressed air was reduced to zero.
– A contribution to food production safety.

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Case 3: Machine tool

Precision metal processing industry Issues with the main axis of a machine tool occurred

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1. Issue: Main axis of machine tool
Galling of the main axis bearing occurred. The main axis was supplied with air and oil in order to cool and lubricate it when it was rotating at high speed. Galling of main axis bearing occurred and maintenance costs of around US$ 8,000 were the result.
2. Investigating the root cause by measuring air quality
The manufacturer observed that the air supply of the machine tool had bad quality and could have accumulated impurities in the main axis bearing. They requested quick improvements of the air quality.
When the air quality was measured with a laser particle counter, impurity particles of over 0.3μm could be found at quantities of around 430,000 pcs/l.

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Maeda Shell Service Co. Ltd.

Business Description: Manufacture and sale of filters for compressed air; manufacture and sale of urethane products; manufacture of shell cores; R&D of new products
Headquarters address: 76-4 Kanayama, Ikegane, Okazaki, Aichi
Representative: Tatsuhiro Maeda
Established: 1965
Number of employees: 73
Website: http://www.maedauni.co.jp/english/2012051411094833.html