Built on the idea of ‘a factory that brings smiles to people and the planet, shaping the future,’ the recently constructed Calbee, Inc. Setouchi Hiroshima Factory is a state-of-the-art ‘mother factory.’

The first Calbee plant constructed in almost 19 years seeks to improve efficiency, improve the work experience, and achieve superior environmental performance by utilizing the newest design and technology.

It is estimated that the facility’s potato processing capacity will generate USD184.1m of products per year, mainly consisting of potato chips, Kataage potato, Jagabee, and Sapporo Potato.

“To minimize its environmental impact, the factory will utilize 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% compared to the Hiroshima-Nishi Factory. Furthermore, by sourcing exclusively renewable energy, the factory will operate entirely on CO2-free electricity, enhancing its eco-friendly footprint,” the company’s representatives mentioned.

To increase productivity, the Setouchi Hiroshima Factory will make use of cutting-edge technologies, such as the most recent digital transformation (DX) projects, to improve automation and introduce labor-saving techniques in manufacturing. The company hopes to enhance quality control and facilitate effective small-batch production of a variety of products by implementing a next-generation production model that integrates IoT technologies. This will also make it easier to remotely supervise production lines in the future. It is anticipated that these improvements will raise labor productivity by about 60% per worker.

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

“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,” Makoto Ehara, CEO of Calbee, said.

Key Initiatives

A. “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.

1. Potato residues will undergo methane fermentation, which will be used as biogas to generate steam for use in the factory.

2. 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.

3. 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.

B. “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.

1. Automation of potato pre-processing, which includes inspection, trimming, and other processes.

2. Automation of transporting products, raw materials, and packaging materials.

3. Remote monitoring and connection of the production line, facilitating remote work in the factory.

C. “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.