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Sakai Plant (Kanaoka Factory, Rinkai Factory)

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The Sakai Plant has two factories: the Kanaoka Factory and the Rinkai Factory.

Sakai Plant Certified as Super Green Heart Factory

In all of us, a green heart

In November 2011, the Sakai Plant was certified as a Super Green Heart Factory. This was the result of all employees making that all important extra effort and working together to systematically reduce environmental impact while strengthening relations with society.

Super Green Heart Factory:
The system was introduced in fiscal 2006 to certify factories with outstanding environmental performance as Green Heart Factories. Plants that score at least 95 points out of 100 on seven criteria including reduction of environmental impact and relations with the local community are designated as Super Green Heart Factories.

Kanaoka Factory

Address 1304 Kanaoka-cho, Kita-ku, Sakai, Osaka 591-8511, Japan
Site area Approx. 117,000m2
Completed February 1963
Employees 1,702
Main products Air conditioning/refrigeration equipment
ISO 14001 certified December 1992
Latest ISO 14001 update March 24, 2010
Bird's-eye view of Kanaoka Factory Bird's-eye view of Kanaoka Factory
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Products manufactured at Kanaoka Factory

The factory manufactures mainly air conditioning-related products for commercial use.

Commercial air conditioning systems

Conveni-Pack: Freezing, refrigeration, and air conditioning heat recovery system for convenience stores

Commercial air conditioning systems   Conveni-Pack: Freezing, refrigeration, and air conditioning heat recovery system for convenience stores

Air conditioner and spot air conditioner for commercial facilities

 

Medium- and low-temperature air conditioner

Air conditioner and spot air conditioner for commercial facilities   Medium- and low-temperature air conditioner

Air purifier, deodorizer

   
Air purifier, deodorizer    
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Rinkai Factory

Address 12 Chikko Shin-machi 3-chome, Nishi-ku, Sakai, Osaka 592-8331, Japan
Site area Approx. 90,500 m2
Completed October 1978
Employees 353
Main products Air conditioning/refrigeration equipment
ISO 14001 certified December 1992
Latest ISO 14001 update March 24, 2010
Bird's-eye view of Rinkai Factory Bird's-eye view of Rinkai Factory
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Products manufactured at Rinkai Factory

Air conditioner and full heat exchanger for stores and offices

Full heat exchanger

Air conditioner and full heat exchanger for stores and offices   Full heat exchanger

Compressor

   
Compressor    
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Energy Saving

SEe Power Source Management Panel Shows How Energy is Used

Environment Practice Hall

Innovative Transport

SEe Power Source Management Panel Shows How Energy is Used

SEe Management Panel, a sign with the manager's name on, is put up at the facilities during operation. This panel gives a visual representation of the facilities' operation, allowing excess energy to be cut and manufacturing to be carried out using only the amount of energy that is needed.

Environment Practice Hall

In the spring of 2009, we established the Environment Practice Hall, a place where all employees can acquire environmental knowledge and raise eco-awareness, as well as learn how to find where energy can be saved.

Innovative Transport

This room is rigged so that by placing parts in their set location, they are sent with the proper part trollies without the need to use any electricity.

Using Natural Energy

LED Outdoor Lighting

Installation of Solar Power Panels

Using Natural Energy

Employees made wind and water power systems that use the airflow from plant ventilation fans and water level differences. The power generated is used for the parts transport trollies.

LED Outdoor Lighting

The outdoor lighting that guides customers arriving at the factory entrance was converted to LED.

Installation of Solar Power Panels

Solar power panels that have been installed on the factory roof generate approximately 20,000 kWh a year. This electricity is used to run the lights in the canteen and to power development of a water heating system in the plant's R&D building.

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Waste Reduction

Achieved Zero Waste Emissions

Achieved Zero Waste Emissions

Achieved Zero Waste Emissions

In August 2001, the Sakai Plant achieved zero emissions (recycling ratio of at least 99.5%).

3Rs Practice Hall

Weighing System

3Rs Practice Hall

The production division established the 3Rs Practice Hall in 2009. Participants take the waste that comes off the production lines and think about how to reduce this amount by either recycling, reusing, reducing, or eliminating it altogether.

