CHEMICAL COMPOUNDING
CHEMICAL COMPOUNDING
Flow of contracted chemical compounding service
We are always ready to receive your requests, whether by visits to our locations, calling us, using our inquiry form, or other forms of contact. If necessary, we will proceed after negotiating an estimated price and concluding a confidentiality agreement.
We conduct laboratory examinations based on the technical data you provide to us.
We offer quotations based on the results of our investigations conducted in the laboratory.
We prepare trial products using a model or real machine scaling after confirming product quality criteria and analytical methods.
We produce quality products stably and continuously using comprehensive process management and quality assurance.
Mixing and filling equipment
Our facilities include a raw material tank, liquid mixing tanks (13), storage tanks (26) and powder mixing tanks (3). The storage tanks allow continuous mixing of chemicals by temporary storing mixed liquids.
Our facilities also include 14 liquid weighing/filling machines.
| Mixing tank | Capacity | Material quality | Temperature range | Pressure range | Stirring blade | No. of storage tanks |
|---|---|---|---|---|---|---|
| Mixing tank (for liquid) |
40KL×2 | SUS | 10-60℃ | Atmospheric pressure | Pfaudler | 40KL×4 |
| 27KL×3 | 27KL×9 | |||||
| 13KL | 13KL×2 | |||||
| 10KL | 10KL×2 | |||||
| 6KL | 6KL×3 | |||||
| 4KL | GL | 4KL×1 | ||||
| 2.8KL | SUS | 2.8KL×2 | ||||
| 2KL | - | |||||
| 1KL | 1KL×3 | |||||
| 0.2KL | - | |||||
| Mixing tank (for powders) |
5000kg | SUS | Room temperature | Atmospheric pressure | ||
| 750kg | ||||||
| 160kg |
| Raw material tank (example) | |
|---|---|
| Nitric acid (67.5%) | Diethylene glycol |
| Sodium bisulfite solution (35%) | Acetic acid (90%) |
| Ammonium thiosulfate solution (75%) | Chelest FN50 |
| Sodium hydroxide solution (48%) | Tartaric acid solution (62%) |
| Potassium hydroxide solution (48%) | Tartaric acid solution (62%) |
| Aluminum sulfate solution (27%) | Ammonium nitrate solution |
| Ammonium hydroxide (27%) | Potassium carbonate solution (49%) |
| Glutaraldehyde (50%) | Ammonium bisulfite solution |
Process flow of mixing and filling
1Dissolving and mixing liquid and/or powder feedstock
Various types of tanks are used to dissolve and mix chemicals.
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Mixing tank
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Storage tank
2Weighing
Using various automatic filling machines, filling is carried out for different types of containers.
We can inspect all products using a checkweigher and vision inspection equipment.
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Fill designated container using the optimal method
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Image processing
3Packaging
We can also package various types of filled bottles into corrugated boxes, etc.
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Fill designated container using the optimal method
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Checkweigher
4Shipment
We can ship products either to the destination you designate or via a collection service at your request.
Analytical equipment
| High performance liquid chromatography (HPLC) | Thermo Gravimeter |
| Gas Chromatography (GC) | Differential Scanning Calorimeter |
| Ion Chromatography (IC) | Reaction Calorimeter |
| Gel Permeation Chromatography (GPC) | In-line Infrared Microspectroscopy (reactIR) |
| Liquid Chromatography Mass Spectrometry (LC-MS) | In-line Particle Vision Meter (PVM) |
| Gas Chromatography Mass Spectrometry (GC-MS) | In-line Focused Beam Reflectance Meter (FBRM) |
| Headspace GC Analyzing System | Moisture Analyzer |
| Fourier Transform Nuclear Magnetic Resonance | Karl Fischer Moisture Meter |
| Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES) | Conductometric Analyzer |
| Atomic Absorption Spectrophotometer (flame, graphite furnace) | Surface Tension Balance |
| Microwave Sample Decomposition Preprocessor | Density/specific gravity meter |
| UV-VIS Spectrophotometer | E type viscometer |
| Infrared Microspectroscopy | B type viscometer |
| Polarimeter | Various dynamic viscometers (Ubbelohde, Cannon-Fenske) |
| Energy Dispersive X-ray Fluorescence Spectrometer (EDX) | Melting Point apparatus |
| Powder X-ray Diffractometer (XRD) | Spectrophotometer |
| Dynamic Light-Scattering Particle Size Analyzer | Turbidity meter |
| Laser-Scattering Particle Size Analyzer | Refractometer |
| Scanning Electron Microscope (SEM) | Automatic potentiometric titrator |
| Powder Characteristics Tester |
Introduction of technology
Prevention of defective product outflow by multi-step inspection process
In manufacturing liquid products, typical defective products are liquid leaks due to loose caps and improper tightening.
