[Answers / Case Study] Bringing ginger nurtured by the rich climate of Tosa nationwide. Tak-Auto contact freezer contributes to Asano's automation line aiming for labor and energy saving. [Maekawa Mfg. Co., Ltd.]
Maekawa Mfg. Co., Ltd. announced a case study of its Tak-Auto automatic loading/unloading continuous rapid freezing equipment at Asano Co., Ltd., a ginger processing company in Kochi Prefecture. This implementation enabled Asano to reduce arduous heavy labor, improve product quality, and decrease drip loss during thawing, thereby creating a better working environment for employees.
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- 📰 Published: May 11, 2026 at 22:30
- 🔍 Collected: May 11, 2026 at 14:01
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Maekawa Mfg. Co., Ltd. (Koto-ku, Tokyo; Representative Director and President: Makoto Maekawa, hereinafter "Maekawa") announced that it released a case study of its implementation at Asano Co., Ltd. (Headquarters: Kami City, Kochi Prefecture; Representative Director and President: Heijiro Asano) on May 11, 2026 (Monday), on its official website's case study content "Mayekawa Answers."
This case study details the background and effects of introducing Maekawa's Tak-Auto contact freezer, an automatic loading/unloading continuous rapid freezing equipment.
"Mayekawa Answers" is a series of case study content provided by Maekawa. It introduces how Maekawa addressed the challenges faced by customers when introducing equipment with its technologies and solutions, presenting them as "Maekawa's Answers." In addition, it focuses on the customer's business content, MVV (Mission, Vision, Value), commitment to manufacturing, and how their initiatives contribute to society, delivering story-based articles.
Overview
Asano Co., Ltd., founded in 1950, is a leading ginger processing and sales company based in Kochi Prefecture, handling approximately 10,000 tons of ginger annually. In addition to ginger-derived products such as frozen ginger and grated ginger, they also handle a wide range of products including garlic, yuzu, chives, and daikon, from products for supermarkets to raw materials for manufacturers. They work closely with local contract farmers who grow "specially cultivated ginger" with over 50% reduction in chemical fertilizers and pesticides, continuing to produce safe, secure, and high-quality products.
This time, we interviewed Mr. Matsumoto and Mr. Nagano about the background and reasons for introducing the Tak-Auto automatic loading/unloading continuous rapid freezing equipment.
For creating an environment where employees can work safely and for a long time
ーーFirst, could you tell us what challenges you faced?
Matsumoto: The production line where the equipment was introduced handles approximately 3,000 tons annually, with about 15 tons per business day, although it varies by season. Before the introduction, we used a so-called slow freezing method, where products were put into a freezing warehouse and frozen overnight, instead of the continuous freezing method we have now. Employees had to manually transport and position heavy trolleys weighing over 200 kg in a freezing warehouse that was as cold as minus 40 degrees Celsius. Furthermore, products frozen overnight had to be transported out again the next morning, meaning about 11 personnel were tied up for nearly 3 hours daily in this arduous heavy labor.
Nagano: We also faced quality issues. With the slow freezing method, products tended to expand during freezing, causing cardboard boxes to bulge and look unappealing when packed, and also reducing the efficiency of the packing process itself. In addition, slow freezing damaged cells, leading to a lot of drip loss when thawed, indicating room for improvement in terms of freshness retention.
ーーCould you tell us about the trigger for considering and the reason for choosing Maekawa Mfg. Co., Ltd.?
Matsumoto: We started considering it around the spring of 2023. At that time, a project called "TD Conference (Think-Different)" was launched within the company, and we were reviewing our manufacturing processes without being bound by conventional ideas.
The background was a labor shortage due to the declining birthrate and aging population. As it became difficult to hire male employees, female employees increasingly supported the production floor. However, handling heavy items placed a significant physical burden, making it urgent to create an environment where women could work safely and for a long time.
Nagano: When we were considering creating a manufacturing line that pursued automation and labor-saving, we found contact freezers. We also considered products from other companies for equipment selection, but they were batch-type machines that required manual loading and unloading. Only Maekawa's Tak-Auto supported automated loading and unloading, so we thought, "This might work!" and decided to introduce it after repeated tests.
ーーWhat have been the effects since its introduction?
