SustainabilityEnvironmentWaste reduction and environmental conservation

Appropriate management of chemical substances

In accordance with the PRTR Law, we report the amounts of chemical emissions and transfers.

In fiscal 2024, TOCALO reported the amount of designated chemicals released into the environment and transferred for seven substances in accordance with the PRTR Law (Pollutant Release and Transfer Register: Chemical Substance Release and Transfer Notification System). The emissions met all regulatory standards under the act.

Waste Reduction

We are properly disposing of all types of waste, from general waste to specially controlled industrial waste.

• General waste
  Paper constitutes the majority of business-related general waste, and we are committed to reusing and recycling paper. When confidentially is an issue, we work with the paper manufacturers to dissolve materials chemically.
• Industrial waste
  Waste oil accounted for 34% of our industrial waste, which was the largest component. Waste oil emits from cooling water that is added to grinding oil for use as a coolant with wet grinders (machines for roll grinding). More than 90% of the water is tap water. After disposal, it is used at cement factories and elsewhere to adjust combustion temperature.
  Sludge made up 26% of our industrial waste, waste alkali 10%, mixed waste 9%, while slag, waste plastic, and glass and ceramic scraps accounted for 6% each.
  The majority of the sludge and waste alkali is waste liquid after cleaning, and most of it is water. We plan to install a system to distill and filter this water for reuse.
  Mixed waste is defined as a mixture of several types of waste that is difficult to sort.
  Slag refers to residue thermal spray material, such as waste blasting material and collected fumes.
  Waste plastics include material containers and secondary materials, as well as waste paper and wood scraps that contain oil.
  Glass and ceramic scraps, such as refractory bricks, contain ceramic-based grinding materials that cannot be recycled.
• Specially controlled industrial waste
  Most of this waste is dust generated by thermal spraying using chromium-containing materials (such as stainless steel) and collected by a dust collector. When the dust volume exceeds the regulatory limit in dissolution tests, it is disposed of as specially controlled industrial waste.

VOICE

Creating a virtuous cycle for the environment and our business through the reduction of waste oil

Toshiro Izumi
Machining Process Department 2, Production Division 2, Akashi Workshop.2,Akashi Plant

My work at the Akashiharima Plant primarily involves machining (processing work that involves the use of machine tools), and I am also responsible for equipment maintenance. My day-to-day tasks include management of the water-soluble grinding oil used in the grinding process for semiconductor manufacturing equipment components (thermal sprayed parts). Grinding oil deteriorates with continued use and must be regularly replaced. This results in the discharge of waste oil, which must be handled appropriately by a wastewater treatment company, using oil-water separation, filtration, and other processes.

In the past, we generated around 360 tons of waste oil each year. This resulted in a significant workload for maintenance staff, since we had to arrange for the disposal and transportation of the waste oil and handle associated administrative tasks.

In 2023 we installed a new treatment system with the aim of enhancing the efficiency of waste oil disposal. The new system slashed the amount of waste oil volume generated each year by 95%, from 360 tons to just 18 tons. In addition, we were able to cut waste oil treatment and transportation costs by around 50%, while also lowering CO2 emissions. Our operating efficiency was further improved through the reduction of administrative tasks relating to waste oil collection.

I take great care to ensure that the treated wastewater discharged from our waste oil treatment systems is within the wastewater standards set by the local government. I keep the system operating normally by regularly replacing and cleaning consumable parts, and I analyze treated wastewater at appropriate intervals to verify its safety.

We are now exploring ways to cut waste still further by preventing contamination of the grinding oil during use, in order to reduce both treatment loads and the frequency with which consumable parts are replaced. Going forward, we will look at the possibility of implementing these improvements at other business sites. We will also work with thermal spraying and grinding staff to reduce material and energy losses by optimizing the thickness of thermal spray coatings. We will continue our efforts to protect the environment and achieve company-wide waste reductions.

TOPICS

Introducing translucent clear paper files

We produce clear file folders printed with our corporate mascot. The folders used to be made of transparent plastic, but to reduce the impact of plastic on the environment, in fiscal 2022 we started producing semi-transparent file folders made of paper.

