Worksite Improvement Case Studies

The Pharmaceutical, Cosmetic and Chemical Workplace

During tank interior steam washing, cracked hose sheath fragments may fall into the tank, causing foreign matter contamination

Tanks of raw material for cosmetics are regularly washed with steam, but just two to three months of use causes the steam hose sheath to crack. Measures were required for the risk of contamination with foreign matter due to small fragments of rubber from the cracked hose falling into the tank.

Costs are high because couplings are discarded at the time of replacement every year!

TOYOSILICONE-S Hose + FERRULE crimping product is used for transporting material from the cosmetic raw material tank to the mixing pot. The hoses are replaced once a year due to deterioration or discoloration, but if it is a crimped product, the couplings cannot be reused and cost is a problem.

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The Semiconductor and Precision Instrument Workplace

An abrasive compound clogging inside a hose stops the production line

At a plant that manufactures silicon wafers, PVC hoses were being used to feed silica grinding powder used in their wafer grinder. But the silica powder got clogged in the hose, causing the production line to stop. The workers would use a hammer on the hose to get it running again.

Hoses for discharging chemical waste degrade quickly, requiring frequent replacement.

At a factory producing printed boards, the effluent had to be brought to a certain pH level in the discharge process to prevent water pollution. Their process involved injecting sulfuric acid, hydrochloric acid and sodium hydroxide to adjust the pH level. This caused their PVC hoses to become brittle and otherwise degrade quickly. Because they needed the hoses to be flexible, they had to replace the hoses frequently.

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The Machinery Manufacturing Workplace

An over-tightened clamp cuts the hose, resulting in a water leak

A clamp had been over-tightened at a plant, cutting into the hose and causing a water leak. When they moved into a new plant, there was electrical wiring near the location of the leak, so they needed to rethink their entire hose piping configuration.

Sodium bicarbonate used in a cleaning machine causes hoses to wear and is very dangerous

A customer had a cleaning apparatus that uses air to blow sodium bicarbonate to clean metal parts used in rolling stock (train cars). The wear on the PVC hose conveying the sodium bicarbonate was so heavy that the hose would break in less than a month, causing the sodium bicarbonate to leak. Operation would have to be stopped because of the high level of danger this posed.

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The Plastic Molding Workplace

Friction opens up holes in the hose, preventing stable supply of raw materials.

When transporting the raw material resin pellets from the dryer to the molding machine, holes can open up in the hose due to friction. While we are taking emergency measures to enable continued use, we have nevertheless been unable to supply the required volumes, molding defects have occurred, and the time set aside for emergency measures could be better utilized.

Heat leads to hose collapse, preventing stable supply of raw materials

Hoses used for transfer of PET resin at drying temperatures of 80°C to 100°C collapsed due to the heat, preventing the stable supply of raw materials and leading to frequent mold defects. As well, static electricity was generated from the powder transfer, adhering the raw materials to the hose interior so that the materials mixed during changeover and contaminated the product with foreign matter, which also required countermeasures.

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Factory Equipment Hose Examples

Coolant oil can cause the hose to harden, bend, and collapse, resulting in coolant stoppage!

The PVC hose used in the mobile parts of cutting machines can harden, bend, or collapse due to coolant oil. If the coolant oil gets clogged, this can prevent cooling and become a cause for production loss. In addition, because replacement is necessary every half-year, we searched for an oil-resistant hose

Due to the effects of mist incorporated in the oil, we frequently need to perform hose replacement…

In addition to the plant facility air piping, we used the SUPER TOYORON Hose for drainage of cutting fluid or grinding fluid mist that tends to get scattered around inside the plant, but hardening due to oil occurred quite rapidly, so replacement was necessary once every two years, and this work was quite tough, necessitating replacement in many locations and occupying up to an entire day

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The Food and Beverage Workplace

Cracks have appeared in the steam hose, raising concerns about possible foreign matter intrusion

Steam cleaning is performed on facilities in an ice cream manufacturing line, but when used it often results vertical cracking of the hose inner surface, and there is a possibility that the cracked fragments will intrude into tanks, etc. The possibility that this may be the cause of a lot rejection is a concern.
In addition, because the hose outer surface is white, surface soiling is highly noticeable, raising the possibility of this being pointed out during inspections, etc.

The steam hose is heavy, so the cleaning work is tough. In addition, foreign matter intrusion due to inner hose deterioration is a concern

To steam clean the cheese adhering to pots and machines, we used a steam hose (made of rubber) with a ferrule barb hose band fastening.
This steam hose is heavy and stiff, making it difficult to use. Moreover, after about one year of use, rubber fragments appear due to inner hose deterioration. Foreign matter intrusion due to the hose fragments is a concern, and we concluded that some countermeasure needed to be done.

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