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Core technology

Ferrite technology

The manufacturing process of ferrite particles is roughly divided into four processes. 

1. Blending of raw materials and pretreatment process
Ferrite raw materials such as metal oxides and metal hydroxides are mixed, pelletized (temporary granulation), and then calcined once at 800 to 1000 °C (temporary firing) to generate oxides. The resulting calcined product is mixed with water and pulverized (slurried). 

2. Granulation process
The step of producing spherical powder from the slurry. Generally the spherical powder is manufactured using a device called a spray dryer. Spherical particles can be obtained by dispersing a slurry of a mixture of raw materials and water, and drying the spheroidized particles through surface tension with hot air. 

3. Burning step
During this step, the spherical powder obtained in the granulation process is burned at a high temperature to cause a ferrite-forming reaction. Heating and firing at a temperature of 1000 to 1300 °C are conducted in an atmosphere where the oxygen concentration in the electric furnace is strictly controlled. This burning step is the most important step in the process for manufacturing ferrite powder. During this process, electrical resistance, magnetic properties, and particle surface properties are controlled by the atmosphere, firing temperature, and time. 

4. Crushing step
This is the step for loosening particle agglomeration generated during burning. 
During this step, the particle size distribution is also adjusted by the classifier.

Powder processing technology

Special qualities that characterize a powder are as follows. 
(1) Particle size
(2) Distribution of particle size
(3) Shape
(4) Specific gravity
(5) Particle surface properties (surface area, porosity, irregularities, etc.)
(6) Surface coating

The following technologies control these special qualities. 
(a) Granulation technology
Particles with various shapes and particle sizes are generated by using the spray drying method (wet method), compression molding method (dry method), and tumbling granulation method (dry method). 
(b) Classification and particle size adjustment technology
The particle size distribution is adjusted by combining multiple methods including the sieve method and airflow classification method. 
(c) Sintering and heat treatment technology
These technologies control the particle surface properties and internal structure by using a heating method suitable for the material and target, such as stationary heating and flow heating. 
It is possible to adjust the specific gravity (particle density) in a wide range by providing pores inside the particles or adjusting the unevenness of the surface. 
(d) Resin coating technology
Various organic resins can be coated on the particle surface to provide functions such as fluidity, electrical properties, and adsorption properties. 

Various powders and particles are created by selecting and combining such technologies.

Production technology

(1) Efforts to improve production technology

◆ High quality, mass production, and low cost
We are working to eliminate loss based on detailed quality control to produce high-quality, stable-quality products in large quantities at low cost. 
We aim to further improve productivity by formulating and conducting a new process for setting up a new line and improving the efficiency of the new line. 

◆ Realizing an environment and safety based on production technology
We are a manufacturer of functional powder materials that operates in urbanized residential areas, assuming coexistence with local communities. We promote global environmentally friendly manufacturing, such as energy saving and waste reduction, and create a safe and comfortable workplace. We are working to improve the production technology that is required to realize these goals. 
    
(2) Scaling up
Scaling up a new product designed by the development department is an important theme of production technology. 
We propose flexible production systems as a bridge between the development department, design department, and site. This includes examination of production conditions for mass-produced equipment and the use of different scales according to the quantity ordered by the customer (production quantity). 

Introduction of products (oxygen absorber, oxygen detector)

Oxygen absorber

The following objects can be realized by making the oxygen inside the bag (container) zero (0.1% or less) by use of the oxygen absorber. 
• Protecting the freshness, flavor, and nutrition of food. 
• Preventing deterioration and discoloration of food, and protecting flavor and color. 
• It is useful for a wide range of uses other than food, such as rust prevention for metal products and pest prevention for clothing and so on.

Oxygen detecting agent

● The presence or absence of oxygen in the packaging container is indicated by color.

This company is recommended by the following support organizations.

Kanto Head Office, SMRJ