Our commitment to safety and security
Sea Vegetable landed from the sea are nurtured by the blessings of the sea and shine brightly, but because they are natural materials, they are covered with small sea creatures, pebbles, and shells that can only be identified by a close inspection.
The sorting process to remove them cannot be automated, and requires a patient and meticulous “human” touch.
On the other hand, the production line, which boasts one of the highest production volumes in Japan, uses state-of-the-art production control techniques and originally developed equipment and devices. Our one-of-a-kind production line is filled with technology and passion for “creation,” and we continue to deliver delicious sea vegetable products to our customers today.
The main factory, located next to the head office, has succeeded in achieving a very high level of automation, from manufacturing to boxing. However, no matter how much mechanization has progressed, the mainstay of the manufacturing site is still the power of “human resources” that combine skilled techniques and motivation.
While the latest machines and equipment are being introduced on the production line at a dizzying pace, there are still more than 300 people working on the production line.
Even for salted and dried products, the delicate senses of the human eye and fingertips are indispensable in identifying and removing minute foreign substances. We do not think of leaving this sorting work to machines alone. We always stand in the customer’s shoes, and our strong desire not to overlook even the smallest foreign matter enables us to maintain our sense of responsibility.
Furthermore, the company has a complete employee training system to develop each individual’s skills. Our efforts to motivate employees, such as our unique monthly gold, silver, and bronze award system for outstanding employees, are also paying off. It is only with a high level of “human resource power” that we are able to steadily improve our production facilities.
We are actively introducing advanced technologies not only in the production line but also in the peripheral facilities surrounding the line, such as original equipment (filling machines, weighing machines, packaging machines, etc.) developed jointly with machine manufacturers and automatic warehouses. We also focus on thorough hygiene management and have established traceability that shows the production, manufacturing, and distribution routes of our products.
Our production system maximizes the power of people and technology. This is a major feature and asset that no other company can imitate.
No matter how much mechanization advances, the main role of the manufacturing site is still played by “human power” that combines skilled techniques and motivation.
Through many processes, we deliver safe and secure products to customers’ tables.
Our quality control department has a number of missions.
Among the wide variety of duties, such as microbiological and physical/chemical inspections, hygiene control of production lines and work environments, quality control from the customer’s perspective is the most important mission. Here we introduce the current status of our quality control system, which manages hygiene and management from the customer’s perspective and supports the creation of safe and secure products.
In Japan, where sea vegetable is the most widely used sea vegetable in the world, we are proud to be a company that is more passionately challenging the potential of sea vegetable than any other.
Our sense of mission to deliver safe and delicious sea vegetable products to our customers is the source of energy that drives our quality control staff.
The foundation of our quality control is our meticulous quality control work, which starts with strict management at the raw material procurement stage, continues through various inspections at the manufacturing stage, and ends with sanitation control.
In the procurement stage, we cooperate with the manufacturing division to conduct hygiene surveys of the fishery companies and contract factories from which we purchase raw materials.
Business trips to Hokkaido and Okinawa are a daily occurrence.
In addition to these inspections, we conduct thorough inspections at the “entrance” to the manufacturing process, including inspections when raw materials are received and physical and chemical inspections at the pre-production stage. We are striving to ensure safety at a higher level.
In preparation for such advanced inspection work, the quality control room in our headquarters plant is fully equipped with inspection equipment such as high performance liquid chromatography. We also take a leadership role in ensuring that each and every employee at the manufacturing site is in charge of hygiene management.
|Raw material control||Microbiological inspection and quality confirmation inspection at the time of receipt and use.|
|Product control||1.Physical and chemical inspection by liquid chromatography (HPLC), pH meter, Brix meter, etc. for each manufacturing lot, etc. at the time of manufacturing.
