Kawabe Shokai Co., Ltd.　2022

A Local Factory: Crafting Daily Plastic Essentials

Home appliances, automobiles, AV equipment, and cameras…plastic is used in all kinds of items that surround us. Have you ever wondered where and how these items are made?

Established in 1955 and based in Sakai City, Kawabe Shokai is a manufacturer specializing in plastic molding, producing everyday plastics found in these familiar products.

“Plastic molding involves shaping molten plastic into a desired form using molds. Since our establishment, we have been continuously engaged in manufacturing plastic molded products, technology development, and mold creation. These products are assembled as components within home appliances and automobiles, playing an active role in your daily lives,” explains Mr. Koichi Fukuda, the fourth-generation representative of Kawabe Shokai.

Kawabe Shokai is preferred by major home appliance and automobile manufacturers for creating items with high added value by using their unique technology. In the factory, plastic items of various shapes are made one after another. You may not be able to tell what parts they are at first glance but will discover that they belong to the ‘plate of an automobile shift lever’ or a ‘ballpoint pen grip’— all items you’ve seen or touched before. 

“In recent years, we have developed the ‘coatless surface’ technology by mixing metal and plastic to create an exterior with a silver metallic appearance. Additionally, we also focus on eco-friendly manufacturing by pursuing technologies for weight reduction and material reuse, both essential for the development of EV automobiles.”

A New Challenge: Expanding our Sales Channels from BtoC 

Kawabe Shokai’s original product, ‘CHOPLATE’, a cutting board that also functions as a plate, has been certified in this time’s Sakai Kitchen Selection. They have always been solely focused on BtoB business, but with the decline in domestic production orders, they decided to expand their sales channels and take on a new challenge.

“While we are confident in our technology, we lack the expertise to develop a plan from scratch, so we consulted TENT, a product design unit. Despite repeated discussions, we struggled to finalize the concept. We had envisioned a continuation from our usual creations, sticking to high-tech items like VR but soon realized that these projects couldn’t be completed in-house. With the goals of ‘creating in-house products using existing machines’ and ‘focusing on introducing original products to the market instead of just selling’, we ultimately came up with ‘a cutting board designed to serve as a plate.’”

Unparalleled Texture Born from Unique Technology

From there, they proceeded with development making full use of their existing technology.

Firstly, the shape. 

“We applied a slight curvature to the rim for ease of use as a plate while still functioning as a cutting board. Its height is just enough to prevent liquids from spilling and to keep the knife from hitting the rim when cutting.”

And then for the materials.

“We experimented with all sorts of plastics to achieve durability and lightweight for prolonged use, but they all ended up looking rather cheap. Eventually, we decided that SPS resin, a high-spec plastic, was the best choice. However, we were not satisfied with the patterns on the surface, which were created by the blended glass fibers added for resilience. After a series of trials and errors, we were able to create a beautiful shade and texture.”

And so, the product ‘CHOPLATE’ was born. Its simple charm reflects the beauty of a practical design perfected through careful calculation. The unique pattern and matte surface that spreads from the center makes the food stand out beautifully. Its ideal hardness and texture that resist chipping from knives and conceals knife marks can only be achieved with this material. It’s microwave-safe too which is always a plus.

Whenever you don’t feel like pulling out your cutting board, this item is the perfect alternative for busy mornings. You can cut and serve directly on the plate, meaning fewer dishes to wash, making it ideal for camping and outdoor activities. With its countless benefits, ‘CHOPLATE’ became a hit, selling 30,000 units in 2021 alone.

A Breath of Fresh Air in Sakai’s Craftsmanship

“It’s inspiring to see the passion and level of craftsmanship in Sakai City, with everyone making new challenges and with many local factories in surrounding areas. Skilled professionals from various fields are always around, creating this supportive horizontal connection that I can always reach for advice whenever I want to bring an idea to life,” says Mr. Fukuda.

With their signature innovative item, ‘CHOPLATE’, Kawabe Shoten has truly brought a breath of fresh air to Sakai’s craftsmanship. We can’t wait to see what comes next.

Edit&Test Tomoyo Tsuchiya
Photographer Yutaka Sato