We are working to prevent the outflow of defective products by detecting with image sensors, inspecting by pressing the bottle, and conducting final visual inspection by human eyes. Here is an example.
Issue
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Diagonal cap detector
Detects if the cap is fitted correctly.
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Inside plug float detector
Some products have an inside plug in the bottle.
The image is used to detect whether the inside plug is floating.
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Image detector
The image is used to detect whether the product is set in the correct arrangement.
Each product is checked individually by the sensor. Finally, everything is checked with human eyes!
We strive to prevent the outflow of defective products every day!
Use of sterilized water, pure water
(ion-exchanged water), and soft water
Water can be selected based on application
We can choose the water to use according to your specifications.
<<Options>>
Soft water
Controlled at a hardness of 1.0 mg/L or less
Pure water (ion-exchanged water)
Electrical conductivity: 3.0 μS/cm or less
Pure water and sterilized water
The above ion-exchanged water can be used for UV sterilization.
|
Manufactured with a sterilized water device ① Activated carbon filter ② RO membrane (reverse osmosis membrane) ③ Decarboxylation membrane ④ Pre deminer (ion exchange) ⑤ UV sterilizer ⑥ Final deminer (ion exchange) ⑦ UF membrane (ultrafiltration) |
Resistivity （MΩ・cm） |
17.5↑ |
| Fine particles (number/ml) |
10↓ (0.2 μm photomicroscopic method) |
|
| Live bacteria (number/ml) |
0.5↑ (Culture method) |
|
| TOC （ppb） |
100↓ (Wet oxidation method) |
Foaming control filling
Controls foaming by devising a filling method for liquids that foam easily
Some of the products we handle contain surfactants, and some liquids foam very easily. With the normal filling method, bubbles blow out before the set amount is filled in the container, and filling cannot be carried out properly. We have a filling line that enables foaming control, and we would like to introduce our efforts.
Issue
Foaming situation at the time of preparation. The liquid level cannot be seen.
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[1] This is a sample that has been left to stand for one day.
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[2] Shake about 10 times ...
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[3] Bubbles still remain after 1 hour
Examples of countermeasures
- ① Minimize foaming by using a nozzle of rectifying type
- ② Control foaming by performing liquid filling step by step
- ③ Control foaming by filling inside the liquid instead of on the liquid surface
- ④ Determine stable and fastest conditions by controlling the filling speed and pump capacity.
With the above, we succeeded in maximizing capacity while controlling foaming!
Preventing fluttering of powder raw materials by using granulation technology
Greatly improved safety and workability by granulating raw materials that flutter easily
We also handle powder blending/small batches. Unlike liquids, powder fluttering is an issue when filling powder. Powder fluttering varies greatly depending on the particle size of the powder. Small particles flutter easily, and there are concerns about problems such as adhesion, suction, and dust explosion. Therefore, by granulating the powder raw material, it has become possible to significantly reduce powder fluttering and make small batches safely.
Issue
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Conventional raw materials
Flutter easily due to small particle size of the powder
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Raw material after granulation
Harder to flutter since each particle is big
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Suppresses powder fluttering during raw material input and small batch work!