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The Flavorings Business Unit has established a distribution center in Rotterdam, the Netherlands, in order to expand transactions with European flavoring manufacturers.
This will shorten the time required for deliveries to Europe from the current over one month to less than one week and will enable us to provide better customer service.
Toyo Gosei is introducing a defined contribution pension plan from April. Toyo Gosei is the third corporation in Chiba listed on the stock exchange to do so, following Aeon and Family. The new system targets all employees. Its objectives are to increase work motivation, raise the financial knowledge of employees, and to provide a place to receive funds connected to superior personnel hired in from corporations already using such a system.
Toyo Gosei's Chiba factory has received the "Award for Excellence in Consistent TPM Commitment 1st Category" for TPM activities promoted by the Japan Institute of Plant Maintenance and was awarded this prize at the Friday, December 17, awards ceremony (held at Pacifico Yokohama, in Nishi-ku, Yokohama City).
TPM is the abbreviation for "Total Productive Maintenance". It is defined as follows.
Building the type of corporation that pursues efficiency in production systems to the ultimate limit (total efficiency) is set as the goal. Mechanisms must be constructed on-site with actual products in order to prevent loss and achieve "zero accidents, zero defects, zero breakdowns", etc. over the entire production system life cycle with the participation of all employees from top management to front line employees, in production departments and across development, marketing, management, and other departments, and zero loss must be attained through redundant small group activities.
As announced in the newspapers, Toyo Gosei has constructed a mass production system for electrolytic solutions and ionic solutions for which demand is expected to grow for use in next-generation batteries.
In recent years, with the shift to higher-performance, higher-capacity batteries, the need for high-purity products is rising. Toyo Gosei has applied quality control techniques for photosensitive materials used in semiconductor manufacture to make possible production of high-purity products.
By introducing the most up-to-date production facilities, Toyo Gosei is able to provide a few tens of tons of electrolytic solutions per month and a few tons of ionic solutions. Toyo Gosei already has put together a system that can meet customers' various needs both for quality and quantity.
We are working hard for your continued patronage.
Toyo Gosei has completed its ArF polymer manufacturing facilities (A-1 facilities) in November 2002 and received more orders from its customers than foreseen. Given the further expansion of demand for semiconductors for digital appliances and cell phones in the future, Toyo Gosei completed its second series of ArF polymer manufacturing facilities (A-2 facilities) with five times the capacity of the A-1 facilities. With the completion of these facilities, a mass production system has been established for annual production of 15 tons of ArF polymer.
These A-2 facilities were designed to make it possible to easily scale up products that have been certified at the A-1 facilities. This will enable us to adequate respond with supplies of products for which sudden increases in demand are foreseen. Utilizing the features of these two facilities, we will now continue with trial production and construction our mass production system.
On the other hand, Toyo Gosei is also tackling integrated production from ArF monomers to ArF polymers. This will make it possible to freely synthesize various ArF monomers to order.
The device capacity and processing amount is as follows.
Attained vacuum: 1 Pa (0.008 Torr) max.
Maximum heated temperature: 160 ℃
Processing capacity: 50 liters/hour
We intend to provide our customers with ArF polymers that meet their needs "with high quality, at low cost".
The Chemical Products Division Flavorings Materials Department produces and sells synthetic flavorings. By using the evaporation technology we have nurtured until now, we can provide high-quality products and enjoy a reputation among our customers for products that they can use with confidence.
Now, Toyo Gosei has introduced a flow film type thin-film evaporator that makes it possible to distill heat-sensitive and high boiling point material, for which there are many requests from our customers. Until now, Toyo Gosei has used continuous refining with tower type stills, but with the introduction of the thin-film evaporators, distilling and refining that was not possible before has become possible, making it possible to manufacture heat-sensitive and high boiling point flavorings.
The device capacity and processing amount is as follows.
Attained vacuum: 40 Pa (0.3 Torr)
Maximum heated temperature: 160 ℃
Processing capacity: 200 kg/h
We intend to meet diverse customer needs by supplying them with higher quality products.
The entire Toyo Gosei Chiba factory is working as one to provide "at low cost with high quality" next-generation photosensitive materials that can work in concert with semiconductor manufacture as the degree of integration rises.
