June 28th, 2019

[Interview Report]
Tokyu challenges global automobile market with IHI centrifugal compressors.
The combination of high efficient three-stage centrifugal compressor "TRA series" and IHI
group control panel greatly reduced unload time and realized the best energy saving
operation.

Tokyu Co., Ltd., Inuyama plant, Japan
Tokyu Co., Ltd. was founded in 1941 as a company that manufactures sewing machines andtextile machineries. Today, as a wholly owned subsidiary company of Toyota Industries
Corporation, Tokyu has covered various business field which mainly engaged in twobusiness, the automotive parts business including aluminum forged parts such as pistons,swash plate, shoes etc. used in car air conditioner compressor and industrial machinery
business of own brand including casting machine, special machine and casting plant design.

Compressor is the heart of car air conditioner and indispensable part for a safe, secure andcomfortable car life and Tokyu has manufactured important functional parts of it. These
parts are installed in Denso car air conditioners adopted by automobile manufacturers allover the world, and Tokyu’s parts are installed in over 40% of cars all over the world.
Tokyu’s plastic processing technology (aluminum forging and precise press technology) is
improved for future market needs such as downsizing and weight reduction as well as
enhancing quality that satisfies current market needs. In particular, the production volumeof aluminum forged parts amounts to approx. 12,000 tons per year, which dominates top
market share in Japan.
In addition, Tokyu’s technology is utilized even for cast products that often requirecomplicated shapes. The strength is comprehensive engineering that offers optimum
casting machines, special casting machines and plant design through analysis of work
environment of the casting factory, installation space and production volume. The flaskless
automatic molding machine "AMF Series" is a best-selling model exceeding the cumulative
production number of over 500 units because it produces castings of high quality and highprecision and is space-saving design.

You can find voice of customer about background and operation results when Tokyu
installed IHI three-stage centrifugal compressor “TRA series” in 2017 from following
page.

1. [Background] Necessity of stable operation and energy saving
Inuyama plant was established in 2001. We had used 5 centrifugal compressors for manyyears, totaling 1 unit of 200kW, 3 units of 340kW, 1unit of 400kW as the driving source ofmachining machines. In recent years, the amount of consumed air had been increased tocatch up production volume, all compressors had been operated without standby machines.
Fortunately, there had been no serious trouble, but we had a risk of stopping production if
any failure is occurred with even 1 unit.
We began studying basic renewal plan of compressor system which has standby machines
by replacing 3 units of old 340kW centrifugal compressors because which were discontinued
compressor model of production so that we were concerned future supply of maintenanceparts.
In addition, it was also a problem that the compressor occupied a high proportion of 34% in
the total power consumption of factory. Raising the electricity cost quickly reflects toproduct cost. Energy saving of compressors was a big issue in terms of efforts to reduce
factory costs. Furthermore, Toyota Industries group had set the reduction targets for Co2
emissions in recent years. We decided to consider plans with emphasis on energy saving
effects when introducing new compressors.

2. [Plan] Pull out maximum energy saving with TRA
We firstly thought about having standby machines by increasing size of compressor from340 kW to 400 kW, and increasing total air flow. TRA series was a state-of-the-art 3-stagess
centrifugal compressor, and we were able to expect significant energy saving by justreplacement because of much better specific power.
In addition, we received suggestion from IHI that improves compressor controlling.
Originally, compressor room was divided into two, and each compressor was operated
individually, so that 1 unit of 340 kW had repeated load and unload for capacity controlling
before. According to the proposal of IHI, we expected unload operation time can be reducedby combination of group control panel and synchronous capacity control of inlet guide vane,so that we decided to install group control panel too.

3. [Results] Energy saving effect by 6% and truly stable operation
As a result of installing 3 units of TRA series, we are very satisfied that we successfullyreduced electricity power consumption by 6% as well as we had calculated the effect with
IHI before installation. Normally we have operated 4 units of centrifugal compressor during
daytime and there have been almost no unload operation time thanks to the combination ofgroup control panel and synchronous capacity control of inlet guide vane.
We have done maintenance suggested from IHI according to the state of compressor every
year and we have never met serious trouble, so far we trust IHI's after sales capability verymuch.
In addition, we have asked IHI not only compressor, but also arrangement of other facilities
in compressor room (e.g. piping, cooling tower, pump and others) for long time. We wereable to install TRA series with certain confidence because we trust IHI engineering capability
too.

3 units of “TRA series” centrifugal compressors (400kW)

“TRA series” centrifugal compressors (400kW)“TRE series” centrifugal compressors (400kW)

IHI Group control panel
According to the signal from pressure transmitter on air tank in compressor room, groupcontrol panel controls every inlet guide vane of centrifugal compressor to follow fluctuatedproduction capacity.

4. [Future vision] Realize further energy saving
Energy consumption of compressors has been reduced significantly, but it has still occupieda high proportion of over 30% in the total power consumption of factory.
We hope to work together to reduce power consumption continuously with IHI. Even at ourside, we will promote policies that will make energy saving for compressors, such as
reducing the amount of air used at factory and reducing discharge pressure. We hope IHI
continues to develop more energy-saving compressors and better operation way.
(Interview date: December 14th, 2018)Please find information of TRA series centrifugal compressor from here.

[Company Profile]
Name: Tokyu Co., Ltd.
Foundation year: October, 1941
Address:
Head office: 1-60, Yono, Ooguchi-cho, Niwa-gun, Aichi, Japan
Inuyama plant: 1-6, Shinkawa, Inuyama city, Aichi, Japan
Website : http://english.tokyu-jp.com/[Products]

Variable Capacity Compressor Piston

Variable Capacity Compressor Shoe

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