For many in Japan’s manufacturing industry, the rising cost of crude oil has long been a major concern. Since Japan imports most of its energy resources—whether oil or natural gas—global events can cause dramatic price fluctuations. The COVID-19 pandemic further destabilized supply chains, intensifying the pressure on companies striving to maintain stable product prices.
A Bold Step Toward Local Energy Production
One company taking a proactive approach is Akidaya Foods Co., Ltd., a food manufacturer located in Gifu Prefecture, central Japan. Determined to reduce its reliance on imported oil, Akidaya Foods partnered with Maruei Co., Ltd., an energy solutions company, to introduce a new boiler system powered by local waste-derived fuel.
We spoke with Mr. Shohei Takagi, leader of the Bioenergy Group at Maruei, to learn more about this innovative project.
About Maruei Co., Ltd.:
Based in Gifu City, Maruei is a comprehensive energy company dealing with liquefied petroleum (LP) gas, natural gas, solar power, and electricity retail. Seven years ago, they launched a new division focusing on renewable energy and biofuels, aiming to promote local energy solutions.
Turning Industrial Waste into Power: Inside the RPF Boiler
The newly installed boiler at Akidaya’s Horado Factory is a Small Rotary Combustion Furnace RPF Boiler System. "RPF" stands for "Refuse Paper and Plastic Fuel"—a solid fuel made from non-recyclable industrial waste such as used paper and plastics. By burning this fuel, the system generates steam used in food production processes.
Traditionally, RPF boilers were large, expensive, and installed only by major corporations. However, with the development of a smaller model by POSCO, a leading South Korean steelmaker, local businesses can now afford to adopt this technology.
Maruei owns and operates the boiler and purchases the RPF fuel from a local waste management company. The steam produced is then piped directly to Akidaya Foods, which purchases it for use in their manufacturing processes, such as sterilizing and melting ingredients for popular jelly drink products (brand name undisclosed due to confidentiality).
This model not only provides Akidaya with stable and environmentally friendly energy but also protects them from the volatility of oil prices.
Fun Fact: The RPF boiler consumes around 2,000 tons of RPF fuel annually—an impressive contribution to waste reduction and local energy independence.
Greener, Smarter, Cheaper: The Triple Benefits of Waste-to-Energy
RPF fuel is slightly less energy-dense than heavy oil—around 6,000 kilocalories per kilogram compared to heavy oil’s 9,000 kcal—but it is much cheaper. Moreover, using waste as fuel reduces the environmental impact and strengthens local economies by keeping production and energy consumption within the same region.
Maruei emphasizes the philosophy of "local production for local consumption" in energy use, minimizing transportation costs and emissions.
The Future of Waste-to-Energy in Japan
While Japan has not been particularly advanced or delayed compared to other countries in waste-to-energy technologies, the need is pressing due to its heavy reliance on imported fossil fuels. Interestingly, Japan is one of the few countries that processes waste into solid fuel (RPF), whereas others tend to burn shredded materials directly.
The success of small-scale RPF boilers like this project could open new opportunities for decentralized, sustainable energy across Japan. Waste materials such as used tires—rich in calorific value—may also become important energy sources in the future.
This initiative aligns with global moves toward a circular economy, where waste is revalued as a resource. As environmental awareness among corporations grows, projects like this are attracting serious interest from major Japanese companies looking for sustainable solutions.
Maruei’s goal is to install at least five similar systems in the near future, beginning with another project already under serious consideration within Gifu Prefecture.
Sources:
- Maruei Co., Ltd. (Official Site): https://www.maruei-gas.co.jp/
- Akidaya Foods Co., Ltd. (Official Site): https://www.akitayahonten.co.jp/aki0102.html