Weighing System

Unnecessary items are divided into 20 categories for recycling. Each workplace weighs the items and thinks of ways to prevent these waste items from being generated in the first place.

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Preventing Air and Water Pollution

Atmosphere-Friendly Equipment

Continuous Monitoring of Wastewater

Atmosphere-Friendly Equipment

The plant has introduced low NOx boilers that emit fewer pollution-causing nitrogen compounds than conventional boilers.

Continuous Monitoring of Wastewater

Plant wastewater is concentrated into one location where it is purified. Based on in-house standards stricter than government regulations, the wastewater is monitored 24- a day, every day of the year to ensure that measurement figures for criteria like COD and pH do not exceed standard values.

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Preparing for Emergencies

Emergency Shed

Drills for Water Quality Emergencies

Soundproof Walls

Emergency Shed

Emergency materials are stored inside a special shed in case of disasters such as earthquakes, fires and chemical substances leaks.

Drills for Water Quality Emergencies

Drills are held twice a year to prevent chemicals and other substances from flowing into storm drains during natural disasters.

Soundproof Walls

The plant constructs soundproof walls around its perimeter or at high locations, and has voluntary noise standards stricter than noise laws. Windows have been placed in the walls to avoid creating a feeling of being closed in, and trees have been planted for aesthetic purposes.

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Greening the Plant

Planting Grass on Playing Fields

Planting Grass on Playing Fields

Planting Grass on Playing Fields

Planting Grass on Playing Fields

We are aiming to create an environmentally friendly facility by having employees plant grass on the playing fields. When sporting events are held (sports day, for example), employees and their families spread seeds over the field, and everyone participates in the monthly maintenance of the playing fields.

Creatures congregate on the grass

Creatures congregate on the grass

Creatures congregate on the grass

Green Wall

Green Wall

Green Wall

The tennis courts at the Kanaoka Factory have a 'green wall' of vegetation. This wall uses hedera helix, a type of ivy ideal for such green walls.

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Exchange with Local Communities

Summer Festival

 

Exchanges

Summer Festival

Every August, a Noryosai Bon dance festival is held to allow plant employees to interact and enjoy with local residents. The 2010 event was attended by about 11,000.

 

Summer Festival

As well, young employees and local elementary school students take the stage to excite the crowd with 'yosakoi soran', a type of modern festival dance.

Exchanges

Every July, an exchange is held with the neighborhood association. By listening to opinions that the association has about the plant, Daikin strengthens bonds with the local community.

Rugby School

Factory Tours for Elementary Schools

Work Experience for Junior High School Students

Rugby School

The plant field is open for use by the Sakai Rugby Club three times a month. This contributes to the growth and development of about 130 students in elementary and junior high school.

 

Factory Tours for Elementary Schools

For more than 20 years, the plant has been helping elementary schools with their open learning classes by inviting grade 5 students from local elementary schools to tour the factory.

Work Experience for Junior High School Students

For about 10 years, the plant has been inviting junior high school students to come and try using the actual tools used in production processes and get first-hand experience at a manufacturing site.

Earthquake Simulations

Local Cleanup Activities

Earthquake Simulations

A special truck with an interior that can simulate an earthquake was at the annual summer Bon Dance to let people experience what an actual earthquake is like. This is one way Daikin contributes to disaster preparation.

Local Cleanup Activities

Once a month, all employees take their turn picking up litter on the streets around the plant site. June 2010 was Environmental Month, when employees picked up litter in a nearby playground for children.

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Social Contribution

Actively Volunteering in Publicly Sponsored Activities

The Sakai Plant took part in tree-planting in the Forest of Coexistence, a project to create green space in the Rinkai area of Sakai City. It also played an active role in a purse-snatching prevention campaign sponsored by the local crime prevention association by providing bicycle carriage covers and promoting awareness of purse-snatching. (The Sakai Plant received letters of appreciation for both of these efforts.)

