Taiyo Kogyo Launches Domestic Sales of "ROBAPS" Automatic Filling System

Automatic Filling System "ROBAPS"

Taiyo Kogyo Co., Ltd. (Tokyo Head Office: Setagaya-ku, Tokyo / Osaka Head Office: Yodogawa-ku, Osaka, President: Yuki Nomura), which handles large-scale membrane structures (tent structures), civil engineering, and logistics materials, will begin domestic sales of "ROBAPS" (Robaps), a system that automatically fills containers with raw materials such as powders and pellets, through an exclusive sales agreement with DYPN Co., Ltd. (Seoul, South Korea, CEO: Shin Seung-dae). Through the introduction of this product, we aim to achieve labor savings in filling operations in the logistics industry and support the improvement of working environments at filling sites. We aim for sales of 1 billion yen by fiscal year 2028.

In workplaces where dust is generated, such as in manufacturing, construction, recycling, and chemical/material-related factories, improving the working environment is a critical management issue. In environments handling dust, there is a possibility of health damage caused by inhaling fine particles during work. Therefore, based on the Industrial Safety and Health Act, the Ordinance on Prevention of Dust-related Diseases, and other regulations, various safety measures are implemented, including the installation of ventilation equipment and the wearing of dust masks and protective clothing (PPE). While dust masks and protective clothing are important for reducing dust exposure, those with higher airtightness and protective performance tend to place a greater burden on the body, which can lead to reduced workability and accumulated fatigue. Especially in summer or high-temperature environments, heat can build up, increasing concerns about the risk of heatstroke.

Furthermore, due to the declining working population against the backdrop of an aging society, there has been a chronic labor shortage in the manufacturing, logistics, and construction sectors. In sites with dusty environments, recruitment difficulties can arise due to the perception of "heavy physical burden" and "harsh working conditions," increasing the need for improved working environments from the perspective of securing and retaining personnel.

The automatic filling system "ROBAPS" that our company will begin selling automates the process from filling container bags with powders and pellets up to the sealing stage.

It is possible to reduce the number of workers required for conventional filling operations. The product is compatible with existing container bags and can fill up to 70 bags per hour. Since existing equipment such as weighing hoppers can be utilized as is, it is easy to introduce into existing lines, reducing the burden associated with equipment upgrades. It addresses the chronic labor shortage issue in workplaces where dust is generated, and contributes to creating a working environment that considers the safety and health of workers and improving operational efficiency.

Image of "ROBAPS" Automatic Filling System Filling Operation Image of "ROBAPS" Automatic Filling System Filling Operation

Benefits of Introducing the "ROBAPS" Automatic Filling System

Reduces physical burden on workers handling heavy objects

Reduces dust exposure, such as inhalation of dust and adhesion to skin and clothing

Labor savings through automation of filling operations

Improved work efficiency through automation of filling operations

Ensures stable filling quality

◇ Business Efficiency Improvement through Introduction of Automatic Filling Machine (Reference)

[Before Introduction]

3 to 5 workers per line for filling operations x 3 shifts = 9 to 15 people/day engaged in filling operations

[After Introduction]

Introduction of "ROBAPS" automatic filling system enables filling operations with 1.5 people x 3 shifts = 4.5 people/day

[Expected Effects]

Reduction of 4.5 to 10.5 workers per line per day

Overview of "ROBAPS" Automatic Filling System

Item

Specifications

Packaging Form

Pallet (sack)

Bag Shape

Round/Square

Lifting Shape

No restrictions

Inner bag presence

Either is acceptable (inner bag requires fixing)

Inlet diameter

~Φ500mm

Sealing (inner bag)

Flat seal

Sealing (inlet)

Automatic sealing with an in-lock tie

Contents

Pellets or powder

Capacity

30-90 bags/hour

Product Lineup:

Manual: Automates only the setting of container bags with a robot arm; filling and subsequent steps are manual.

Semi-Auto: Automates the setting of container bags with a robot arm and the filling operation; sealing is manual.

Full-Auto: Automates from setting container bags with a robot arm to sealing.

Future Development

We will promote the proposal of automatic filling systems, focusing on manufacturers handling powders such as resins, chemicals, and ceramic raw materials. By providing solutions that combine flexible container bags with automatic filling systems, we will contribute to improving productivity and creating a safe working environment. We aim for sales of 1 billion yen by fiscal year 2028 and will work to promote automation in the powder logistics field.

About Taiyo Kogyo's Logistics Business In 1963, Taiyo Kogyo began its logistics business after successfully developing flexible container bags suitable for the logistics of powders and granules such as synthetic resins, chemicals, food, and fertilizers. Initially used for feed transport, its applications gradually expanded to synthetic resins, chemicals, food, and more, leading the granular bag market to this day. In addition to manufacturing, our strength lies in reusable running types through cleaning and maintenance, and they are widely used in Japan as a logistics system with low environmental impact.

About Taiyo Kogyo Co., Ltd.

Taiyo Kogyo is a leading company in large-scale membrane structures with over 100 years of history. At the 1970 Japan World Exposition, we realized the world's first air-supported membrane structure with a low-rise (height-controlled) system that supported the roof solely by air pressure in the American Pavilion. Since then, we have participated in large-scale projects worldwide, including the construction of the Tokyo Dome's membrane roof and the Millennium Dome (now The O2 Arena) in London, one of the world's largest dome facilities. Furthermore, for the 2025 Osaka-Kansai Expo, we handled the design and construction of over 20 pavilions, supporting the creation of the Expo site. With membrane structure technology, which excels in economy, constructability, light transmission, and design, we are expanding our business into architectural projects such as sports and transportation facilities, as well as civil engineering, logistics, and environmental fields, supporting the safety and security of society.

Together with our group companies, including TSP Taiyo Inc., which handles event consulting, and Actio Corporation, which manages facilities, we will provide new value to society under the banner of "Softening the world. Warming the future.". https://www.taiyokogyo.co.jp/