In order to meet customer needs and to further optimize the business process, the casting, can manufacturing, 3D printing, and other forming processes are carried out in cooperation between the Futtsu Plant, the China Plants (2 locations), and the Vietnam Plant. Click here to view a detailed video showing the China Plants and Vietnam Plant.
What is a pump?
Pumps are machines that are used to suck up or transfer various liquids from low to high altitudes or to distant places.
They are used in building facilities for buildings and apartments, water infrastructure-related facilities for sewage and seawater desalination systems, and energy-related facilities for oil refining plants and power plants.
Futtsu Plant
The Futtsu Plant is a production facility of custom pumps.
Custom pumps are pumps that are customized to customer design and assembly specifications.
EBARA manufactures pumps that support social infrastructure.
Manufacturing base for large-scale and high pressure pumps
There are four plants for large-scale pumps in Japan, China, and Vietnam.
In order to further optimize business processes in accordance with customer requirements, our Futtsu, China (2 locations), and Vietnam plants are working together to implement these processes.
Manufacturing Process of pumps
Materials
Parts that are roughly shaped by applying heat or force to the material (semi-finished parts) are called “roughly-shaped raw materials.” Material processing methods such as canning and casting are used to create the shapes. Processing is mainly carried out at overseas plants.
Canning
This process involves bending thick metal plates by applying force and welding.
Casting
This process involves heating the material at a high temperature of approximately 1,500°C, turning it into a liquid, pouring it into a mold, and cooling it to give it shape.
3D printing
China EGP Plant
Vietnam EVPC Plant
China：EMZ Plant
Acceptance and inspection
Pump parts manufactured by group companies and subcontractors are received, inspected, and stored in warehouses.
Processed and repaired goods are also inspected.
Dimensional inspection
Products are inspected using measuring instruments to ensure that their dimensions comply with the drawings.
Automated warehouse
Automated warehouses are used to perform a series of operations, including product reception, storing, and shipping.
3D scan
Product shapes are measured three-dimensionally using 3D measuring instruments.
Non-destructive inspection (penetrant testing)
Scratches on the product surface are magnified and visually inspected.
Processing
Machine tools and cutting tools are used to process materials (such as metals and plastics) into the desired shape.
A variety of shapes can be produced with high precision. The processing methods and machine tools will vary depending on the shape to be fabricated.
Lathe turning
This is a machining method in which a fixed blade is pressed against a rotating material and cut to the desired shape and length. Since the material is rotated during processing, it is often used to cut the periphery and sides of cylindrical parts.
Milling
This is a machining method in which a rotating blade is applied to a fixed material to cut it down to the desired shape.
It cuts down the flat surfaces, sides, and grooves of the machined material.
Five-axis machining
Machining is performed on five axes, including three linear axes and two rotating axes. Compared to three axes, this configuration allows for more flexible and productive machining in a single setup.
Painting
It has three functions of surface protection; Protection of structures (rust prevention), appearance (color)and added value (antifouling, etc.).
This is a surface treatment process that protects the structure from corrosion by coating.
Painting
Brush coating, airless application, and film thickness measurement inspection are performed in a sequential order.
Glossary
- What is brush coating?
- It is pre-coating areas that cannot be reached by spraying during airless applications.
- What is airless application?
- It is coating the entire surface using a coating machine(Paint sprayers).
- What is a film thickness measurement inspection?
- It is an inspection that checks that the paint thickness complies with the specification.
Assembly
Various types of pumps are assembled. Pumps are made by assembling together many parts such as casings, shafts, and impellers.
Each pump is manufactured under strict quality control.
Large-scale pumps
These pumps are used for applications in rivers as well as during typhoons and floods.
Large-scale pumps have very large diameters of 3,000 mm or more and utilize very large parts and components.
High pressure pumps
High pressure pumps are manufactured primarily for power plants, steelworks, and fertilizer plants.
These are pumps that rotate more than 5,000 revolutions per minute. These high speed models require careful adjustment.
Horizontal pumps
These pumps are highly demanded in water supply applications.
Their structure is simple, but requires careful assembly techniques.
Testing
Completed pumps and components are operated and measured for discharge flow and pressure to determine if they have the required performance and functionality for the site. In addition, Machine monitors are installed in measurement rooms to check for abnormal vibrations and noise at the site.
Large-scale pumps
High pressure pumps
Shipping
Completed products are shipped by trucks. When products are shipped overseas, they need to be reloaded onto trucks, ships, or freight cars. Therefore, they are shipped in containers or large wooden crates.
Shipping
After-sales service
We supply spare parts for pumps delivered to customers, perform repair and modification work, and handle on-site troubleshooting by dispatching service personnel.
Parts supply
We supply customers with replacement parts that become necessary due to wear, deterioration, corrosion.
Repairs and modifications
Pumps received from customers are cleaned, inspected, repaired, have parts replaced, painted, and assembled before being returned to the customer. In addition to maintenance, modifications such as performance, shape, and dimensional changes, are made at the customer’s request.
For 110 years since its foundation, the EBARA Group has contributed to solving social issues on the strength of its technological capabilities and reliability.
Over the next 100 years, we will continue to grow and further strengthen our technological capabilities and reliability to become a company that supports the world.
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