The dedicated ArF resin manufacturing facilities were completed at the end of November 2002. After the completion of the facilities, we received more orders from our customers than foreseen. In order to meet the demand for ArF resin, which will steadily increase in the future, we are planning manufacturing facilities with annual production of 10-15 tons and will start up in the spring of 2004 in order to quickly answer our customers' requests.
For ArF resin, many products are being development through the combination of departure material monomers.
In order that many types of products can be used "quickly and with low cost", Toyo Gosei will tackle the entire series of work from raw material monomer synthesis to ArF resin manufacture. In October 2003, in order to efficiently refine raw material monomers, a thin-film evaporator is being introduced at the Chiba factory. By utilizing thin-film evaporators, it is possible to efficiently refine high-molecular weight material, which was difficult with conventional separation refining.
By expanding ArF resin facilities and introducing thin-film evaporators, we will adapt to future orders for steadily diversifying ArF resin products for which product demand will expand.
At this time, complete automation from empty drum introduction to filling, weighing, and cap sealing has been attained through the use of a fully automated filling machine.
The filling quantities are all weighed automatically and there is also a data storage function. This promises accurate fill work. Since it is also possible to connect to the 61 storage tanks with dedicated pipes, there is no need to worry about contamination.
Combined with the three-dimensional automated warehouse completed at the same time, all the work from delivery of empty drums to the storage of filled drums is carried out indoors to prevent damage to or stains on containers.
At this time, the facilities with a 25KL x SUS 304 mixing vat with agitator machine and heating, cooling, heat holding functions and odor removal tower have been completed.
In addition to bringing in products with trucks in ISO containers, it is also possible to connect to the 61 storage tanks with dedicated pipes, so these facilities can handle various oil mixing operations. In addition to Type 1 oil, these facilities can also handle high hazard chemicals, highly reactive chemicals, highly odorous chemicals, and other difficult to handle chemicals. We also carry out analysis work with our technology to make the quality of the work even more certain.
In addition to the conversational English classes we talked about last month, Toyo Gosei is starting basic chemistry courses and chemical engineering courses.
The objective of the basic chemistry courses is for employees to learn the basic knowledge of chemistry needed for their duties and to broaden the range of their duties. The targets for these courses are first or second-year employees enrolled in skill courses. We use a system in which those employees who post the best marks for the year serve as the instructors for the next year. This leads to further improvement of skills. The basic chemistry course is held once per week at the Ichikawa factory and the Chiba factory.
The chemical engineering course targets mainstay employees and higher who are enrolled in skills courses. The aim of the course is to raise their capacity for independent maintenance on-site. The instructors are employees of the Toyo Gosei engineering group. The course is held once per week at the Chiba factory. This is how Toyo Gosei is always thinking about and acting for its educational system to support employee skill improvement. We will continue to strive to beef up our internal educational system.
In order to increase transactions with overseas, Toyo Gosei has emphasized English-language education for in-company education. In recent years, accompanying the steady increase in sales to overseas users, in order to be able to respond quickly to customers world-wide any time in any manner required, we have invited native speaker instructors from the outside and greatly beefed up our training conversational English.
Nowadays, with the Internet reaching into every nook and cranny of the world, the distance to the rest of the world is shrinking and English is becoming the de facto global common language. In such an age, the objective of this training is that all our language course recipients reach a level at which they can converse without hesitation when sent overseas on business and can explain our products and services persuasively when overseas customers pay a visit to one of our factories.
With the further development of economic globalization and a new society being built, Toyo Gosei is seriously tackling the strengthening of its company educational system, including conversational English classes, in order to develop the personnel who will be responsible for the future.
As the second phase of construction in the site utilization plan accompanying the decommissioning of LPG operations at this chemical tank terminal, the hazardous material three-dimensional automated warehouse construction started at the end of last year was completed at the end of March this year and began operating as planned from April 1.
The warehouse is 20 m high x 53 m long x 13.6 meters wide
Storage capacity is 10,000 drums or 180 one-ton containers.
Major features
Three automatic running cranes, computer online control system
By using a ventilation system to control the temperature inside the warehouse, materials are stored, loaded in, and loaded out without mistake even for multi-type, small-lot, diverse containers.
A wide range of handling space has been secured around the warehouse, making possible effective and speedy loading and unloading.
Marketing warehouse Accompanying the acquisition of warehouse bonding, importing and exporting is possible.
