Case Study
- Oven
- Cookie
NAKAYAMASEIKA CO., LTD.
Established in Sasazuka, Shibuya City in Tokyo in 1952, NAKAYAMASEIKA manufactures and sells baked sweets such as Russian Cake at their factory in Sano City, Tochigi Prefecture. Russian Cake is a festive-looking double baked cookie topped with jam and chocolate and is one of the long-time sellers for NAKAYAMASEIKA that has been in the business for over 60 years. In October 2019, NAKAYAMASEIKA was forced to suspend operations for about 13 months due to flood damage caused by Typhoon Hagibis, but in November 2020, construction of the new Sano Factory was completed, and the company successfully rebuilt themselves.
Location：3-43-11 Sasazuka, Shibuya-ku, Tokyo JAPAN
URL：https://www.nakayamaseika.co.jp/ja/
Publication：MASDAC news February issue in 2022
Oven lines
With the completion of the new Sano Factory, they replaced two oven lines. The long lines are laid out in a way that makes them easy to operate. NAKAYAMASEIKA produces a variety of baked sweets using these lines such as Russian Cake with a long shelf life of 180 days as well as tarts.
Russian Cake line
Two ovens are incorporated in the Russian Cake line. NAKAYAMASEIKA’s signature product, Russian Cake has six variations with different batter and shapes. The production of each variation is switched around depending on the day. With this replacement, more rows have been added, and the production volume has increased by about 1.2 times. Furthermore, replacing the filling depositing equipment that is used after baking increased the accuracy greatly.
Russian Cake (rich bitter) in production
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Entrance of Oven 1. It bakes the cookies that make up the foundation part.
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Deposit the dough on cookies and double bake in Oven 2.
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Rising during baking
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Deposit the chocolate, and then the cookies are moved to the packaging process.
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Leaf Cookies (orange honey) in production. The Russian Cake line also produces various cookies in Oven 2.
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Steel Belt Oven: The batter is deposited directly onto the steel belt and baked, which allows for efficient continuous production.
Tart line
The tart line produces tarts in various sizes. During the replacement, automation was added to removal of products. Equipment to send back the sheet pan and cleaning equipment was also added.
NAKAYAMASEIKA spoke about the effect of saving manpower, “The problem we had was that the sheet pan was heavy and there was a lot of burden on the operators, but this was eliminated by automation. The number of operators working on the line was reduced by one third.”
Tarts in production
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Depositing of tart batter, molding, depositing of jam and more batter is done before going into the oven.
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Entrance of the oven. The wide oven efficiently bakes the tarts.
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Product depanning
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The sheet pan is automatically sent back and cleaned.
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To the packaging process
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Caterpillar Type Oven: A Caterpillar Type Oven, where you can put mold trays or sheet pans to bake, is perfect for multi-production.
Reference
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