Nihon Matai Co., Ltd.

Comprehensive Materials for Logistics
Nihon Matai offers suggestions in a consistent style covering the phases from design to production in accordance with customer needs. We are also ready to offer customized products that are best suited to customer applications. Further, Nihon Matai realizes comprehensive logistics that are environmentally friendly by using corrugated paperboards and paper cores.

Nihon Matai’s products Dan-Pallet, Roll Container, and Dan-Spacer are all manufactured by using materials with a 100% material recycling rate. Thus, we offer consistent suggestions covering the phases from design to production in accordance with customer needs. Further, we can custom design products that fit cargos to be loaded and the weight and transportation conditions of such cargos according to customers’ needs. We run production bases in both Japan and overseas countries and are determined to continuously make suggestions and supply environmentally friendly materials for logistics, thus contributing to a recycle-based society in the future.

Product Lineup

?Dan-Pallet (Paper Core Type, Block Type)
Dan-Pallet was developed from the viewpoint of conservation of nature and the environment and is now playing an active part in global logistics scenes.

For the purpose of strengthening import quarantine restrictions, maintaining the viewpoint of conservation of nature and the environment, introduction of pallets using new raw materials substituting wood is being promoted today. Nihon Matai’s corrugated paperboard Dan-Pallet that was developed by utilizing our superb processing technologies is now expanding needs in global logistics scenes with 100% recyclable products, featuring superb strength and not requiring fumigation.

For such needs as:

- Solving the issue of fumigation
- Design according to customer specifications
- Delivery with short lead time

● Pallet for grouped packing
Block type of products wherein the block size can be altered according to packing specifications are also available.

Advantages

The pallet is free from vermination and generation of bacterium and does not require fumigation.
Since materials other than paper are not used, the pallet is 100% recyclable as genuine recycled waste-paper.
Weight of the pallet is 1/3 the weight of the wooden pallet, significantly increasing workability.
Injuries of workers caused by nailing or fine wooden splits and damages on cargos is not a concern.
The patented structure incorporating the paper core in corrugated paperboard achieved higher shock resistance compared to the conventional type of corrugated paperboard pallets.

Main Specifications

Paper core type: Paper cores used for beams
Block type: possible to make a Flexible design in accordance with sizes of goods to be loaded
Unit type: (Has a resistance to unbalanced loads and is applicable to mobile goods, such as powder bags
Log pallet Recyclable pallet made of paper cores

● Paper Core Type

Standard size	1100 mm × 1100 mm Pallets can be manufactured in desired sizes pursuant to customer request.
Paper core	126φ × 9 pieces; Top plate: 2 sheets; Bottom plate: 2 sheets Spacing between paper cores can be adjusted pursuant to customer request.
Paper core size	83 mm, 126 mm
No. of paper cores	4 to 16 cores can be attached
Material	ABF K220/MM180/SCP160/MM180/K220
Others	By combining the pallet with corrugated paperboard boxes, the pallet itself can be used as a transportation tool.

● Block Type

Standard Sizes (Beam Strength)
140 mm × 160 mm × 100 h	Max. strength	986kg
150 mm × 300 mm × 90 h	Max. strength	1,510 kg
200 mm × 300 mm × 90 h	Max. strength	2,030 kg

Loading test of a 1,200 kg FIBC bag

Lifting test of a 1,200 kg FIBC bag

Fork insertion slots

Roll Container

Roll containers are innovative pallets for transportation use, substituting conventional steel racks and wooden crates with feature of buffering effect of rolled products. Since all materials of Roll Container consist of corrugated paperboards, Roll container is 100% recyclable . The integrated design with a pallet contributes to the streamlining of work.
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Advantages

Flexible use in accordance with roll diameter;
Stacking is possible;
Product-friendly because loads can be applied evenly on the product;
Achievement of cost reduction;
Easy disposal;
Easy to open the packing;
No fumigation required.

Setting Procedures

1. Exploded status of the roll container?

2. Start assembly

3. Set alignment-setting to the center

4. Place the film roll at the center

5. Set side plates at the front and back

6. Cover the plate with the exterior box

7. Apply a gum tape on top of the exterior box

7. Apply a kraft tape on top of the exterior box

Roll Box

This is a pallet to transport or store rolled products that are lifted in Midair for transportation . Because components of the pallet are assembled for use and roll Box Ras a structure that offers pallet function, Roll Box enhances transportation/storage efficiency.

