Zao Plant starts full operations of its newly-installed aseptic line with an aim to contribute simultaneously to stable product supply and conservation of the environment!
Coca-Cola Bottlers Japan installed a new aseptic production line in the Zao Plant (Zao-machi, Katta-gun, Miyagi), and started its full-scale operation from July 1, 2020.
This new line is designed to produce both small and large PET bottle products, and features the latest IoT data-driven automated production system that produces up to 900 bottles per minute, which is approximately 1.5 times faster than the previous production capacity at the Zao Plant.
Environment-friendly aseptic line
This aseptic production line features a sterile production environment that replaces the conventional filling process. It allows drinks, such as coffee and tea to maintain their natural flavor and is also more environmentally-friendly because the aseptic process allows for lighter bottles, which reduce CO2 emissions during transport.
Since 2019, Coca-Cola Bottlers Japan has been pushing forward its major plans to bolster its total manufacturing capacity by installing and operating a total of seven new production lines by 2020 in order to be able to respond more readily to the changes in the market environment and diversifying customer needs, while also contributing to the achievement of sustainable development goals (SDGs) through the introduction of various new technologically-driven environment-friendly features. This new aseptic line in Zao Plant marks the sixth installation, following one line in Kumamoto Plant, two lines in Kyoto Plant, one line in Hakushu Plant and one line in Hiroshima Plant that are already up and running. The remaining one more line has also started operating as Line No. 2 in Hiroshima on July 3, two days after the launch of this aseptic line in Zao.
【Overview of the new line (No.6) in Zao Plant】
| Name | Aseptic line for PET bottle products (Line No. 6) |
|---|---|
| Location | Zao Plant (1-1 Minamikawazoe, Miya, Zao-machi, Katta-gun, Miyagi) |
| Total floor space | 10,352.56㎡ |
| Production items | Coca-Cola, Ayataka, Sokenbicha, Georgia Japan Craftsman, etc. |
| Production capacity | 900BPM (280ml-600ml) / 300BPM (1.5L) / 260BPM (2.0L) (BPM: Bottle per minute) |
| Characteristics of this new line | Capable of manufacturing a wide variety of products from 280ml to 2.0 L. including aseptic products like tea, coffee and carbonated products, such as, Coca-Cola. The maximum production speed is 900 BPM, which is approximately 1.5 times faster than Line No. 5 (the existing aseptic line) in Zao Plant. |
Zao and Coca-Cola Bottlers Japan
Zao Plant is located in Zao-machi, a town in the southwest area of Miyagi Prefecture, at the base of the eastern peak of the Zao mountain range. Zao-machi is blessed with rich nature, including the five springs certified as high-quality ground water that have long been quenching the thirst of local people since ancient times.
Coca-Cola Bottlers Japan has been donating a part of its proceeds of its natural mineral water brand, I LOHAS, to non-profit organizations working on conservation of water resources across the country through The Coca-Cola Educational & Environmental Foundation. A part of this donation is used to fund the "I LOHAS no Mori Katsu" project (*1) for supporting initiatives to preserve the precious water sources in Zao-machi and the activities of Shiraishi Zao Forestry Cooperative that is proactively working on environment conservation and revitalization of local mountain villages.
*1）Water source conservation project "I LOHAS no Mori Katsu" (Japanese)
Through the launch of this new aseptic line in Zao Plant, Coca-Cola Bottlers Japan will be able to ensure more stable product supply mainly in the South Tohoku area and intend to contribute to the development of the region more than ever.
In closing, we would like to share the comments of Bruce Herbert, Executive Officer and Head of SCM, on Zao Plant.
Comment from Bruce Herbert, Executive Officer, Head of SCM, Coca-Cola Bottlers Japan Inc.
Coca-Cola Bottlers Japan Zao Plant is located at the foot of Mt. Zao and manufactures Coca-Cola, Fanta, Aquarius, Sokenbicha, Georgia Coffee, and so on.
We utilize groundwater cultivated by the rich nature of Zao and have been supplying safe and delicious products mainly to customers in South Tohoku area. We are also promoting water resource conservation activities by maximizing the effective use of water for manufacturing and cleaning the used water to return it to nature.
By starting the operation of the new production line, we will be more considerate than ever to the environment and to our customers, and we will ensure we are a good partner to the local community.