The following real-life examples illustrate how the ElectroLife process is utilized by different industries.
As experienced by a company Yaizu Refrigeration
IDTj installed 5 ElectroLife units to Yaizu’s cooling tower setup which maintains the refrigeration at a -60°C range (-172° F temperature range).
Due to the removal of the scaling, and as a result, the restoration of the full efficiencies of the cooling tower process, there was a 20% reduction to the electrical usage. Their normal annualized electricity bill was for $1M dollars and this was reduced to $800,000.00
As experienced by Sumitomo Semi-Conductor in Osaka, Japan
Sumitomo manufactures semi-conductors at their factory. IDTj installed the ElectroLife unit and the efficiency increase to the cooling ability resulted in a 20% reduction to electricity consumption. Additionally, the increase in efficiency resulted in a 40% reduction to the amount of water utilized.
As experienced by Toyo Seikan, Hiroshima plant
Toyo Seikan manufactures PET bottles. IDTj installed the ElectroLife unit onto the blower compressor since during the hot Summer months, the operating temperature of the compressor was running high causing for shutdowns to occur. Since the installation of the ElectroLife, the compressor has been running normally and with no shutdowns occurring during a period of 2 years.
As experienced by Shinomura Chemical
Shinomura Chemical manufactures the thin film that is used on the top layer of gum tape. When delicately applying this thin film, a chilled roller is utilized. During this process, friction is caused resulting in the temperature to rise and to minimize this, water is flowed through the chilled roller.
The problem surfaces due to the excessive building of scaling coupled to the level of rust that is present in the chilled roller making it difficult for the chilled roller to function properly. The average life span of this roller is 5 years. In order to resolve the issues experienced by the chilled roller, the assembly line was shut down for a period of 2 months and the scaling and rust problems remedied by the descaling done by the ElectroLife process. To date, scaling or rust has not formed allowing for the film application to function at peak efficiency.
As experienced by Suzuki Precision
In the process of Suzuki Precision assembling gear boxes for automobiles, they utilize methods to control metal temperature.The waterway transporting the cooling water utilized for this process had ongoing scaling issues which regularly created malfunctions resulting in down time. Since the installation of the ElectroLife process, there have been no malfunctions or downtimes.
As experienced by Kimura Chuzo
In the process of pouring hot metal into moulds, an electrical heat element is utilized. These processes rely upon water for its cooling needs. On an average once in a 3 month period, the line will intermittently shut down requiring repair work for the removal of scaling; however, after the nstallation of the ElectroLife unit, no further shut downs have occurred.
As experienced by Kasai Sangyo
In the process of Kasai Sangyo placing thin layers of plastic sheets onto a hot press, the cooling for this process was based upon water. Again, due to the amount of scaling that occurs resulting in a diminished cooling capacity that occurs, a higher production time was routinely required. After the installation of the ElectroLife unit, what normally required processing time of 60 minutes was reduced to 50 minutes. On account of the volume of material that was processed in this manner, with the 16.7% improvement that was made to the processing time, a reduction of $800,000.00 to operating cost was attained. A total of 5 ElectroLife units were installed.
As experienced by Lister
In the processing line for the manufacturing of moulds to form plastic, an ElectroLife unit was installed to the cooling tower system. Since scaling formed on the inner side of the mould prior to the use of ElectroLife, the rate of defects were reduced by 20% coupled to the non-occurrence of malfunctions bringing a shutdown to the operation. These were malfunctions brought about by oil being used during the process which elevated in operations temperature causing shutdowns to occur.
As experienced by Suzuki Motors, Iwate Plant
Located inside the assembly plant is the cooling tower system for air conditioning. This system required periodic cleaning for which the ElectroLife unit was installed as a test. The problem surfaced annually during the hot Summer months with the air conditioning reduced in its cooling capacity. The cleaning process required the use of approximately $80,000.00 of chemical product.
The installation of the ElectroLife unit, and its initial 5-month descaling process conducted during the Winter months, successfully removed the scaling and restored the air conditioning function to its peak performance.