We wanted a material that would provide the benefit of plastic’s transparency and the environmental friendliness of paper, and came up with the idea of making file folders using semi-transparent tracing paper.

We started by trying the folders in-house, and now are sharing them outside the Company, such as by inserting them in the pamphlets we give out at exhibitions.

We have produced a cumulative total of 10,000 of these folders. This initiative has reduced CO2 emissions by approximately 858 kg compared with plastic folders.

The clear paper file folders are even better than plastic folders in many ways because they last longer and are stronger. Every day, we are thinking of ways to make the ideal folder that is easy to use and good for the environment. The clear paper folders are giving us more opportunities to think about what we can do to protect the earth.

Air pollution prevention

Dust generated in the thermal spraying process is safely collected before it can be released into the atmosphere.

TOCALO's main products modify surfaces by way of thermal spraying, which uses powder or wire as a material. The material is fed into a combustion flame or plasma jet, where it is melted and then sprayed to form a coating.
Powders that did not melt or did melt but were not deposited when sprayed become dust. Dust collectors collect the dust before it can be released into the atmosphere. (Photo)

Thermal spraying is a dry process and the collected dust is mostly dry, so there is no need for waste liquid treatment. A duct draws the airborne dust in a thermal spray booth into the dust collector where it is filtered with internal filters made of woven and nonwoven fabrics. The fine layer of dust that collects on the filter surface becomes thick can clog the filter, causing the filter to lose suction pressure and reducing the efficiency of the dust collection. Using a pulse jet, compressed air is used at regular intervals to remove the dust and maintain process efficiency.

Dust that can be reused is recycled, and dust that cannot be reused becomes industrial waste.
As of the end of fiscal 2024, we have not confirmed the generation of sulfur oxide (SOx) from our operations.

Soil and water pollution prevention

Soil and water pollution prevention is particularly critical because soil and water quality directly affect surrounding communities.

Processes at the Kobe Plant use surface modification technologies other than thermal spraying. Wastewater that requires detoxification treatment is detoxified at a coagulating sedimentation treatment facility prior to being discharged into the sewage system. When discharging wastewater, we rigorously comply with quality standards established as water pollution indicators.

As a precaution for an accidental leak of wastewater, the plant has installed pipes and concrete walls to prevent and quickly and visually detect leaks. Anti-spreading materials are also in place to prevent leaks from spreading. In addition to periodic monitoring and measurements, the equipment is controlled by a rigorous system compliant with applicable laws and regulations.

Noise countermeasures

Noise barriers have been installed and noise measurements are also carried out regularly.

The main types of equipment that generate noise of a concerning level are air compressors, dust collectors, and other blowers. However, in addition to this equipment, there are other noise sources, and we are taking steps to avoid disturbing the neighborhood by implementing soundproofing measures such as installing these facilities inside buildings and installing special soundproof walls.
In addition, we regularly measure noise levels to ensure that our facilities and equipment are within regulatory limits.

Reduction of water usage

We are actively working to reduce water consumption by collecting and storing water in underground tanks for reuse.

Our surface modification processes primarily use a dry method, which requires a minimal amount of water. The Kobe Plant uses a certain volume of water for cooling and cleaning purposes. The system, which previously drained water from the nitrogen cooling tank, has been modified to collect and store the discharged water in an underground tank for reuse in the cleaning tank. We are committed to reducing water usage and using water resources efficiently and with consideration of the environment.

Supporting environmental organizations

TOCALO has begun actively supporting the following environmental organizations as another way to help protect the global environment through our activities. We are providing support for greening, protecting biodiversity, and other environmental activities.

In May 2024, we donated ¥500,000 yen to the Green Fund managed by the National Land Afforestation Promotion Organization.
The Green Donation Funds is used for forest maintenance in communities in Japan and overseas as well as for disaster relief, forest environment education, and to support greening efforts overseas. We will continue to support efforts to promote forest conservation and greening both in Japan and overseas.

In August 2025,TOCALO contributed ¥200,000 to WWF Japan.

You can find out more about TOCALO’s contributions to society at the following links. ​​
For further information, click here:

Green Donation Funds:https://www.green.or.jp/english/​