[Los Angeles (U.S.) = E-Daily Reporter Han Jeon-jin ] Hundreds of gyoza dumplings, freshly formed by a molding machine, pour onto the conveyor belt. As they flow in a line, they undulate like a white wave. The dumplings are immediately fed into a steamer, where they are steamed and then cooled. The production line never stops. This is the scene at the CJ CheilJedang Corp(097950) plant in Beaumont, which produces 6 out of every 10 Bibigo dumplings sold in the U.S. Melissa Thompson-Troup, Vice President of Asian Food Manufacturing at CJ Corp., said, “The food made here ends up on the tables of millions of Americans.”

When I visited the Beaumont, California, plant on the 14th (local time), the facility was bustling nonstop with the production of K-food items such as dumplings. It is located about 78 miles (126 km) east of Los Angeles, roughly a 1 hour and 30 minute drive away. This facility is a key hub among the 20 production sites operated by CJ CheilJedang Corp. in the U.S., producing the largest volume of Asian foods. The site covers an area of 41,249 square meters (approximately 12,500 pyeong), and more than 600 employees report to work each day. Daily production of dumplings totals 350,000 pounds (approximately 160 metric tons), which is equivalent to about 860,000 pieces based on the Bibigo Steamed Dumplings (187g) package size.

Dumplings are the heart of the Beaumont plant. Of the 350,000 pounds produced daily, Bibigo dumplings account for 250,000 pounds (approximately 113 metric tons). There are four dumpling production lines alone—more than the combined total of the two fried rice lines and the noodle and seaweed lines. This facility accounts for 58% of CJ Corp.’s total dumpling production and 60% of Bibigo dumpling production. After opening a frozen food warehouse in 2019, the facility expanded into ambient-temperature products in 2022. In 2023, when CJ CheilJedang Corp. integrated its U.S. food subsidiary under Schwans, the facility solidified its position as the hub of dumpling production. It also produces products exclusively for the local market, such as kimchi cheese fried rice.

The production process consists of eight stages. Thinly rolled dough sheets and separately mixed fillings are fed into a molding machine to form the dumplings, which are then steamed, cooled, and packaged in pouches and boxes. The entire process, from raw material input to finished product, takes 60 minutes. The entire production process takes place within a single building. Different production lines—ranging from chilled fresh noodles to frozen dumplings, fried rice, and instant rice—operate simultaneously. Key technologies that determine texture—such as the rapid-freezing temperature for dumplings—are not disclosed to the outside world. Taking notes and photographs are strictly restricted within the facility.

Automation is the driving force behind this speed. Of the eight production steps, the supply of dumpling wrappers, pouch packaging, and palletizing (the process of stacking product boxes onto pallets) are handled by machinery, while steaming and cooling are carried out entirely without human intervention. Factory officials explained that the automation rate stands at approximately 70%. Five collaborative robots from Doosan Robotics were deployed in the palletizing section last May. This effectively means that the automation system equivalent to that of the Korean factory is being replicated exactly at the U.S. site.

Localization begins at the product design stage. A prime example is the “Bibigo Chicken & Cilantro Dumplings,” which replaced the traditional Korean filling of chives and pork with chicken and cilantro. For kimchi products, the blend of oils used is also partially adjusted to account for North American consumers’ eating habits and preferences. This reflects the local food culture, where kimchi is enjoyed more as a snack than as a side dish. Similarly, separate flavors of instant noodles—such as Spicy Chicken—have been developed to suit North American tastes.

As of 2024, Bibigo dumplings hold the top spot in the U.S. B2C (business-to-consumer) dumpling market with a 41% market share. Schwan’s Red Baron pizza also leads the frozen pizza market with a 20.8% share, surpassing competitor Nestlé De Giorno. The turning point for this growth was the acquisition of Schwan’s in 2019. Starting the following year, the two companies integrated their B2C distribution networks, enabling Bibigo to leverage the logistics network and distribution channels that Schwan’s had established across the United States. Currently, Bibigo K-Food products are sold at approximately 80,000 stores across the U.S., including Walmart, Kroger, and Costco.

This growth is also reflected in the numbers. CJ CheilJedang Corp.’s U.S. sales rose from 3.3286 trillion won in 2020 to 4.9136 trillion won last year, a 47.6% increase over five years. The U.S. accounts for 82.9% of the company’s overseas sales. In effect, the success of its overseas business hinges on the U.S. market. In November 2024, the company also broke ground on a new Asian food factory in South Dakota, with completion targeted for 2027.

CJ CheilJedang Corp. is accelerating its expansion into North America with the Beaumont plant as its base. Vice President Melissa Thompson-Troop said, “Our food might be part of a school lunch or shared at a table with friends and family,” adding, “We take pride in being a part of those moments.” She continued, “Our strategy is to ensure that CJ Corp. Foods can be enjoyed anywhere in the U.S.,” adding, “We aim to become the fastest-growing food company in North America.”