We not only carefully select raw materials and seek the best taste, but we are also particular about the quality control and production of products that our customers can eat with peace of mind.
We use not only scientific methods and numbers, but also our five senses to confirm quality and safety.
In order to secure safe and secure raw materials, we established an agricultural production corporation, Agri Takano, and produce rice and Sasage Beans for red bean rice at our own farm. We also visit our suppliers nationwide to check production information.
All raw materials are inspected for acceptance, and only raw brown rice that meets the inspection standards is accepted. We also use ZEN-NOH Anzen System Rice (rice whose production information is disclosed by JA ZEN-NOH) to create products that show the production area and production information.
In order to provide safe and hygienic products to our customers, we have introduced a food safety management system that incorporates HACCP methods. Process flow diagrams and inspection items are created for each product, and thorough management is carried out to produce safe and delicious products.
In order to deliver safe and reliable products to our customers, we conduct physical and chemical tests on products and raw materials, such as measuring moisture and residual oxygen, as well as microbiological tests, such as general viable bacteria counts and food poisoning bacteria, to ensure the quality and safety of our products.
We use our five senses to make sure that we are producing delicious products that meet our internal standards.
During the sensory test, we actually eat the product to make a final confirmation of its deliciousness in terms of color tone, aroma, sweetness, stickiness and firmness.
The terraced rice fields are beautiful fields that our ancestors worked hard to create. Growing rice on these fields is labor-intensive and difficult, but protecting these terraced rice fields in the mountains also helps to preserve the natural environment of the plains below the mountains. It is said that rice grown in the mountains tastes especially good because of the variation in temperature throughout the day.
Furthermore, the rice is stored in snow storage that takes advantage of the power of nature to bring out the flavor and sweetness of the rice.
Seawater from the naturally rich Sasagawa Nagare in the northern part of Niigata Prefecture is repeatedly passed through a bleaching cloth to carefully remove dirt and lime from the sea, and is then slowly boiled down over time using large amounts of firewood to produce salt.
The salt from the richness of the sea enhances the taste of red bean rice.
It takes a lot of time and effort to harvest sasage beans.
Due in part to the shortage of farmers, many have quit cultivating, and the amount of Japanese produce is decreasing. Therefore, we decided to grow Sasage Beans in our own fields and also asked local farmers to grow them for us.
We are proud of our Sasage Beans produced from melting snow water and fertile soil.
The taste of the carefully grown rice in the rich natural environment of Sado is exceptional. In order to preserve this blessing of nature, Sado not only reduces the use of pesticides and chemical fertilizers, but also creates a paddy field environment that is easy for creatures to live in, and uses farming methods to nurture them.
We purchase such rice from Sado.
In order to ensure that our products are safe to eat, we have published a process flow diagram and inspection items.
| Manufacturing Process | Details | Inspection Details |
|---|---|---|
| Raw rice subject to acceptance | Acceptance inspections are conducted, and raw brown rice that conforms to the inspection standards is accepted. | Check the place of origin, brand name, grade, quantity, appearance, and quality (shape, aroma, etc.). |
| Polishing | Mill brown rice into polished white rice. | |
| Selection | Remove damaged rice such as colored grains and insect-eaten rice, as well as foreign objects such as glass and stones. | |
| * From here the cleanroom process begins. | ||
| Washing | Wash away rice bran adhering to the surface of polished rice with a stream of water. | |
| Soaking | Soak the washed rice for about three hours to allow it to absorb water thoroughly. | |
| Steaming | Steam the soaked glutinous rice in a steam oven for about 30 minutes. | |
| Pounding | Use a continuous pounding machine to pound the steamed rice in stages to make mochi. | The pounded mochi is subjected to physical and chemical tests, microbiological tests, and taste checks. |
| Measurement | Measure out the mochi into the container and spread it by hand. | |
| Cooling and solidification | Cool in the refrigerator for about two days to solidify the mochi. | |
| Cutting | Remove the mochi from the container and gradually cut them into pieces of about 50 grams each. | |
| Personalized Packaging | Wrap cut mochi one by one.。 | |
| UV (ultraviolet) Sterilization | Apply UV (ultraviolet) light to the packaged rice cake to sterilize the surface. | |
| Metal Detection | Use a metal detector to make sure there is no metal in the product. | Check the sensitivity of the metal detector with a test piece. |
| Inspection | Make sure there is nothing wrong with the product. | |
| X-ray Inspection | Check for foreign objects with an X-ray machine. | Check the sensitivity of the X-ray machine with a test piece. |
| Weighing and Packaging (Insert oxygen absorber) | Measure the specified amount of individually wrapped mochi and fill them into the outer bag. At this time, an oxygen absorber is also enclosed to prevent the formation of mold. | |