The Forest of Coexistence in Sakai

The Forest of Coexistence in Sakai

Letters of appreciation

A purse-snatching prevention campaign

A purse-snatching prevention campaign

A purse-snatching prevention campaign

Letters of appreciation

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Environmental Performance Data

Click the graph to enlarge it.

Energy Consumption

Energy-Induced CO2 Emissions

Energy Consumption   Energy-Induced CO2 Emissions

Greenhouse Gas Emissions Other than CO2

 

Release of Substances Designated by PRTR Law

Greenhouse Gas Emissions Other than CO2   Release of Substances Designated by PRTR Law

Water Used/ Waste Water

 

Amount Disposed of and Amount Recycled

Water Used/ Waste Water   Amount Disposed of and Amount Recycled

Release and Transfer of Chemical Substances (PRTR)

Unit: kg
Substance name Amount emitted Amount transported
Air Public waterways Soil Waste Sewage
Toluene 2,754 0 0 4 0
Chlorodifluoromethane (also called HCFC-22) 97 0 0 4,180 0
Xylene 643 0 0 3 0
Ethylbenzene 244 0 0 0 0
Water soluble lead compounds 0 0 0 760 0
total 3,738 0 0 4,947 0
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Kanaoka Factory

Air Pollutant Measurements

  Unit Facility name (Legally designated facility) Law regulation value Voluntary standard value Actual average value Actual maximum value Measurement frequency
SOx Nm3/h (N/A)
NOx ppm Boiler1-12 150 60 44.5 46 Twice/year
Boiler1-2A 150 46 30.5 32 Twice/year
Boiler1-13 150 53 35.5 36 Twice/year
Boiler1-4A 150 53 36.5 37 Twice/year
Boiler1-6 150 53 39 39 Twice/year
Boiler1-7A 150 60 23.5 24 Twice/year
Boiler1-8A 150 60 25 25 Twice/year
Boiler1-9A 150 60 25 25 Twice/year
Boiler1-10A 150 60 25 25 Twice/year
Boiler1-11A 150 60 25 25 Twice/year
Boiler1-14 150 60 24.5 25 Twice/year
Boiler1-15 150 60 35.5 36 Twice/year
Dust g/Nm3 (N/A)

Water Pollutant Measurements

  Unit Facility name Law regulation value Voluntary standard value Actual average value Actual maximum value Measurement frequency
COD mg/l General wastewater outlet Analysis 15 2.7 4.3 Once/month
BOD mg/l 300 25 2.2 4.1 Once/month
Total nitrogen mg/l 240 50 8.9 21 Once/month
Total phosphorous mg/l 32 3 0.131 0.2 Once/month

Noise and Vibration Measurements

  Unit Measurement location Law regulation value Voluntary standard value Actual average value Actual maximum value Measurement frequency
Noise dB Day Plant perimeter 65 54 45 54 Once/month
Night 55 44 41 44 Twice/year
Vibration dB Day 65 59 24 35 Once/year
Night 60 54 17 24 Once/year
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Rinkai Factory

Air Pollutant Measurements

  Unit Facility name (Legally designated facility) Law regulation value Voluntary standard value Actual average value Actual maximum value Measurement frequency
SOx Nm3/h (N/A)
NOx ppm No. 1 boiler 150 80 28 28 Twice/year
No. 2 boiler 150 80 33.5 34 Twice/year
Drying furnace No. 2 (12-1-1) 230 130 72 110 Twice/year
(SCW compressor, coating facility) 230 207 23.5 27 Twice/year
Dust g/Nm3 (SCW compressor, coating facility) 0.001 0.001 Once/year

Water Pollutant Measurements

  Unit Facility name Law regulation value Voluntary standard value Actual average value Actual maximum value Measurement frequency
COD mg/l General wastewater outlet Analysis 25 13.5 4.8 5.9 Once/month
BOD mg/l 25 13.5 4.2 7 Once/month
Total nitrogen mg/l 60 40 6.7 22 Once/month
Total phosphorous mg/l 8 2 0.22 0.5 Once/month

Noise and Vibration Measurements

No measurements since not covered by legal restrictions.
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