Nagano: We've heard from the field that "it's just so much easier." The introduction of Tak-Auto has automated many processes, including bagging, freezing, palletizing, and the conveying processes connecting them. It has become possible for a small number of manufacturing members to complete the work, allowing for flexible responses to seasonal lines and busy periods.
The product finish is also very clean. With the slow freezing method, product surfaces would expand, causing boxes to bulge, but now they are pressed flat, making the packing process very smooth. Furthermore, drip loss during thawing has decreased by about 5%, from the conventional 25% to 20%, maintaining quality.
This case study details the background and effects of introducing Maekawa's Tak-Auto contact freezer, an automatic loading/unloading continuous rapid freezing equipment.
"Mayekawa Answers" is a series of case study content provided by Maekawa. It introduces how Maekawa addressed the challenges faced by customers when introducing equipment with its technologies and solutions, presenting them as "Maekawa's Answers." In addition, it focuses on the customer's business content, MVV (Mission, Vision, Value), commitment to manufacturing, and how their initiatives contribute to society, delivering story-based articles.
Overview
Asano Co., Ltd., founded in 1950, is a leading ginger processing and sales company based in Kochi Prefecture, handling approximately 10,000 tons of ginger annually. In addition to ginger-derived products such as frozen ginger and grated ginger, they also handle a wide range of products including garlic, yuzu, chives, and daikon, from products for supermarkets to raw materials for manufacturers. They work closely with local contract farmers who grow "specially cultivated ginger" with over 50% reduction in chemical fertilizers and pesticides, continuing to produce safe, secure, and high-quality products.
This time, we interviewed Mr. Matsumoto and Mr. Nagano about the background and reasons for introducing the Tak-Auto automatic loading/unloading continuous rapid freezing equipment.
For creating an environment where employees can work safely and for a long time
ーーFirst, could you tell us what challenges you faced?
Matsumoto: The production line where the equipment was introduced handles approximately 3,000 tons annually, with about 15 tons per business day, although it varies by season. Before the introduction, we used a so-called slow freezing method, where products were put into a freezing warehouse and frozen overnight, instead of the continuous freezing method we have now. Employees had to manually transport and position heavy trolleys weighing over 200 kg in a freezing warehouse that was as cold as minus 40 degrees Celsius. Furthermore, products frozen overnight had to be transported out again the next morning, meaning about 11 personnel were tied up for nearly 3 hours daily in this arduous heavy labor.
Nagano: We also faced quality issues. With the slow freezing method, products tended to expand during freezing, causing cardboard boxes to bulge and look unappealing when packed, and also reducing the efficiency of the packing process itself. In addition, slow freezing damaged cells, leading to a lot of drip loss when thawed, indicating room for improvement in terms of freshness retention.
ーーCould you tell us about the trigger for considering and the reason for choosing Maekawa Mfg. Co., Ltd.?
Matsumoto: We started considering it around the spring of 2023. At that time, a project called "TD Conference (Think-Different)" was launched within the company, and we were reviewing our manufacturing processes without being bound by conventional ideas.
The background was a labor shortage due to the declining birthrate and aging population. As it became difficult to hire male employees, female employees increasingly supported the production floor. However, handling heavy items placed a significant physical burden, making it urgent to create an environment where women could work safely and for a long time.
Nagano: When we were considering creating a manufacturing line that pursued automation and labor-saving, we found contact freezers. We also considered products from other companies for equipment selection, but they were batch-type machines that required manual loading and unloading. Only Maekawa's Tak-Auto supported automated loading and unloading, so we thought, "This might work!" and decided to introduce it after repeated tests.
ーーWhat have been the effects since its introduction?
Nagano: We've heard from the field that "it's just so much easier." The introduction of Tak-Auto has automated many processes, including bagging, freezing, palletizing, and the conveying processes connecting them. It has become possible for a small number of manufacturing members to complete the work, allowing for flexible responses to seasonal lines and busy periods.
The product finish is also very clean. With the slow freezing method, product surfaces would expand, causing boxes to bulge, but now they are pressed flat, making the packing process very smooth. Furthermore, drip loss during thawing has decreased by about 5%, from the conventional 25% to 20%, maintaining quality.