Aiming to completely eliminate landfill waste through more recycling
At Takasago Food Products we manufacture powder spices that are used in many varieties of foods, along with food additives such as fruit juices, natural flavorings, and food dyes. We are constantly aware of and work toward easing environmental impact and functioning in harmony with the local community. In all of our manufacturing-related activities we strive to use energy effectively, save resources by recycling, and minimize waste.
Actively reassessing energy sources
LPG boiler equipment. CO2 emissions were reduced by approximately 1/4th the size of Tokyo Dome in fiscal 2009.
In 2008 we made a full switchover from the use of LPG (Liquid petroleum gas) to LNG (liquid natural gas), resulting in a 15% reduction in CO2 emissions. In the boiler we use a plate heat exchanger that offers excellent heat transfer performance, aimed at the energy-efficient use of energy resources.
We also use a plate heat exchanger that offers excellent heat transfer performance to utilize energy resources more efficiently. All forklifts are now electric-powered, as well.
The air conditioning system in the factory is powered by a gas heat pump system, but we are in the process of switching to Eco-Ice (thermal storage air conditioning). Eco-Ice is an air conditioning system that allows nighttime electricity to be used -- ice for cooling and stored hot water for heating. Each unit can reduce our CO2 emissions by about 2 tons annually. In the summer we set the indoor temperature to go down to 28°C. Of the 7 units we have in operation, 4 have already been converted over. Not only has this improved energy efficiency but it has lowered our CO2 emissions to 83% of previous figures.
Takasago Food Products employs six people as energy managers in compliance with the Rationalization in Energy Use Law and plans to increase that number in the future.
Slashing landfill waster by making fertilizer from sludge
Sludge dryer installed at the factory
Takasago Food Products acquired ISO 14001 certification in January 2003 and continues working to reduce landfill waste and incinerated waste to less than 3%. (11.6% in FY2003 to 5.0% in FY2009).
We have been making fertilizer from dewatered sludge from the treatment facility since 2002. This has helped to reduce the volume of industrial waste significantly. Waste sludge is dewatered and dried at the treatment facility to a moisture content of about 5% to prevent putrefaction, but since all odors pass through water in an airtight system, there is almost no odor at all. The system has been approved by the Ministry of Agriculture, Forestry and Fisheries of Japan, and the mixed sludge fertilizer is registered as "TFP 1."
Mixed sludge fertilizer "TFP 1"
Much waste is generated from the containers in which raw materials for the manufacturing process are received. In the past, all waste plastic was sent to landfill, but now we sort carefully and an increasing percentage is recycled as auxiliary fuel material for boilers. Fiberboard drums are cut up and handled as cardboard, earning money when recycled. Plastic containers used to be strong-smelling waste, but we developed a machine to give them a quick washing and now they can be recycled. Prune pits are incinerated as waste, but by grinding them we have succeeded in converting them into material for fertilizer.
Treating wastewater until it is clear enough for carp
The activated sludge wastewater treatment facility has four 1000 m3 aeration tanks. We are careful to constantly regulate the inflow load and stabilize the water temperature. Atop the settling tank we have meters to measure COD and pH, along with a camera, plus surveillance by security teams on patrol for monitoring around the clock. The discharged water is treated until it is clear, but we also keep carp (koi) in the filtration tank to ensure normality in the microorganisms in the water before releasing the water into the river. We have set our voluntary controls to stricter standards, requiring figures to be less than half of those agreed upon with the local government.
Deodorizing in two stages with scrubbers
We pay careful attention to measures that prevent odors from leaking out of the factory. Each factory building is equipped with a scrubber as deodorizing equipment. When drying highly concentrated effluent in a factory that manufactures powder spices, however, a strong odor is emitted, so we further process odors that have gone through primary deodorizing using a large deodorizing tower in a two-stage process both inside and outside the factory building.
Large deodorizing tower
We also improve the factory's deodorizing system based on experts' odor measurement evaluations. In 2008 we boosted the deodorizing performance of the scrubbers. Other improvements we have made include changing the buffer material and boosting deodorizing efficiency by using alkali or other odor neutralizers when manufacturing products that produce a strong odor.
Tea growers are using our special fertilizer
In addition to our fer tilizer brand "TFP 1," we have registered the ordinary fertilizer "Kocha Kasu" and the special fertilizer "Coffee Kasu." For convenience we use private dump trucks to supply fertilizer to nearby farms.
"We supply fertilizer made from sludge to nearby farms (primarily growing tea) in private dump trucks, and it is well received for its growth promotion." said Tsuneo Hirai General Manager of Environmental Protection Section.
