What is the Impregnation?

Impregnation is a technology that utilises impregnation solution to permeate 'porosity' caused by the gas, pin holes that unavoidably occur in the manufacturing process of molded products such as aluminum die castings. A variety of other areas of application include timber, textiles and stone.

 

Purpose of impregnation process

The products of impregnated will enable it to grant a variety of characteristics.

 

・Provides pressure resistance and air-tightness
・Provides corrosion resistance
・Pretreatment before chemical treatment
・Improves cutting operations
・Improves physical strength
・Improves insulation resistance

 

Reduces costs

We realized to reduce Significant production cost because of using impregnation. We can use valuable good that as dispose or recasting as defective goods.

 

Let's suppose that instead of impregnation of the metal, recasting was performed. The necessary expenses would include recasting costs, labor costs, processing costs, flow costs, and management costs. Thus performing impregnation reduces the total cost and eliminates the time wasted in recasting.

含浸は大幅なコストの低減を可能とします

 

Process of impregnation

 

Mechanism of impregnation

Vacuum
Products are placed in a large impregnation tank. Air is extracted from the impregnation tank to create a favourable environment for the impregnation solution to permeate 'porosity'.

Filling Impregnation solution
Impregnation solution is injected into the impregnation tank and extra air compression applied. As a result, the impregnation solution thoroughly permeates the microscopic 'porosity'.

Heat Curing
After cleaning, with the impregnation solution still filling the microscopic 'porosity', heat curing takes place to complete the impregnation process.

Finish
Airtightness is improved in products that have been through this impregnation process, removing worries of air, oil, gas or water leakage. Strength is also enhanced, meaning that they can also be used, for example, in applications to improve cutting accuracy or to prevent blisters forming after coating/plating treatments.

 

 

A variety of products that can

Castings for automobiles and motorbikes, Snowmobiles, Railway, Aviation fields, Ship casting, Water and gas, Telescopes, Optical equipment, Art and craft products before coating, Precision instruments, Plastics, Fibers, Timber, Stone strength enhancement (※), Paper manufacture, Architectural fields, Medical fields

 

※Effective in improving strength.

 

Main products that can be treated and salvaged by impregnation

Cylinder blocks, Cylinder heads, Carburetors, Torque converter cases, Transmission cases, Crank cases, Aluminum wheels, Intake manifold, Fuel injection pumps, Steering cases, Valves, Water pumps, Hydraulic pump bodies, Hydraulic cylinder, Compressor bodies, Bodies of binoculars, Electric/electronic bodies, Underwater camera bodies, Gas regulators, Air guns, Spray guns, Fire extinguisher caps, Cases, Covers, Water taps, Electric coil molded objects(※), Product with sprayed coating, Machine tool parts, Trophy mirror surface parts

 

※Effective in improving electrical insulation and preventing coil windings from coming undone.

 

Product warranty

At Sutai we are proud of the high quality finish achieved by our impregnation technology. We are committed to providing a system of warranty for finished machined products, including pressure tests and the like, that is second to none.

Products before the impregnation process

Air is leaking from porosity.

Products after the impregnation process

Greater airtightness means leakage has been improved.

Pressure testing

Pressure is applied to test air leakage.

Pressure apparatus

 

Reducing the environmental impact

Our impregnation technology is kind to the environment. The impregnation technology itself makes the production processes of various engineering products more efficient, contributing to energy and CO2 savings.

What’s more, the impregnation solution used in our impregnation treatment is a modern technology we have proactively developed so that it can be recycled.

 

General impregnation sealant recovery system "SKISS"New technology

Only 2% of the impregnation sealant is actually used as sealer on the product while the remaining 98% ends up being released as waste material.

Because of this condition, Sutai has worked to develop a total impregnation sealant recovery system. With this system, the cleaning water from the impregnation process is collected and then separated into remaining sealant and water, which can be reused. With this system, we have been able to recognize a significant reduction in the burden of this process on the environment and a major increase in the economic benefits.

 

含浸液回収総合システム「SKISS」

Special features

1. Can be recovered for Impregnation solution and water

We employ a method of recovery that is completely different from conventional gravity separation impregnation solution recovery methods.

2. Can be re-use for Impregnation solution and water

Because the composition and performance of recovered impregnation solution is no different from when it is freshly used, recovered impregnation solution can be used again and again. The water which is recovered can also be reused for cleaning.

3. Can lower the burden of waste treatment and disposal

There is no need to polymerise or incinerate highly concentrated wastewater, nor to use an industrial waste disposal contractor.

4. Can reduce costs

We significantly reduce the volume of purchased impregnation solution and the cost of wastewater treatment.

What's more, the equipment has been automated, which translates into a significant reduction in recovery process labour costs.

 

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