Research and Development

Through the integration of research and development facilities,
the laboratory has evolved into an innovation hub.
The world leading thermal technology now enters the next phase. ───

The role of thermal technologies is expanding wider and wider, including the development of combustion technology to eliminate CO₂ emissions and to achieve carbon neutrality and thermal treatment facilities for EVs, secondary batteries and components for semiconductors, and innovation of existing thermal technologies for the development and the production of customers’ new products. We, Chugai Ro, integrates its research and development facilities with Sakai Works in November 2023 to maximize the potential of the core thermal technology and to meet customers’ needs. We accelerate innovation through the co-creation of both inside and outside the company and partners to contribute to creating a sustainable society.

Core facilities that play a central role in innovation creationThermal Technology Creative Center

Our central facilities for research and development have been established to strengthen our research and development capabilities, boost joint development with members both inside and outside the company, and practice actively and rapidly "New Value Creation," as stated in the management philosophy.

Combustion Zone

As a leading company of industrial burners in Japan, we are continually developing decarbonizing and energy-saving combustion technologies.

  • Entity Heating Demonstration Furnace

    This furnace allows users to check the effects of hydrogen combustion on a substance and to experience a hydrogen combustion flame.

    Specifications
    Furnace dimensions 1,000W×1,000H×1,000L
    Maximum combustion volume 232 kW
    Compatible fuel 13A, H₂, O₂
    Maximum furnace temperature 1,300℃
  • 1.5MW Large Test Furnace

    The main purpose of the furnace is to develop large-capacity ammonia combustion technology, which will contribute to the realisation of decarbonisation.

    Specifications
    Furnace dimensions 2,500W×1,500H×5,000L
    Maximum combustion volume 1.5 MW
    Compatible fuel 13A, LPG, NH₃, H₂, O₂
    Maximum furnace temperature 1,300℃
  • 2.5MW Large Test Furnace

    The main purpose of the furnace is to develop large-capacity burners in excess of 2 MW, and tests with multiple burners can also be carried out.

    Specifications
    Furnace dimensions 2,000W×3,000H×8,000L
    Maximum combustion volume 2.5 MW
    Compatible fuel 13A, LPG, H₂, O₂
    Maximum furnace temperature 1,300℃
  • Medium-size Test Reactor

    The cylindrical horizontal design allows the furnace length to be divided into four sections, which can be set according to the purpose of the test.

    Specifications
    Furnace dimensions φ800×4,200L
    Maximum combustion volume 0.6 MW
    Compatible fuel 13A, LPG, H₂, O₂
    Maximum furnace temperature 1,300℃
  • Compact Test Furnace

    The main purpose of this furnace is to develop and check the performance of small-capacity burners, and ammonia combustion can also be carried out.

    Specifications
    Furnace dimensions φ620×2,600L
    Maximum combustion volume 0.3 MW
    Compatible fuel 13A, LPG, NH₃, H₂, O₂
    Maximum furnace temperature 1,300℃
  • Radiant Tube Furnaces

    Test furnaces specially designed for radiant tube burners, with a range of 5 to 7 inches.

    Specifications
    Furnace dimensions 600W×1,250H×1,600L
    Maximum combustion volume 64 kW
    Compatible fuel 13A, LPG, H₂
    Maximum furnace temperature 1,050℃
  • Simulated Tundish Furnace

    The main purpose of the furnace is to develop energy-saving TD/LD burners, which can burn in a downward direction.

    Specifications
    Furnace dimensions 700W×1,170H×4,200L
    Maximum combustion volume 1.1 MW
    Compatible fuel 13A, LPG, H₂, O₂
    Maximum furnace temperature 1,300℃
  • In-flame Treatment Unit

    Multifunctional testing machine for the development of new processes and demonstration tests of powder heat treatment using flames.

    Specifications
    Furnace dimensions φ300×3,500H
    Maximum combustion volume 174 kW
    Compatible fuel 13A, LPG, H₂, O₂
    Maximum furnace temperature 1,300℃
  • In-flame Treatment Mini-Tester

    The tester is ideal for rapid development of new materials, as small-volume prototyping of in-flame treatments can be easily carried out.

    Specifications
    Unit dimensions φ200×1,200L
    Maximum combustion volume 35 kW
    Compatible fuel 13A, LPG, H₂, O₂
    Maximum furnace temperature 1,300℃
  • Detoxification Equipment

    This system removes unburnt NH₃ from combustion flue gas before it is released into the atmosphere. It consists of a detoxifying furnace and a cooling system.

    Specifications
    Dimensions of main unit φ1,600×6,000H
    Cooling equipment Heat-exchange type
    Process gas quantity 3,000N㎥/h
    Process gas temperature 1,000℃
    Inlet NH₃ concentration 10,000ppm
    Concentration of NH₃ at exit 25ppm以下 

Functional Material Zone

This is a specialized zone for the development of processing materials that are in the spotlight, including all-solid-state battery electrolytes and functional materials for semiconductors.