Confidence in storage is established with a crime prevention system with a security system using three guards overnight and mechanized security.
[The hazardous material three-dimensional automated warehouse is under construction aiming for operation from April of this year.]
The construction of the warehouse is currently underway without delay and is proceeding on schedule for operation in April. In another month, we will be able to show this new warehouse to you. It will be worth the wait.
Currently, in order to construct a system that all of you will praise for the ease of warehouse use, in parallel with the warehouse construction, before the warehouse starts operation, we are identifying how to efficiently and functionally ship from the drum warehouse and load vehicles and how to load into the warehouse from vehicles, and how to carry out related work.
Allow us again to summarize the hazardous material three-dimensional warehouse.
Building size 20 m high x 53 m long x 13.6 meters wide
Storage capacity (converted to drums) 2500 shelves x 4 drums = 10,000 drums
(Can store 180 one-ton containers)
All operations are computerized to handle multi-product lots and large numbers of lots.
Keywords
With one phone call, you can handle your entire distribution flow, from filling to storage and shipping, which contributes to reducing your company's distribution costs.
[Start of construction of multi-function drum filling station]
The construction of a multi-function drum filling station has started. At the current time, the steel frame has just been assembled, but this construction is proceeding at a rapid pace in order to be ready when the warehouse is complete.
This drum filling station will have the following functions.
Building size: 20 m long by 27 m wide
Blending and compounding functions
One 25m3 stainless steel stirring vat and space for one expansion vat
This vat has heating facilities, so it can melt high-viscosity liquids and solids for filling.
Functions for bi-directional handling of drums from trucks and ISO containers
Direct drum filling and removal is possible.
High-capacity empty drum storage functions
Space is secured for 200 empty drums. Your company's products are filled into clean drums to raise the product value.
Fully-automated drum filling
A double filling port type with exhaust hood is used for speed and to prevent offensive odors and drums are filled speedily.
Precision filter functions
These functions provide filtration precise enough to satisfy requirements.
Function for eliminating offensive odors
Scrubbers are installed to prevent offensive odors and also with an eye on improving the work environment.
How much value you can add to your products by combining your company's technology with these functions depends on you.
When you want to differentiate your products, consult our marketing personnel.
From the 54th term starting April of this year, Toyo Gosei is managed with a three-division system. Therefore, the products and services provided by Toyo Gosei are all supplied to customers from these three divisions.
Toyo Gosei is currently moving forward with personnel system reform. We started studying this from February 2002 and are aiming to introduce reforms in April 2003. This month's topic is a summary explanation of the current state of the new personnel system.
Read more "Basic Concept of Personnel System Reform Proposal" »
The Ichikawa factory was inspected in June by NKKKQA and obtained its environmental management systems certification dated July 31. The factory will continue its activities for reducing its environmental load in according the environmental policies below.
* Environmental policies
The Toyo Gosei Ichikawa factory aims to contribute to society through the manufacture of photosensitive materials and organic industrial chemicals, through the refining and recycling of organic solvents, as well as through production activities that take into account the reduction of its environmental load. Standing in the awareness that "it is the duty of the current generation to maintain the global environment in a healthy condition and pass it on to future generations", we promote environment protection activities within the range of technological and economic feasibility.
Our approach to protecting the environment is positioned as one of the most critical issues of management. We set environmental targets and goals, taking into account the results of environmental impact evaluations and with all employees tackle the continuous improvement of environmental protection and the prevention of pollution. Also, we periodically review our environmental targets and goals and revise them as necessary.
We strictly observe all laws related to protecting the environment and all other requirements that the Toyo Gosei Co., Ltd., Ichikawa factory has agreed to and also work proactively on our own initiative to protect the environment.
Amidst the impacts of our business activities on the environment, we give the following items particular priority.
- Energy conservation, primarily holding down evaporation from production facilities etc. and holding down power consumption
- Resource conservation through improved product yields
- Reduction in the amount of chemical material emitted into the environment
- Reduction in the amount of waste material generated and effective use of those materials as resources
We disseminate these environmental policies among all our employees, publicize them, and work to attain them.
Toyo Gosei already produces and sells various fatty acid esters, fatty acids, aldehyde, etc. as flavoring materials. Amidst this, many customers have requested us to manufacture and sell food additives. Now we have completed the facilities for this and were able to obtain the public health center permit on October 8th.