2.Microbiological inspection of each production lot after production, keep sample retention.
|Manufacturing process and equipment control||Sampling and wipe inspections by process and equipment.|
|Control of additives, drugs, etc.||Control of quantity and prevention of misuse.|
|Employee management||Education and guidance on hygiene, etc.|
|Shelf life control||Shelf life inspection for setting shelf life.|
|Document management and preparation||Product specifications, labeling checks, etc.|
Sea Vegetable has been attracting a lot of attention for its health and diet benefits, and we are the nation’s leading supplier of sea vegetable.
We handle all kinds of sea vegetables from popular colored sea vegetable to rare species.
We also develop and manufacture salted and dried products, private brand products for supermarkets and convenience stores, and original products developed in-house. We are able to meet not only domestic needs but also overseas needs because we are a pioneer in the sea vegetable industry.
We have established a system that enables us to reliably procure the required products from more than 1,000 customers in Japan, from Hokkaido to Okinawa, as well as overseas.
In general, most trading companies and manufacturers specialize in one or two or three sea vegetable products, such as wakame seaweed or hijiki seaweed, but we are one of the few comprehensive manufacturers in Japan that handle all kinds of sea vegetable products.
This wide range of product capabilities is supported by a network of about 200 domestic and international suppliers.
It is not unusual for us to participate directly in the bidding of fishing federations throughout Japan.
For example, we purchase the finest kelp from a middleman in Kushiro, Hokkaido, and procure selected mozuku and sea grapes from a fisheries company in Okinawa.
We also procure wakame seaweed from Sanriku, Ise Bay, and Naruto, and tosakanori (sea vegetable) from all over western Japan, carefully selecting the best seasonal ingredients.
Similarly, we have suppliers in Kumamoto, Mie, and Fukushima for aosa, and our great strength is that we have suppliers in various regions for the same items.
By keeping a close eye on market price changes and seasonal trends, we are able to deliver the highest quality and most reasonably priced merchandise at that time of the year.
In addition to procurement from all over Japan, we are also expanding our procurement network overseas for some sea vegetables that are difficult to procure domestically.
Examples include Canada’s Primula canadensis and Chile’s Suginori seaweed. We have also secured procurement routes to neighboring Asian countries to prepare for possible shortages.
Major procurement locations: excerpts
The secret behind the delicious texture of Kaneryo is the heating and sterilization method using THC (Takagi Heating and Cooling Machine)!
A stainless steel plate is attached to the device as an electrode, and when sea vegetable is placed in the device and electricity is passed through it, the sea vegetable becomes a conductor and self-heats, allowing it to be heated in a short period of time.
The heating time is greatly reduced compared to fire or steam by passing electricity.
Sterilization of raw sea vegetable without losing its texture is now possible.
|Kaneryo’s THC (Takagi Type Heating and Cooling Machine)||Conventional steam machines|
|Formula||The turnip itself is heated by electric resistance and sterilized by heating the turnip directly through electricity.||Mekabu is moistened with water, and then heated and sterilized by indirect heating with steam from the mekabu and water.|
|Sterilization||Direct energization allows electricity to flow throughout the body, enabling uniform heating by self-heating. Fast response speed because the temperature control directly controls electricity. This allows continuous sterilization at a stable temperature.||Uniform heating is impossible due to uneven solid temperatures caused by indirect heating.|
|Qualilty||“Since the entire solid is energized and self-heats, uniform and rapid heating is possible, which reduces the burden on the solid.
This enables production with minimal deterioration in the color, flavor, texture, and other qualities of the solid itself.”
|“Indirect heating by steam causes significant damage to solids because the temperature rises in the order of water, solid exterior, and solid center.
There is a problem that components of solids (such as umami nourishment) are drained out in draining after heating in order to adjust the amount of water required for heating.”
|Manufacturing Environment and Other Information||“Know-how is required to provide stable heating for raw material pretreatment.
No fossil fuels, etc. are used and earth-friendly fuels (electricity) are used.”
|Temperature control can be easily achieved, but the hygiene and noise associated with rising temperatures in the operation can be distracting.|