*AI Translated
Mary Chocolate, founded in 1950, has created numerous hit products with the desire to "help customers 'send their feelings'" and "create sweets that make everyone who eats them smile." It's a popular brand not only for gifts to loved ones but also as a "Japanese souvenir" to brighten travel memories.
One of Mary Chocolate's signature products is the "Millefeuille." You might be surprised, thinking, "Wait, a chocolate manufacturer makes millefeuille?" But one bite will convince anyone. This is truly a "chocolate-delicious millefeuille" that only a chocolate specialist could achieve.
This time, the Mary Chocolate Funabashi Factory, the birthplace of this "Millefeuille," extended a special invitation to us. A "FUN! JAPAN" editor will explore the secrets of its deliciousness!
* If you purchase products or make reservations introduced in this article, a portion of the sales may be returned to FUN! JAPAN.
What is Merry Chocolate?
In 1950, Mary Chocolate began manufacturing and selling high-quality chocolates and candies in Shibuya-ku, Tokyo. Under the founder's belief that "good products speak for themselves," it has been a long-established brand leading the development of chocolate culture in Japan.
Mary Chocolate consistently takes on new challenges, such as advocating the tradition of "women giving chocolates to men on Valentine's Day" in 1958, and becoming the first Japanese manufacturer to participate in "Salon du Chocolat Paris," the world's largest chocolate exhibition, in 2000.
Their stores are primarily located in department stores and mass retailers across Japan.
Mary Chocolate Funabashi Factory: The Sole Baked Goods Manufacturing Plant
We visited the Mary Chocolate Funabashi Factory, which is Mary Chocolate's only baked goods manufacturing plant. This is where the Millefeuille, which we'll see being made today, along with cookies and other items, are produced.
Apparently, an astonishing 37.24 million Millefeuille are produced here annually! In addition to the classic "Chocolate," "Strawberry," and "Almond" flavors, seasonal and regional limited-edition products are also made at this factory. We were simply overwhelmed by its scale and production volume.
Grand Prize Winner of the "Japan Food Selection"!
What's more, Mary Chocolate's "Millefeuille" received the Grand Prize—the highest award—at the Japan Food Selection in June 2025. The Japan Food Selection is a food evaluation system originating in Japan, organized by the General Incorporated Association Japan Food Analyst Association. It's a highly reliable award, with strict evaluations conducted by approximately 23,000 food analysts.
This factory tour was specially planned to coincide with this award, with the aim of helping people understand the passion and meticulous care that goes into making the "Millefeuille." What's more, the production process of the "Millefeuille" is being revealed to the media for the very first time!
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To the Manufacturing Floor! A Report on How "Chocolate-Delicious Millefeuille" is Made!
The factory prioritizes cleanliness! After changing into the designated uniform, we're ready to go. The manufacturing process for "Millefeuille" is broadly divided into three phases.
Manufacturing Process ①: Baking the Puff Pastry
First up is baking the puff pastry. The initial step involves preparing the pastry before the cream filling.
The most crucial point in this process is the baking consistency of the puff pastry. Baking it too much would add an unwanted savory aroma to the dough. To maximize the chocolate flavor, they intentionally avoid overbaking.
Manufacturing Process ②: Cream Filling
The next step is filling the puff pastry with cream and chilling it in the refrigerator. On the day of our visit, they were filling the "Strawberry" cream. They layer more puff pastry on top of the cream-coated pastry.
Each "Millefeuille" puff pastry sheet has 144 layers. While the number of layers can be adjusted, extensive trial and error showed that this specific count offers the most delightful crispness and light texture without overpowering the chocolate's melt-in-your-mouth quality.
They're also particular about the cream filling. It's specially formulated to have a robust flavor so it doesn't get lost amidst the rich taste of the chocolate. After filling the cream and carefully layering the puff pastry, the millefeuille is then left to chill thoroughly in the refrigerator overnight.
Manufacturing Process ③: Dressed in Chocolate and Ready for Completion!
Finally, the last step involves finishing the puff pastry, which has been resting overnight, into its complete form. First, the large puff pastry is cut into appropriate sizes. An impressive 162 millefeuille pieces are cut from a single large sheet!
And now, we come to the essence of "chocolate-delicious millefeuille": the chocolate coating process. The chocolate used here is specially developed to ensure the best chocolate flavor experience in the millefeuille. It's applied in "two coats."
After the first coating of chocolate, air is blown to apply a thin, even layer over the entire millefeuille. This process is then repeated. Since the surface of the crispy puff pastry is uneven, applying two coats ensures the chocolate is evenly distributed everywhere. This creates that exquisite balance, allowing you to enjoy consistent deliciousness with every bite.
The chocolate-coated millefeuille then passes through a cooling tunnel and proceeds to a metal detector. Mary Chocolate mandates that all its products go through this metal detector to ensure there are absolutely no foreign objects.
For individual packaging, one machine processes approximately 250 pieces per minute. With two machines operating today, that's over 20,000 pieces per hour – an incredible speed! Witnessing the millefeuille being individually packaged one after another was truly impressive. Although the boxing operation wasn't active today, we were told it's handled by boxing robots.
During the factory tour, I strongly felt that while the latest machinery handles efficient production, human eyes and hands are consistently involved at crucial points. It's through this meticulous checking and accumulated manual work that Mary Chocolate's high-quality millefeuille is maintained and delivered to us.
Tasting the Freshly Made "Millefeuille"!
Finally, the long-awaited tasting time! During the factory tour, the factory manager personally picked out a freshly made "Millefeuille" that had just come off the line, especially for us.
So, how did the freshly made Millefeuille taste? I felt the puff pastry was slightly crispier, but honestly, it was hard to say which was better when compared to the packaged ones we usually buy. Both were equally delicious!
Once again, I was truly impressed by the high quality of Mary Chocolate's products.
Surprising Combinations! Recommended Ways to Enjoy Millefeuille in Summer?
Millefeuille is perfectly delicious on its own, but we were also taught a new way to enjoy it, perfect for summer!
Millefeuille (Strawberry) × Black Pepper
Generously sprinkle freshly ground black pepper over the strawberry cream millefeuille. The sweet and sourness of the fruit, combined with the aroma and spiciness of the black pepper, creates an exquisite match, transforming this sweet treat into a sophisticated adult snack! It paired exceptionally well with Chardonnay white wine.
Millefeuille (Chocolate) × Chocolate Ice Cream
Next, we tried a combination with Mary Chocolate's "Cacao Ice Dessert." This chocolate ice cream was specially developed to change its texture depending on how long it's been out of the freezer. After about 10 minutes out of the freezer, it transforms into a melt-in-your-mouth texture, just like nama chocolate!
The combination of cool ice cream and millefeuille is undeniably delicious! It was truly a perfect reward dessert for a hot summer day.
The Secret to "Millefeuille's" Deliciousness is Indeed "Chocolate"!
Finally, I directly asked the factory manager, "What is the secret to the deliciousness of your Millefeuille?" And as expected, the answer was in the "deliciousness of the chocolate."
Throughout the factory tour, I realized that every element—from the crispy puff pastry to the flavorful cream—is meticulously designed and created to maximize the deliciousness of the chocolate. There was no doubt; it truly is a "chocolate-delicious millefeuille"!
Mary Chocolate offers not only classic flavors but also seasonal and regional limited-edition Millefeuille. Other flavors are surely packed with the same meticulous attention to deliciousness. I encourage all of you to try various flavors and savor their depth!
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