Food product business permit (Granted October 8)
The completed facilities comprise drum/can filling equipment, truck filling equipment, tanks, etc. The facilities have sanitary specifications and carefully take into account health and safety too. We intend to develop more products and fill out our lineup in order to meet the desires of all our customers.
Since its founding in September 1954, Toyo Gosei has held "improving research and development capacity" as a basic ideal of company development and has constantly pursued new products and enlarged our fields of business. Currently, our diverse photosensitive material products are recognized by customers for their "high quality", 'stable quality", and "quality that meets customer needs".
Also, in the field of chemical products, where we have a history of over 40 years, we have used the "precision distilling technology" we cultivated over the long years to powerfully promote research and development in flavoring materials.
As a result, Toyo Gosei is nowadays able to manufacture about 100 alcohol, aldehyde, acid, ester, and ketone products.
At this time, in order to check the true value of our flavor and fragrance materials, we have established a permanently-staffed office in Europe, the home of flavorings. With this office in Amsterdam, Holland, we are spreading our wings into world flavoring markets.
The third photosensitive materials factory at Toyo Gosei Co., Ltd.'s Chiba factory was completed in January 2001. In order to obtain the certification of new facilities by resist manufacturers, trial production was carried out and certification obtained. The production capacity of these new facilities is 200 tons/year and will be increased to 300 tons/year through the reinforcement of some facilities. In order to meet customer needs and with the objectives of "high quality", "stable quality", and "low cost", the NQD-ester manufacturing facilities of the third photosensitive material factory "has managed processes with all-process computer control", "has lowered cost through larger facilities", and "has reduced labor needs by introducing robots in the drying and filling processes".
As a result, Toyo Gosei has become able to supply users with stable quality free of quality fluctuations between product lots.
Inversion type centrifuge separator
The semiconductor industry has been unable to shake itself free of recession, but Toyo Gosei photosensitive materials are supported in applications other than micro-photo-resist and operating ratios are steadily improving. Also, currently continuing on the KrF photo-resist resin manufacturing facilities in the space within the factory, dedicated facilities are under construction for polymer resins for ArF photo-resist. Accompanying this, it is planned to further raise the degree of cleanness within the factory. Space for expansion has also been secured so that it will be possible to meet future expanded demand.
In response to customer needs, evaluation samples will be produced within the year and we will request evaluation of their quality.
Stimulated by the introduction of TPM (Total Productive Maintenance) activities, all the employees of the new factory are tackling production from the same angle of providing "high quality and low price" to meet the desires of all our customers.
The Chemical Tank Terminal decided to eliminate its LPG business and completed construction of two 2000kl tanks and six truck shipping lanes on the site in mid-July 2002.
Two 2000kl chemical tanks and filling station for containers
* Features
With the emphasis placed on the environment, vapor return pipes were installed on the ship side and truck side of the chemical tanks and shipping facilities in order to hold down release into the atmosphere of organic solvent vapor.
The truck filling stations are 15-meters deep with a roof 6.5-meters high and can handle containers.
Two 150m3 pumps are installed for filling and they can fill a container in less than 30 minutes.
Also, the construction of a multi-purpose drum filling station and the construction of a hazardous material three-dimensional warehouse are scheduled to start in September, with operation scheduled to start from April.
* Features
Multi-purpose drum filling station
Petrochemicals can be mixed and compounded. (Two 24m3 blending tanks with heating and filtering equipment)
Chemicals can be transferred from drums to trucks and containers.
Drums can be filled from containers and trucks.
Drums can be filled with the automatic double filler. (Filling capacity: 50 drums per hour)
A broad indoor storage space for empty drums is secured.
Hazardous material three-dimensional automatic warehouse
10,000 drums can be stored.
In our automated warehouse, we can store and manage not only drums filled in our own facilities, but also drums we are contracted to store. Even multi-product and small lots are no problem.
It has been 14 years since manufacturing of bis-azide family photosensitive materials, water-soluble photosensitive materials (including chrome-free CRT materials), organic alkaline developing solutions, positive-type photosensitive materials (naphthoquinone family), and photooxidation agents (PAG) began within the Toyo Gosei Chiba factory. With the integration of semiconductors moving steadily forward, in February 2002, we completed KrF photoresist resin manufacturing facilities in order to supply our customers with the next-generation photosensitive materials with "high quality and low cost".
