Production & Logistics

The Calbee Group uses nature’s gifts to produce and deliver products to its customers.As inhabitants of Earth living alongside its plants and animals, we believe that we have a social responsibility to conduct environmental protection initiatives in order to achieve a sustainable future and ongoing corporate growth.

Efforts to Reduce the Workload

We are working on various measures in the logistics division to address social issues such as a serious shortage of drivers and an increased workload in logistics operations. We have reduced drivers’ waiting time and incidental work by 50% by sharing and improving issues with our business partners. At the Kyoto Factory, autonomous forklift trucks were introduced, realizing unmanned operations of movement and storage of products.

We reduced labor requirements by automating packaging and boxing at all domestic factories. Currently, we are in the process of automating manual potato trimming and defect detection processes. The Company is reviewing previous production procedures and equipment allocation in order to streamline and simplify its operations and improve productivity.

Efforts to Reduce Environmental Impact

Change in Package Form

Calbee strives to reduce adverse impacts on the environmental by making product packaging more compact. We reduced the size of the cardboard box used to package Frugra, reducing the amount of material used. In the future, we will improve the efficiency of distribution and warehouse storage by reducing the thickness of bagged products to promote reductions in the use of cardboard materials.

Shrinking Product Packaging

Improving the Cardboard Used for Frugra Containers

Frugra is sold in volumes of 600g, 700g, and 800g but we had been packaging all volumes in boxes designed to hold 800g. We reduced the sizes of cardboard boxes containing 600g or 700g of Frugra and greatly reduced expenses.

20mm smaller

Environmental Activities Promotion Structure

Calbee’s Production Management Division is the core driver of Companywide initiatives aimed at achieving emissions targets with respect to the environment. The Companywide Energy Management Committee, Companywide Waste Management Committee and Companywide Wastewater Management Committee hold regular meetings based on individual themes and follow the PDCA cycle of environmental management. In addition, we conduct educational activities for all employees and strive to create a corporate culture that works together to achieve environmental goals.

Environmental Activities Promotion Structure

Overview of Business Activities and Environmental Impacts in the Fiscal Year Ended March 31, 2019 (Target organizations: Domestic Group Companies)

Overview of Business Activities and Environmental Impacts in the Fiscal Year Ended March 31, 2019

Contributions toward Building a Low-Carbon Society

The entire Calbee Group works to reduce greenhouse gas emissions by setting numerical emissions targets. We aim to reduce greenhouse gas emissions throughout the Group with initiatives through switching our source of production energy from class A heavy fuel to liquefied natural gas (LNG), and changing cargo transportation methods in our distribution and energy-saving activities at our offices. Moving forward, we will work to reduce emissions throughout the supply chain while sharing information regarding environmental risks.

Initiatives in Factories

In March 2016, the Calbee Potato Obihiro Factory commenced full-scale operations having switching from heavy fuel oil A to liquefied natural gas (LNG), which resulted in improved energy efficiency. In addition, the launch of biomass boiler* high-efficiency operation and other measures led to energy efficiency, and although CO2 emissions increased due to the increase in overall production volume, we were able to achieve our per-unit targets.

Energy Used Per Unit
Energy Used Per Unit
*Aggregate target organizations: Domestic Calbee Group companies (with the 2011 = 100)

CO2 Emissions Volume and Energy Used Per Unit
CO2 Emissions Volume and Energy Used Per Unit
*Aggregate target organizations: Domestic Calbee Group companies

Promoting integrated inter-factory energy conservation projects through collaboration with other companies

We are participating in the integrated inter-factory energy conservation project to establish the Kiyohara Smart Energy Center centering on a 30,000 kW class gas cogeneration system with Canon Inc., Hisamitsu Pharmaceutical Co., Inc., and the Tokyo Gas Group. The facilities are scheduled to start by the end of fiscal year ending March 31, 2020.
This is the first integrated inter-factory energy conservation project in Japan that provides electricity and heat (steam and hot water) to multiple business sites in different industries.
By sharing energy supply systems with seven business sites in different industries that are close to each other, each business site is able to reduce the environmental burden to an extent that cannot be achieved by itself. This is expected to result in energy savings of about 20% and CO2 emissions reductions of about 20%*. In addition, it will be possible to provide
a stable energy supply even in the event of a power outage, is expected to strengthen the company’s Business Continuity Plan (BCP).

* Reduction rate against the CO2 emission total at seven business sites of the three companies (Calbee, Canon, Hisamitsu Pharmaceutical) in fiscal year ended March 2016 About 23,000 t/year

Diagram of Electricity and Heat (Steam and Hot Water) Supplies

Elimination of CO2 Emitted During Transportation

In 2007, Calbee was designated as a “specified shipper*” and has been engaged in reducing the amount of energy used per unit. In collaboration with logistics companies, we are working on revising delivery routes, improving fuel efficiency through eco-driving, expanding joint deliveries and modal shifts in long-distance transportation (from truck to rail).

Eco Rail Mark

Number of vehicles equipped with eco-drive tools and usage rate
Of 400 vehicles, 94.3% are equipped with eco-drive tools
*Aggregate target organizations: Domestic Calbee Group companies

  • * Specified shipper: In accordance with the Energy Saving Act, this designation is conferred when annual transport volume exceeds 30 million ton-kilometers, requiring the creation of an energy conservation plan and regular reports on energy consumption.
  • * Eco Rail Mark: Calbee has been certified to receive the Eco Rail Mark, which is conferred when 30% or more of land freight transportation of 500km or more is done by rail.

Expanded Joint Deliveries

Amount of CO2 reduced by joint deliveries
*Aggregate target organizations: Domestic Calbee Group companies

Elimination of CO2 in Offices

Calbee promotes energy conservation in its factories and distribution facilities, as well as its headquarters and other offices. We raise awareness of energy conservation among all employees through efforts that include using a in-house database to manage the amount of electricity used in each workplace and the resulting CO2 emissions. We are continuously working to conserve energy through various activities, such as switching to LED lighting, optimizing air-conditioning temperature settings.

Effective Use of Resources

The Calbee Group conducts waste sorting, curtails its total volume of generated waste, and converts leftover food residue into feed. These initiatives compose the main pillars of the Group’s zero emission, and recycling strategies, which are geared toward achieving a recycling society. Through adherence to the “3 Rs” (reduce, reuse, and recycle), we have achieved a recycling rate of almost 100%.

Waste Output Breakdown
Waste Output Breakdown
* Target organizations: Domestic Group companies

Food Loss Reduction Initiatives

Calbee is discussing manufacturing processes that do not produce loss in pursuit of food loss reduction. We use plant and vegetable residue such as potato skins as livestock feed or in mushroom-bed cultivation and donate products that cannot be shipped to foodbanks.

Results in the fiscal year ended March 31, 2019

CO2 emissions reduction amount
Per unit of sales compared to the FY ended March 31, 2010 -21%
Waste reduction amount
Per unit of sales compared to the FY ended March 31, 2010 -18%
Water usage reduction amount
Per unit of sales compared to the FY ended March 31, 2010 -16%

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