Sharp Kameyama LCD Factory

Sharp Kameyama LCD Manufacturing Plant, the World’s most advanced production base for integrated manufacture of large LCD televisions. The Kameyama Plant (Kameyama, Mie Prefecture, Japan) is Sharp’s latest manufacturing facility for LCD TVs. With this plant, Sharp aims to create a business model that serves as the ultimate example of economic efficiency, social mindedness and environmental conservation.

Integrated LCD Production

The plant combines Sharp vast experience and knowledge in R&D and mass production, with 50 years of TV and 30 years of LCD — into a world-first, cutting-edge facility that carries out highly efficient integrated production of LCD TVs, from the manufacture of LCD panels to the assembly of final products. With a site area of about 330,000 m², the plant’s high-efficiency production lines eliminate wasted work and shorten production lead-time.

The plant produces the world’s largest mother glass substrates for LCD panels (Example yield per 1,500 x 1,800 mm substrate is six 37-inch wide format LCD panels). This enable Sharp possible to produce LCD models with even larger screen size and reduces production time and costs, responding to a significantly expanding large-screen LCD TV market.

Large Mother Glass Substrates

Green Factory

The Kameyama Plant has also been designed as a Super Green Factory, giving maximum consideration for the environment. Eliminating the transport of LCD panels between different plants means less packaging material is needed and less CO2 and nitrogen dioxide are emitted from transport vehicles. Sharp uses its existing environmental technologies as well as adding new technologies to dramatically reduce the burden on the environment.

• Installation of Cogeneration System Using LNG - A cogeneration system supplies the plant with about one third of its annual electricity and utilises waste heat for air conditioning. This reduces CO2 emissions by about 40% of the current level. LNG (liquefied natural gas) is supplied through pipelines, eliminating the need for tanker truck transportation.
• Installation of a Solar Power Generation System – The wall of the plant has about 600 photovoltaic modules.
• 100% Water Recycling in the Production Process – The plant collects all the wastewater from the production process (max. 9,000 tons a day) and recycles it with water purification techniques using microorganism treatment.
• Zero Discharge to Landfills – For process waste as well, the plant is designed to achieve zero discharge to landfill, by reducing discharge and reusing and recycling as much waste as possible with diverse technologies and know-how.

Currently, the Sharp LCD plant at Kameyama is putting nut to bolt at a frenetic pace, cutting out all sort of series LCD panels from 8th generation mother glass. A note about LCD generations for the uninitiated: the term ‘generation’ corresponds to the size of the mother glass out of which LCD panels are cut.

Factory snapshots
Kameyama LCD factory was a mammoth techno complex. State-of-the-art automated robots and conveyor belts populated the place, and the intricacy and neatness was impeccable.

Energy Supply System of Kameyama Plant

Sharp Kameyama Plant Facts

LCD TV Test Facility

Anti Earth Quake System

Sharp Memorial Hall In Kameyama

Thin-film Solar Cells Covering Windows of Building