Advantages

The pallet is assembled as required for use, contributing to space saving during transportation and storage;
The pallet can be designed according to roll sizes and weights;
Stacking is possible;
No fumigation is required.;
Easy disposal
Achievement of cost Reduction.

Assembly Procedures

Components
Top plate
Bottom plate
Support plate
Spacer

Assembly 1
Bend the bottom plate into a U-shape and insert the support plate into the groove on the bottom plate.

Assembly 2
Insert the other support plate onto the bottom plate (as described in Assembly 1 above).

Assembly 3
Place the product (roll) on the pallet. Then, insert spacers at both sides of the support plates to limit movement of the roll.

Assembly Completed
Top plate
Finally, place the top plate.

DAN Pallet for packing accumulated rolls　 DAN CHEST

This is a pallet for packing rolled products by standing, laying, or hanging.

DAN CHEST is a corrugated cardboard pallet for transporting and storing rolled products. The amount of the corrugated cardboard used can be reduced by standing, laying, or hanging multiple rolled products from states where the individual packing of rolled products in corrugated cardboard boxes are stacked or rolled products are laid and stacked as they are. This also significantly improves the efficiency of operations and loading.

Features

The assembly time can be shortened. The number of workers required for assembly can be reduced.
Since the product can be stacked, loading efficiency can be improved and space can be saved.
The packing operability can be improved and parts can be used repeatedly.
Since the product is made of paper and no adhesive tape is used, it is easy to recycle the material.
The product can be designed flexibly to fit the roll dimensions, weight, and specifications.
It is possible to provide optimum specifications for standing, laying, or hanging.
A single type of pallet can be shared for rolls with different widths.
It is possible to reduce the resource consumption of packing materials. (The amount of the emitted CO2 can be reduced compared to ordinary specifications.)

Reduced amount of packing material in comparison with our ordinary products.
Example: To pack 80 rolls of 240φ × 150 L roll (core width: 180 mm)

Amount of corrugated cardboard to be used

Ordinary product (2 rolls/box)	：	46.8㎡
DAN CHEST (vertical alignment)	：	20.3㎡ (excluding DAN Pallet)

The amount of the used corrugated cardboard per square meter can be reduced by about 57% from the ordinary product
If the total amount of corrugated cardboard used annually is 80,000 pieces, about 422 tons of emitted CO2 can be reduced (when manufacturing corrugated cardboard).

Specifications

Standing	Laying	Hanging

Uses

For transporting/storing films

Roll hanging simple type DAN pallet　DAN LOAD

DAN pallets for transporting/storing rolled products by hanging them

DAN LOAD is a DAN pallet for transporting/storing rolled products by hanging them. This product is designed for easy assembly and removal, so that packing operations can be simplified and save resources for the materials used.

Features

The product will be supplied as components (DAN pallets, Supporting board, Covers and Spacers etc), so that it can be assembled easily.
The ground paper and the cover are combined in a U-shape from the top and bottom sides, so that the product has a durable structure against shocks during transportation.
The product can support different rolled product standards (roll diameter, roll width and the number of units to be loaded).
ince the products can be stacked (the number of units to be loaded may vary with the specifications, for instance two-layer piling to four-layer piling), the loading efficiency can be improved and the required space for storing products can be minimized.
Since the product is made of corrugated cardboard, it is easy to recycle.
If products are packed with stretch films, the external case is unnecessary.

Uses

For transporting/storing electric materials and optical films

Standard roll specifications

Roll diameter	：	200φ to 800φ
Roll width	：	Max 1,600 mm
Roll weight	：	Max 400 kg/unit

* However, the roll specifications are standard values, and it is possible to provide any specifications according to product requirements.

Packing procedures

①Stand the U-shaped ground paper at the top of DAN pallet and insert the support board

②Unload the rolls on the support board.

③If rolls will be aligned in two lines, load the rolls on the other side.

④Set the partition to prevent slipping off the rolls.

⑤Set the U-shaped cover on it. Then you’re finished.