  • Furnaces for Solid Electrolytes

    Verification furnace for solid electrolyte sintering processes with a glove box for anaerobic treatment sample verification.

    Specifications
    Furnace temperature max.1,000℃
    Furnace dimensions 440W×320L×240H
    Dewpoint DP-60℃
  • Hot Press

    The use of hollowed-out thick-plate press frames reduces age-related changes such as surface curling and deformation.

    Specifications
    Furnace dimensions φ300×300H
    Furnace temperature max.2,500℃
    Furnace pressure Vacuum to 280 kPa abs
    Press pressure max.290kN
  • Reduced-pressure CVD Furnaces (Organic materials)

    Verification furnace for pyrolysis coating processes under reduced pressure with the introduction of organic gases.

    Specifications
    Furnace temperature max.900℃
    Furnace dimensions 420W×420L×240H
    Furnace pressure Vacuum to normal pressure
    Atmospheric Organic gas
  • Multi-purpose High Temperature Furnace

    Suitable for dry purification (halogen free) and graphitisation of ceramics, graphite, etc.

    Specifications
    Furnace temperature max.2,600℃
    Furnace dimensions φ150×300H
    Furnace pressure Vacuum to 0.98 MPa G
  • 3-chamber Continuous Vacuum Furnace

    Enables quality checks in continuous furnaces. Contributes to energy savings and reduced running costs.

    Specifications
    Furnace temperature max.1,400℃
    Furnace dimensions 600W×600L×450H
    Furnace pressure 1.3Pa abs
  • Muffle Furnace

    Multi-purpose muffle furnace for degreasing and firing. Ideal for condition setting.
    Various sizes are available to meet various temperature ranges.

    Specifications
    Furnace temperature max.1,000℃ (max. 1,200°C by changing muffle material)
    Furnace dimensions max.φ300×600L
    Furnace pressure Vacuum to atmospheric pressure
  • Metal Element Furnace

    Its contamination-free hydrogen atmosphere allows processing of high vacuum to pressurised atmospheres.

    Specifications
    Furnace temperature max.2,600℃
    Furnace dimensions φ160×200H
    Furnace pressure Vacuum to 280 kPa abs
    Atmospheric N₂、Ar、H₂
  • Single-chamber Gas-cooled Vacuum Furnace

    The use of a square chamber halves the furnace volume and installation space compared with conventional models. Gas consumption can be significantly reduced.

    Specifications
    Furnace temperature max.1,320℃
    Furnace dimensions 650W×1,000L×600H
    Attained pressure 7×10-3Pa abs
    Cooling pressure 70~280kPa abs

Other functional materials testing facilities
at the Sakai Works

VPAX® shaft-type powder firing furnaces/VFC vertical fine sintering furnaces

Vertical furnaces for powder materials with container-less conveyance. Energy cost and CO₂ reductions can be expected due to direct heating.

Specifications
Installation dimensions 3,800W×4,600L×8,500Hmm
Processed materials Various powders and powdered materials(5 to 100 µm)
Operating temperature 2,800 to 3,000℃ (regular use)
Atmospheric gas N₂/Ar

Co-creation Space

A community space where the latest products and the history of the company can be seen and that promotes 'showing', 'learning' and 'gathering'

Creating new technologies that contribute to a recycling-oriented societyZero Emission Technology Laboratory

The laboratory advances the technologies of Chugai Ro, has developed sledge treatment technology and air pollution control technology ahead of its time, and it now develops technologies for resource recycling and reducing environmental loads, as well as heating and cooling technologies for highly functional materials.

Rotary Kiln

The use of our unique multi-cylinder structure ensures that it is containerless and highly productive.
※The test equipment were of the mono-tube type.

Specifications

〈Test equipment No. 1 : resource recycling process applications〉
〈Test equipment No. 2 : heat treatment process applications for high-performance materials〉

Furnace (retort) dimensions 125A×900L (Effective heating length:600L)
Heating method Electrothermal (external heating) system
Heating capacity max.9kW (3kW×3-zone control)
Furnace temperature max.1,000℃

Hydrogen Combustion Superheated Steam Heating System

A new decarbonised heat-treatment system that can be applied to other applications such as degreasing, calcination and recycling processes-using superheated steam at very high temperatures with hydrogen combustion.

Specifications
Furnace dimensions H400×W300×L300[Maximum size of material to be processed: H150×W150×L50]
Heating method Hydrogen × oxygen combustion system
Heating capacity max. 35kW
Furnace temperature max.1,600℃
Atmosphere in furnace Oxidizing atmosphere (O₂=0~25%), Reducing atmosphere(H₂=0~10%)

Further accelerate the development of our globally active carburizing technologyVacuum Carburizing Technology Laboratory

The laboratory is equipped with the latest model of a vacuum carburizing furnace, needs for which is increasing and we promote the improvement of existing technologies.

