The Care We Take Over Our Factory
Hikari Foods released a sauce onto the market that contains no artificial food additives in 1964, followed by another sauce made with organic ingredients in 1977. Ever since then, we have been committed to using safe and organic ingredients to make foods that truly are the real thing, and contain no additives.
Having acquired the organic JAS certification for our factory in 2000, we do not simply aim for efficiency, and rather than going fully automatic, still do some of the processes manually. In this way, we continue to create products that still retain that hand-made goodness, never compromising, and sparing no effort.
The basic rule is that the production tanks are washed by hand with hot water, and the main filling line has a CIP cleaning system to perform thorough washing to ensure there is no contamination by allergens and so on.
The walls and ceilings of the production room, bottle-cleaning room, filling room, packaging room, and storage tank room are all stainless steel, creating an extremely hygienic manufacturing environment.
Some rooms are kept at positive pressure to prevent insects from entering, and the filling room is a clean room. Multiple cameras are installed inside the factory for traceability and food safety.
Our manufacturing processes have been managed in accordance with HACCP for a long time, and in February 2020, we acquired the international safety certification FSSC 22000. (Scope of acquisition: Manufacture of sterilized seasonings, including sauces and processed tomato products, and of concentrated fruit juice beverages, in glass bottles, plastic bottles, and cans)
FSSC 713500 / FSSC 22000
The production control ensures that records are kept in a wide range of manufacturing processes. In addition to having a production system that meets the HACCAP standards, we also take food safety measures that are made visible in accordance with global standards, in order to make our foods more safely than ever.
The Facilities in Our Factory
Vegetable Washing Room / 蔬菜清洗室
Some of the raw materials, such as vegetables produced on our own farms, are cleaned and processed in our factory. Vegetables are washed in a separate area from the production room, etc., in order to prevent soil bacteria and insects from getting into the factory.
Vacuum Concentrator / 真空濃縮機
The equipment installed includes a liquid downward flow vacuum concentrator. This enables us to make tomato puree from tomatoes without using any additives, and at a lower temperature so less heating is required.
Flash Pasteurizer (Tubular Pasteurizer) / 瞬間殺菌裝置(加熱管)
In order to pasteurize heat-resistant bacteria, etc. without compromising the flavor of the raw materials, we use a tubular pasteurizer to sterilize in a flash.
Bottle-Cleaning Room / 洗瓶室
Empty bottles are cleaned and sterilized with hot water only and no chemicals, etc.
Empty Bottle Inspection Machine / 空瓶檢查機
We have introduced an inspection machine that instantly detects flaws or stains on the top surface of empty bottles through image analysis, and can reject bottles and store image data on them at the same time. This enables us to detect minor scratches, etc. not visible to the human eye, and to fill the bottles with products more safely than ever before.
Filler / 充填機
The filling room is a clean room. When the containers are being filled, foreign objects are removed using physical or magnetic filters.The main filler fills each bottle, weighs it, and keeps a record. For screw cap bottles, the force applied to close the cap is controlled and recorded for each bottle.
CIP Cleaning System / CIP清洗裝置
In order to prevent contamination by allergens, the main filler line is equipped with a CIP cleaning system. This enables the inside of the pipes to be cleaned without disassembling the line.
Packaging Room / 包裝室
In order to prevent printing defects when labeling or wrapping with film, the main labeler uses a camera to inspect what has been printed, and in the event of a defect, rejects the product and keep a record of it.