DAN SPACER

This product substitutes lumbers or air bags used for fixing products during transportation in marine containers. While giving the greatest importance to material recycling that does not require heat treatment, such as lumbers, DAN SPACER reduces impact loads on commodities with its lightweight and easy-to-assemble design, as well as its flexibility to loading space and stress-dispersing capabilities.

Advantages

Easy to assemble design; and
Paste (glue) and tapes not used, making assembling and disassembling work easier.
Recycling
Since DAN SPACER is made of paper (corrugated paperboards, paper cores), it is adequate for material recycling.
Flexible design
Since plane withstand load/space width can be easily modified, design specific to product weight and size is possible.
Reduction in impact load
Since the contacting area with the product is planar, stress forces can be dispersed to reduce impact loads on the product.
Promotion of efficiency
By assembling DAN SPACER just before loading the product, more efficient use of component storage space and transportation will be achieved.
Moisture resistance
DAN SPACER offers excellent moisture resistance due to the spiral structure and material employed for paper cores.
Weight saving
Due to the weight-saving design, DAN SPACER can be assembled and constructed by one person, leading to the reduction in transportation costs.

Assembly Procedures

① Exploded status of corrugated paperboard sheet.

③ Bend the sheet along the lines at both ends.

④ Turn the sheet over, put the protruded portions together, and insert them into the holes. Status should be that protruded portions are put together and inserted into the holes.

⑤ Assemble two sheets since they are used in a pair.

⑥ Place the first assembled sheet on the floor and insert paper cores.

⑦ Status should be that all paper cores are inserted into the first sheet. The case should be that six (6) cores are used.

⑧ Place the other sheet on the first sheet to accept the six (6) paper cores.

⑨ Cut out a hole into which an inner paper core is inserted.

⑩ Insert an inner paper core into the cutout hole over the sheet.

⑪ The end of the inner paper core should be flushed with the sheet surface (at both ends).

Completion
Insert the inner paper cores to the sheets at both ends of the paper cores, completing the assembly procedures.

Cargo-Safe Airbag

This protects collapsing of cargos and shocks to them during transportation. It offers superb workability, cost reduction, and easy disposal.

Advantages

Protection of products
Use of Cargo-Safe Airbag will completely protect important products during transportation in containers, by trucks, or by trains.
Speeding up the loading work
Use of Cargo-Safe Airbag will secure safety of products during transportation by speeding up the loading work.
Easy operations
A special paper made in Denmark is used. Two paper sheets are used in a crisscross pattern and both ends of the bag are bent and pasted up, thus assuring high compression strength.
High storage capability
Cargo-Safe Airbag can be folded for storage when it is not in use, thus requiring minimum storage space.
Deliverable in small lot
Cargo-Safe Airbag can be delivered in the minimum quantity of 25 to 50 sheets. The lead time is 4 to 5 days after acceptance of the order. (Order should be made in units of case.)
Range of maximum occupation space per sheet
25 cm to 45 cm

■ Table of Sizes

Model	Size (cm)	Max. Clearance (cm)	Type	Content (pcs.)	Carton Size (cm)	Weight/carton (kg)	Bursting Pressure at 20 cm (Internal pressure kgf／cm2)
CP-60／110	60 × 110	25	L	50	40 × 105 × 31.5	25.7	1.10
CP-60／110	60 × 110	25	M	40	〃	21.0	1.25
CP-85／120	85 × 120	37	L	45	40 × 105 × 31.5	33.8	1.10
CP-85／120	85 × 120	37	M	30	〃	23.2	1.20
CP-100／140	100 × 140	45	M	25	40 × 105 × 31.5	32.1	1.20
CP-100／160	100 × 160	45	L	25	40 × 105 × 31.5	32.0	1.00
CP-100／185	100 × 185	45	L	25	40 × 105 × 31.5	32.0	1,00
CP-100／185	100 × 185	45	M	20	〃	26.0	1,20
CP-100／220	100 × 220	45	L	25	40 × 105 × 31.5	37.0	1.00
CP-100／220	100 × 220	45	M	20	〃	30.0	1.20

Application Example

International Marketing and Sales Dept. International Business Division

Phone	81-3-3843-2192
Fax	81-3-5246-8746

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