Takasago Coffee's Iwata Factory produces regular coffee roasted coffee beans in kraft paper bags and coffee extract from coffee beans. The extract is used in coffee and milk-based drinks, frozen desserts, etc. Coffee gives off a distinctive aroma, so we conduct "odor patrols" on a daily basis and take measures to counteract odors in each process of roasting, grinding, and extracting.
Handling odors, the ever-present issue
At the roasting factory, a platinum catalyst is used as an oxidant in combustion-type deodorizing equipment to decompose odors. The exhaust steam from grinding the roasted beans is passed through a layer of water in a device known as a "water scrubber" for odor adsorption. Also, the steam discharged from the coffee grounds after extraction is cooled under a water shower and adsorbed.
In 2010 an expansion pipe was installed as part of measures to improve the line and strengthen odor prevention measures. Also, by using circulated water in certain areas we were able to cut down on our use of water. We plan to implement many other environmental measures to ensure that the local community fully accepts the factory.
Reducing CO2 in various ways
Beginning in 2007 we joined the "Iwata Town Cleanup Partner" system and have been participating in weed pulling along surrounding roads and cleanup of ditches and the river. In 2009 for "Cool Earth Day" (July 7), we dimmed our signboard lights and exterior lights. We have also planned a "No Car Day." These are some of the actions we take to help reduce CO2 emissions.
Currently we are working hard to try to completely eliminate the disposal of coffee grounds. We have begun delivering to farms a special fertilizer made from coffee grounds, but a large amount still requires disposal.
Odor Countermeasures
An extended deodorizing line and completely airtight system are used to prevent odor leakage.
Coffee grounds from the extraction column are discharged in three locations. The space is large enough to hold the trucks that deliver the grounds.
The steam discharged from the coffee grounds after extraction is sprayed with water when it goes through the deodorizing line and odors are adsorbed. We lengthened the deodorizing line by 60% and installed spray nozzles in eight new locations. We also installed an airtight cover to the bypass section. The well water used for spraying is sent to the wastewater treatment facility where it is reused for dilution before being discharged into the sewage system.
Greening the Factory Premises by 25%!
Under Japan's Factory Location Act, a minimum portion of factory grounds (currently 25%) must be used for plants or other greenery. To comply with this regulation, we use plantable concrete blocks for the parking lot which allow green grass to grow in the gaps between concrete blocks. The connected green strips that are formed create a nice, green area on the factory grounds.
For the parking lot, instead of grass, which requires periodic maintenance, we laid plantable concrete blocks and our employees seeded the sections with clover.
We laid sod mats which are designed to be laid over concrete to create over 10 m2 of green space.
Resource Recycling
We produce a special fertilizer made from post-extraction coffee grounds labeled "Hosaku-kun" (Grow Well)." We then supply this fertilizer to such concerns as tea-growing farms, vegetable growers, livestock farmers, and agricultural high schools. The fertilizer is left to sit for 3 to 6 months and when fermentation takes place it begins to improve the soil. The inner skin of the coffee bean known as the "silver skin" is also reused by livestock farmers.
On a daily basis we deliver "Hosaku-kun" (Grow Well) by the truckload from the factory to farms.
The "Iwata Town Cleanup Partner" System
Corporations and groups interested in cleaning up and maintaining town roads, rivers, parks, and green areas in Iwata register with the "Iwata Town Cleanup Partner" system. We joined in 2007. Cleanup events are held four times a year during which we clean up surrounding roads, ditches, storm drain ponds, and the river area.
Exhaust deodorizing
Exhaust air from roasting the beans is fed through a large duct into a deodorizing system. Ordinarily, a temperature close to 800°C is required to produce the oxidation reaction that burns up odors, but using a platinum catalyst we were able to lower the temperature to 350°C for breaking down odors.
The effective reuse of groundwater
Takasago Coffee's Iwata Factory uses both tap water and well water. The steam emitted from the extraction process is cooled and odors are adsorbed using well water. This water is sent to the wastewater treatment facility where it is reused for dilution before being discharged into the sewage system.
Reducing waste
The sludge discharged from the wastewater treatment facility is incinerated as industrial waste, but we intend to install a sludge dryer to further reduce the volume of waste.
The coffee extract filling process. Worn out safety shoes used at the factory are collected and returned to the manufacturer for the recycling of resin, rubber, and other materials.
