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 in Reducing Environmental Impact

Change in Package Form

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

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.

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

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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