Vacuum Carburizing Furnaces for Mass Production
HIFALCON™

Processing with this equipment, which is layout-free and easy to expand and maintain, is possible in the size of the actual machine.

Specifications
Furnace dimensions 760W×1,220L×700H
Loading capacity Gross 900 kg
Furnace temperature max.1,100℃

Vacuum Carburizing Furnaces for In-line Applications (Small-lot Processing Type)
COMPACTFALCON™

Carburizing furnaces for compact and in-line production of a wide variety of products in small quantities. Equipped with three carburising chambers, they are capable of processing that is equivalent to actual facilities. Gas cooling and oil quenching can be selected.

Specifications
Furnace dimensions 600W×500L×250H
Loading capacity Gross 100 kg
Furnace temperature max.1,100℃

Vacuum Carburizing Furnaces for In-line Applications
COMPACTFALCON™(Carburized 1 chamber + oil quenching)

Can be used for special specifications, such as nitriding.

Specifications
Furnace dimensions 610W×460L×220H
Loading capacity Gross 70 kg
Furnace temperature max.1,100℃

Exploring the new value of metals with unlimited possibilitiesMetal Heat Treatment Technology Laboratory

The laboratory is equipped with a gas carburizing furnace that meets all the requirements for carbon neutrality, and it opens up new possibilities of metal thermal treatment.

Hydrogen-fired Demonstration Furnaces

Indirectly heated hydrogen-fired burners to ensure carbon neutrality of the heating source.

Specifications
Furnace dimensions 610W×920L×550H
Loading capacity Gross 500 kg
Furnace temperature max.1,050℃

New Hi-SHIFTER™

Oscillating oil tank with a high-output heater and servo motor for short-duration and low-distortion processing.

Specifications
Furnace dimensions 760W×1,220L×660H
Loading capacity Gross 900 kg
Furnace temperature max.950℃

Batch-Type Gas Carburizing Furnace Hi-SHIFTER

Best-selling gas carburizing furnace. Ideal for high-mix low-volume production.

Specifications
Furnace dimensions 300W×700L×300H
Loading capacity Gross 100 kg
Furnace temperature max.1,050℃

Multi-purpose Nitriding Furnace

Energy-saving type with A-gas generator inside the furnace, applicable to a wide range of temperatures.

Specifications
Furnace dimensions 400w×400L×390H
Loading capacity Gross 70 kg
Furnace temperature max.1,000℃

Muffle Furnace

Multi-purpose muffle furnace for degreasing and firing. Ideal for condition setting.
Various sizes are available to meet various temperature ranges.

Specifications
Furnace dimensions max.φ300×600L
Furnace temperature max. 1,000°C (max. 1,200°C by changing muffle material)
Furnace pressure Vacuum to atmospheric pressure

New Vacuum Cleaner

Shower and soak to increase cleaning power. Can be tested on actual equipment size in as little as 20 minutes.

Specifications
Furnace dimensions 760W×1,220L×700H
Loading capacity Gross 900 kg
Washing-up liquid Hydrocarbon-based

Development of one and only coating technology.Converting Technology Laboratory

Major expectations are placed on “RS Coater™” for the development and production of the latest semiconductors and batteries. This laboratory widens the application range and expands the line-up of “RS Coater™”.

Wafer Coating Equipment
RS COATER™

Equipment for loss-free, uniform application of expensive coating liquids to substrates such as silicon wafers and glass. Oddly shaped coatings can also be applied.

Applications
  • Application of various semiconductor layers
  • IC packages
  • MEMS
  • Application of optical adhesives
  • µLEDs and other FPDs
  • Next-generation battery-related materials

RS COATER™ System

This is an automated coating and drying system that combines an RS coater with a robot, drying equipment, and baking equipment.

Wheel Coater

Ideal for coating verification on thin substrates (R2R substrates) such as metal foil and film. Coating of irregularly shaped substrates is also possible.

Applications
  • All-solid-state batteries
  • Fuel cell
  • PSC solar cells
  • OPV
  • Semiconductor processing materials

Access

2-4, Chikko-Shinmachi, Nishi-ku, Sakai 592-8331, Japan

By train
Take the Midosuji Subway Line to Namba, change to the Nankai Main Line and alight at Ishizugawa Station.
Five minutes by taxi.
Driving from the north
Take the Wangan Route of the Hanshin Expressway Wangan Route and get off at Dejima Exit, about 10 minutes. (Osaka Rinkai Route, turn right at the intersection at Ishizu Nishimachi).
Driving from the south
Take the Wangan Route of the Hanshin Expressway and get off at Ishizu Exit. Our office is about 5 minutes from there.
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