Among ArF resin, the use of methacrylate ester, adamantine compounds, and other polymers is becoming the mainstream, but each resist manufacturing company is moving forward with its own development.
In order to quickly meet the desires of photo-resistor manufacturers, Toyo Gosei completed its ArF resin manufacturing facilities (multi-use) for 193nm in March 2002.
Construction to convert from a multi-product factory to dedicated facilities has started with the objective of completion by the end of November 2002. These facilities are equipped with dissolving vessels, reaction vessels, crystallization vessels, centrifuge separators, dryers, and filters. The introduction of process computers for process management and the conversion of the factory to clean status is proceeding and plans give top priority to quality.
A production capacity of 500kg per month or more is planned, but in order to handle increased demand, facilities space (for monthly production of 2,000 kg or more) is being secured and at the same time, a system is being put in place to make possible timely supply.
All our employees are tackling production from the same angle of using the fruits of the introduction of TPM (Total Productive Maintenance) to provide "high quality and low price".
The TGK-R type and TGK-A type are water-soluble photo-resist for the formation of black matrices (BM) developed for CRTs. Compared to conventional photo-resist (PVP+DAS), these new types have high sensitivity and high resolution. Photo-resist sensitivity adjustment is possible, as is the adjustment of reciprocal side irregularity indispensable for black matrix production, so these new types can be used on a wide variety of manufacturing lines.
1. Preface
We reported to you previously that the LPG storage and handling operations that started operation in October 1985 using about 8,275 square meters within the Takahama Chemical Tank Terminal were abolished as of the last day of September last year and that as the first construction plan for using the about 8,275-square meter site, two 2000kl tanks and six truck filling booths were under construction with the aim of completion by the end of this July.
However, the LPG site is still half empty and here we intend to execute operations that put our ideals into practice and that make use of the features of Toyo Gosei as the second construction plan.
2. Second Construction Plan Summary
We think that anyone who has the facilities can store and handle liquid chemicals and have constantly wondered if chemical tank terminal management that makes use of the fact that the parent body of this chemical tank terminal is a chemical company is possible.
Also, we have been constantly struggling with the questions of how we can satisfy our customers, how we can meet current diversifying needs, and how we can add value to the products of our customers. Now we have finally found the answer.
(1) Construction of advanced-function liquefied chemical drum filling facilities and mixing and compounding facilities (Building size 20 m x 27 m)
- Installation of various equipment that can handle current electronic grade products
Precision filtering equipment, equipment for filling various containers in clean rooms, dehydration equipment
- Installation of various equipment for mixing and compounding various substrates and chemicals
Installation of up to two 20m3 stainless steel stirring vats is possible.
- Securing indoor storage space for empty drums
- Drum filling from ISO containers and truck filling from drums is also supported.
- In addition to normal chemical product analysis, analysis is also carried out for ICP mass, particle counts, and other electronic grade products.
(2) Construction of automated three-dimensional warehouse for hazardous material drums and 1-ton containers
- The drums and 1-ton containers filled in (1) are stored and managed in the automated warehouse. All drums and containers are managed by computer, so multi-product lots are not a problem either.
- Since a storage capacity of up to 10,000 drums is possible, this facility also greatly welcomes storage of drums from the outside.
- Drums can be filled, moved into and out of the warehouse, stored, and shipped with one telephone. Toyo Gosei will take care of your difficulties for you.
* Chemical structures
Material: Photosensitive solution absorption maximum (324.2 nm)
Sensitivity: 25 mJ (Patterning possible with UV-35 illumination 5 mW/cm2 in 5 seconds)
Film thickness on glass sheet 1&mu The glass sheets are not subject to special treatment. Drying, 60 ℃ 10 minutes After exposure to light, water developing is executed while shaking the Petri dish for one minute.
The Takahama Chemical Tank Terminal started operation in October 1985 as an LPG secondary base under a 15-year contract with the K company, a comprehensive trading company, but unfortunately the contract ended at the end of September 2000. Thanks to Toyo Gosei's marketing prowess, subsequent contracts were signed with two companies and LPG operations were continued and maintained, but in the distribution environment that affects fuel related operations in recent years, for the sake of cost reduction, emphasis is placed on primary bases and factory shipments and the amount of LPG we shipped as a secondary base fell drastically.
