A Landmark in Sustainable Food Production
Calbee, Inc. has unveiled its cutting-edge Setouchi Hiroshima Factory, marking the company’s first new production facility in Japan in nearly 19 years. Slated to begin operations on January 13, 2025, this factory embodies Calbee’s commitment to sustainability, automation, and innovation. By integrating advanced digital transformation (DX) initiatives and eco-friendly energy solutions, the facility aims to revolutionize the potato processing industry in Japan.
Pioneering Sustainability in Potato Processing
The Setouchi Hiroshima Factory is a ‘mother factory’ designed with a vision of bringing smiles to people while benefiting the planet. Calbee has committed to minimizing its environmental impact by employing a circular energy system that reuses waste heat, wastewater, and potato residues.
Key environmental goals include:
- 50% reduction in CO2 emissions compared to the Hiroshima-Nishi Factory.
- 50% decrease in waste output through biomass energy solutions.
- 30% reduction in water usage, with water recovery and reuse during production.
- 100% reliance on CO2-free electricity, using renewable energy sources.
A standout feature of the facility is the biomass boiler system, which converts potato residues into biogas through methane fermentation. This biogas will generate steam, which will be recaptured and reused within the plant, creating a closed-loop system that significantly reduces emissions and energy waste.
Advanced Automation and Digital Integration
In a push to modernize production, Calbee has incorporated cutting-edge automation and IoT-driven technology at the Setouchi Hiroshima Factory. These advancements are expected to increase labor productivity by approximately 60% per employee.
Key technological enhancements include:
- Automation of potato preprocessing, including inspection and trimming.
- Automated transport of raw materials and packaging, reducing manual handling.
- Remote monitoring of production lines, allowing for real-time adjustments and operational oversight.
- Elimination of handwritten documentation, reducing human errors and inefficiencies.
By leveraging digital tools, Calbee aims to optimize small-batch production while maintaining strict quality control, ensuring consumers receive the highest-quality potato products.
Employee-Centric Design for a Better Workplace
Calbee has prioritized employee well-being by designing a workplace that fosters comfort and productivity. Located facing the scenic Seto Inland Sea, the factory includes amenities such as:
- Well-lit cafeterias and break areas with panoramic views to create a pleasant work environment.
- Ergonomic workplace solutions, reducing heavy lifting and physical strain.
- Enhanced safety measures, ensuring a secure and inclusive environment for employees.
Strategic Growth and Future Expansion
The Setouchi Hiroshima Factory is part of Calbee’s broader Change 2025 growth strategy, which aims to optimize Japan’s supply-demand balance and enhance efficiency across its supply chain. In addition to this factory, Calbee has plans to develop another next-generation facility in Shimotsuma City, Kanto, further solidifying its leadership in the potato processing sector.
Calbee’s Setouchi Hiroshima Factory represents a milestone in sustainable food production, combining eco-friendly innovation with cutting-edge automation. As the company continues its expansion, this facility sets a new industry standard, showcasing how technology and sustainability can work hand in hand to create a more efficient and environmentally responsible potato processing industry.