| Inspection | Make sure there is nothing wrong with the product. | |
| Inverse Metal Detection | Make sure there is an oxygen absorber in the package. | Check the sensitivity of the metal detector with a test piece. |
| Weight Check | Use a weight checker to confirm that the weight conforms to the standard. | |
| * This is the end of the cleanroom process. | ||
| Packed in a Box | Pack a specified amount of product into a box. | |
| Quality Inspection | Conduct product inspections to ensure that products conform to standards. | Physical and chemical tests (weight, moisture, pH, residual oxygen), microbiological tests (general viable bacteria count, fungi), and sensory tests are performed. |
| Manufacturing Process | Details | Inspection Details |
|---|---|---|
| Raw rice subject to acceptance | Acceptance inspections are conducted, and raw brown rice that conforms to the inspection standards is accepted. | Check the place of origin, brand name, grade, quantity, appearance, and quality (shape, aroma, etc.). |
| Polishing | Mill brown rice into polished white rice. | |
| Selection | Remove damaged rice such as colored grains and insect-eaten rice, as well as foreign objects such as glass and stones. | |
| Washing | Wash away rice bran adhering to the surface of polished rice with a stream of water. | |
| Soaking | Soak the washed rice for about three hours to allow it to absorb water thoroughly. | |
| Washing | ||
| Metal Detection | Use a metal detector to make sure there is no metal in the product. | Check the sensitivity of the metal detector with a test piece. |
| Measurement | Measure and fill the container (tray) with soaked rice and water. | |
| Cooking | Align the filled container with the frame and place it in the steam oven to cook the rice for about 20 minutes. | Monitor the pressure, cooking temperature, and cooking time of each oven to make sure it conforms to the standards. |
| Heat Insulation | Keep the cooked rice warm until the film is sealed to prevent it from getting cold. | |
| Gas Displacement and Sealing | Before sealing the film, nitrogen gas is sealed to lower the oxygen concentration in order to reduce bacteria and deterioration. Seal the film after filling with gas. | Measure the residual oxygen and confirm that the gas replacement is properly done. Measure the seal strength and verify that the seal is properly in place. |
| * This is the end of the cleanroom process. | ||
| Cooling | Release the warm product to cool. | |
| Inspection | Check for any abnormalities in appearance or seals. | |
| X-ray Inspection | Check for foreign objects with an X-ray machine. | Check the sensitivity of the X-ray machine with a test piece. |
| Metal Detection （Inverse Metal Detection） | Use a metal detector to make sure there is no metal in the product. | Check the sensitivity of the metal detector with a test piece. |
| Weight Check | Use a weight checker to confirm that the weight conforms to the standard. | |
| Packed in a Box | Pack a specified amount of product into a box. | |
| Quality Inspection | Conduct product inspections to ensure that products conform to standards. | Physical and chemical tests (weight, moisture, pH, residual oxygen), microbiological tests (general viable bacteria count, fungi), and sensory tests are performed. |
| Manufacturing Process | Details | Inspection Details |
|---|---|---|
| Raw rice subject to acceptance | Conduct acceptance inspections and accept raw materials that meet the inspection standards. | Check for any abnormalities in appearance and quantity. |
| Measurement | Measure out the amount of formula determined for each item. | |
| Mixture | Mix the raw flour, add water, and mix further to make a dough for the shiratama. | |
| Kneading | To make the dough more even, pass it through a kneading machine for further kneading. | |
| Molding | Form the dough. | |
| Boiling | Boil in a boiling tank for about 10 minutes. | Measure the temperature of the boiling tank and the temperature of the center of the shiratama after boiling to make sure that the boiling is done properly. |
| Water Cooling | Remove the rough heat of the shiratama with water, and then cool it further with cooled water. | Measure the temperature of the water-cooling tank and the center temperature of the shiratama after water-cooling to confirm that the water-cooling is done properly. |
| Alignment | Arrange the shiratama in a line so that they do not stick together. | |
| Freezing | Put the shiratama through a tunnel freezer to freeze quickly. | Check the temperature and speed of the freezer, measure the center temperature of the shiratama after freezing, and make sure that freezing is done properly. |
| Inspection | Check for any abnormalities in appearance. | |
| Metal Detection | Use a metal detector to make sure there is no metal in the product. | Check the sensitivity of the metal detector with a test piece. |
| X-ray Inspection | Check for foreign objects with an X-ray machine. | Check the sensitivity of the X-ray machine with a test piece. |
| Weight Check | Use a weight checker to confirm that the weight conforms to the standard. | |
| Inspection | Check for any abnormalities in appearance or seals. | |
| Packed in a Box | Pack a specified amount of product into a box. | |
| Management | Store in a freezer below -18°C. | |
| Quality Inspection | Conduct product inspections to ensure that products conform to standards. | Physical and chemical tests (weight, moisture, pH, residual oxygen), microbiological tests (general viable bacteria count, fungi), and sensory tests are performed. |
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