Toyo Gosei judged that future development of LPG operations as a secondary base could not be expected and decided to lower the curtain on the 16 years of LPG operations at the end of September 2001.
The removal of all the LPG storage and shipping facilities built in the 8,275-square meter LPG area and the development of new business in this area was studied based on the following concepts.
Within the Toyo Gosei Chiba factory, there are bis-azide family photosensitive material manufacturing facilities, water-soluble photosensitive material manufacturing facilities (including chrome-free CRT materials), and organic alkaline developing solution manufacturing facilities and positive-type photosensitive material manufacturing facilities (naphthoquinone family). These facilities have been in operation for 14 years.
With the integration of semiconductors moving steadily forward, in February 2002, we completed KrF photoresist resin manufacturing facilities in order to supply our customers with the next-generation photosensitive materials with "high quality and low cost".
It is known that KrF photo-resist materials are used adding photooxidation agent (PAG) to the material in which the protecting group is introduced in PHS (polyhydroxystyrene). Toyo Gosei's PAG is already on the market and has achieved high marks.
The resin manufacturing facilities are dedicated to adding the protecting group (blocking) to PHS (polyhydroxystyrene). These facilities are equipped with reaction vessels, filtration machines, crystallization vessels, dissolving vessels, centrifuge separators, dryers, clean booths, and filters and products can be supplied as "powder" or "liquid", whichever the user desires.
All our employees are tackling production from the same angle of using the fruits of the introduction of TPM (Total Productive Maintenance) to provide "high quality and low price".
In October 2001, Toyo Gosei obtained kosher approval for 21 flavoring products, including fatty acids, alcohol, ester, and ketone.
The approved items are as follows.
With this approval, we are now able to supply these flavor and fragrance raw materials to the United States and the rest of the world.
Photo-resist for semiconductors is shifting from infrared (UV) to KrF laser chemical amplification types.
As a specialized manufacturer of photosensitive materials, Toyo Gosei has greatly altered its Chiba factory N/E-(I) family in order to be able to provide full-scale supply of the most advanced materials. This device is a dedicated blocking device that adds the protecting group to PHS (polyhydroxystyrene). Blocking can be used for multiple purposes, be it the acetal or SCAP family and a variety of know-how has been built into this device so that the supply to the reactor vessel, the amount, the reaction temperature, stirring, etc. can be controlled with even higher precision. Of course, this device can provide products with unmatched quality.
Operation of this device started in November 2001 and it boasts a production capacity of 3 tons per month and 30 tons per year. With the completion of this device, the production of photooxidation agent (PAG), which had been produced together with PHS, now has its own dedicated devices too. This marks the completion of a system with no blind spots for the product of next-generation materials.
The third photosensitive materials factory at Toyo Gosei Co., Ltd.'s Chiba factory has been completed. Tonoshomachi, where the factory is located, is 25 kilometer up the Tone River from Inubo peninsula, Choshi City, where on New Year's Day the "first sunrise" in the Japanese archipelago is worshipped.
In the first phase 1988 construction, bis-azide family photosensitive material manufacturing facilities, water-soluble photosensitive material manufacturing facilities, and alkaline developing solution manufacturing facilities were put into operation one after the other. In the second phase 1992 construction, operation began at the second factory, which is the main factory for positive-type photosensitive materials (naphthoquinone family).
This factory moved forward with a higher level of cleanness within the factory according to the needs of photosensitive materials users and laid the foundation for the top reputation the company enjoys among today's users.
The photosensitive materials factory completed in January 2001 uses the gravitation flow technique to move the material through the processes in order from above, first the raw material weighing room, then the reaction tanks, filtration equipment, crystallization tanks, the centrifuge separator equipment that separates solids and liquids, and the drying equipment. With the introduction of the DCS system, process management prevents operation mistakes and stabilizes quality. With an eye on the smaller labor force of the 21st century, we have also introduced robots.
These manufacturing facilities make full use of Toyo Gosei's 30 years of experience and track record with photosensitive materials. We are certain that with these facilities we will be able to provide the kind of quality that satisfies our customers.
This factory has 110 employees and with their average age under 30, this is a young factory. With the steady advance of semiconductor integration, we will tackle production with "fair, proactive, and rapid" always in mind.
