Calbee opens next-generation Potato Processing Factory in Setouchi Hiroshima

Calbee, Inc. has announced that its newly constructed Setouchi Hiroshima Factory in Hiroshima City will commence operations on January 13, 2025. This facility is Calbee's first new factory in Japan in nearly 19 years. 

The Setouchi Hiroshima Factory is a cutting-edge ‘mother factory’ built around the concept of ‘a factory that brings smiles to people and the planet, shaping the future.’ By incorporating the latest in technology and design, it aims to achieve superior environmental performance, enhance productivity, and enhance the employee experience.

To minimize its environmental impact, the factory will utilize a renewable energy and a circular energy system that reuses waste heat, wastewater, and other forms of waste. Calbee aims to use this technology to reduce CO2 emissions by 50%, waste output by 50%, and water usage by 30% comparedto the Hiroshima-Nishi Factory. Furthermore, by sourcing exclusively renewable energy, the factory will operate entirely on CO2-free electricity, enhancing its eco-friendly footprint.

Regarding productivity, the Setouchi Hiroshima Factory will utilize advanced technologies, including the latest digital transformation (DX) initiatives, to enhance automation and implement labor-saving measures in production. By adopting a next-generation production model that incorporates IoT technology, the factory aims to improve quality control and enable efficient small-batch production of diverse products. In the future, this will also facilitate remote monitoring of production lines. These enhancements are expected to increase labor productivity by approximately 60% per employee.

Calbee is committed to enhancing its working environment with a focus on both safety and inclusivity. At the new factory, it will implement measures to alleviate the burden of heavy labor, ensure comfortable temperatures in facilities, and create facilities that accommodate diverse employee needs.

Makoto Ehara, CEO of Calbee:

"As part of our growth strategy, 'Change 2025,' Calbee is laying the groundwork for next-generation factories in Japan. We are excited to today announce the start of operations at the Setouchi Hiroshima Factory, which is located in our founding city of Hiroshima. Looking ahead, we aim to optimize the supply-demand balance across Japan and develop a more efficient supply chain alongside our existing facilities and the new factory planned for the Kanto area in Shimotsuma City."

Key Initiatives

1. “An Energy System that Uses Potatoes” – Introduction of Biomass Boiler Using Methane Fermentation and Waste Heat Recovery

By fully leveraging potatoes used in production for energy and other resources, Calbee aims to improve energy conservation, decarbonization, and waste reduction.

• Potato residues will undergo methane fermentation, which will be used as biogas to generate steam for use in the factory
• Water and heat will be recovered from the steam generated during the frying process. The recovered water will be used for washing potatoes, while the steam will be reused within the factory
• In the future, semi-finished product losses, such as burnt or broken pieces, will be able to be converted into biomass fuel to provide CO2-free steam, among other initiatives 

Left Image: Conceptual Chart of Energy System Utilizing Every Part of the Potato | Right Image: Methane Fermentation Tank, Desulfurization Equipment, and Gas Holder, etc.

2. "No Searching, No Carrying, No Mix Ups, No Writing by Hand, No Heavy Lifting" – Automation and Labor-Saving Initiatives Using Digital Technology  

Calbee will implement its next-generation production model utilizing IoT technology, as demonstrated at its Konan Factory. This model will achieve among the highest levels of automation in the industry, enabling a transition from conventional working methods.

• Automation of potato preprocessing, which includes inspection, trimming, and other processes
• Automation of transporting products, raw materials, and packaging materials
• Remote monitoring and connection of the production line, facilitating remote work in the factory  

Left Image: Automated Product Transportation Using Robots | Right Image: Raw Materials and Packaging Materials Transported by Automated Guided Vehicles (AGVs)

3. “A Vibrant and Motivating Workplace That Employees Are Proud of” – Combining Safety and Comfort

Leveraging its location facing the Seto Inland Sea, employee facilities, including the cafeteria and break spaces, will provide a comfortable environment with views and ample natural light.

Spacious facilities with a panoramic view of the Seto Inland Sea (left: balcony, right: cafeteria)

Factory Overview

Factory Overview