PRODUCTION

Our products are manufactured in a facility approved under JAFA's GMP recognition system in compliance with HACCP.

Daiichi-Kasei manufactures food materials made from various types of proteins; food products such as soup bases and sauces; food additive preparations, for example, that are mixtures of seasonings, coloring agents, and preservatives; and other kinds of premixtures, which consist of food additives and food materials, are offered from our specialized production plants in two locations.
Since all our five plants produce foods related products, we take such measures as registering under JAFA's GMP recognition system for plants producing food additives and premixtures, for those plants producing food ingredients and sauces, we introduce hygiene and quality control systems of HACCP, and for all our manufacturing plants operational procedures of production control standards, hygiene control standards, and quality control standards are set.

Efforts for safety and security

We have established an "Integrated Production Management System", which links "QC/QA's quality assurance system", "R&D's product development system" and all five plants' production system. With this system, we are able to monitor and control the entire procedures of manufacturing, in real time, from warehousing of all the raw materials to shipment of final products. Moreover, this system makes us enable to manage all quality control and quality assurance data related to our products, and guarantee 〝safety" of our products by managing all data in unified manner to build a traceability system.
As preventive measures for contamination in the manufacturing process of the specified ingredients defined by the food sanitation law, each plant have taken actions to improve the facility. All plants implement measures now to prevent contamination from special ingredients associated with allergies that are not included in the recipe.

Production lines for aseptic filling or for allergen-free products

Manufacturing of the product requires high-level safety and/or allergen removal is performed in the clean room provided with an advanced hygiene system.
To enter the clean room, take another extra steps are required even though these procedures have been done when entering the Plant: Sanitation disinfection of hands and fingers with alcohol, change of a regular working cloth to the special one which is made of dust-free cloth material, and pass through the air shower tunnel.
By taking an extra caution, we are able to offer our customers more reliable and safe quality of products.

Introduction of each plant

Production of our five plants are controlled by our own systems based on GMP and/or HACCP.

Daiichi-Kasei has established a consistent production management structure from reception of raw materials to shipment of products at all the plants.

  • We have developed an integrated production control system to monitor from the initial stage of receiving raw materials to the final stage of product shipments.
  • Compliance of GMP recognized by JAFA as well as HACCP approved by Kyoto City's Food Safety Control System
  • Setting self developed standards for controlling the entire production processes
  • On line management program to monitor the production and quality control data.
  • Storage all data regarding production, quality control and product distribution in an integrated system to enable the food traceability. This is how we deliver our products to our customers along with safety and high quality .

Yamashina North Plant approved by JAFA's GMP

The Yamashina North Plant produces a variety of food additive preparations and Premix.
Food materials are precisely measured according to the recipe, sieved, passed through the iron removal process, and uniformly mixed. Mixed produced is then sent to an automatic packing machine for packaging into various forms according to the customer requirement.

Yamashina South Plant approved by JAFA's GMP

The Yamashina South Plant produces Prepared Mixture.
All receipes and process control flows are computerized; feeding of the ingredients, blending to mix all ingredients, and filling into bags are automated on a closed line. After checking the weight, bags are sent to the automatic sealer.
The packages are rechecked for weight by an automatic weight checker. Then inspected for quality and packaging conformation before shipment.

Yamashina DF Plant is HACCP Certified by Kyoto City's accreditation system for food hygiene and safety (Miyako shoku no anzen eiseikannri ninshou system).

Sauces, bastings, dressings and other liquid seasonings are produced at the Yamashina DF Plant. Raw materials in the filtered water are dissolved and uniformly mixed by a steamed blending machine, sterilized by heat and packed by an automatic filler. "Hot filling" method is practiced to prevent the secondary contamination of bacteria after the heating process. A clean room has been installed for production of allergen-free food and other kinds of related food requiring higher level of sanitary and safety control.

Kameoka Genesis Plant (HACCP Certified)

Kameoka Genesis Plant, Daiichi-Kasei's state-of-the-art manufacturing facility, produces the processed whey protein, the Genesis. Genesis, manufacutred by utilizing SLAWP technology, is a food material with many new functional properties not found in conventional protein materials.
Genesis production, from dissolution of raw materials to preparation and modification processes are all computer controlled. This series of process is carried out in the completely closed lines. This ensures high quality and safety of the product. Additionally, the product is retort sterilized, followed by automatic packing, using an aseptic filtering system.
Finished Genesis products are stored in an automated warehouse. Only those products, that have cleared out own quality tests, are delivered to our customers.

Kameoka Food Ingredients Plant approved by JAFA's GMP

At our state-of-the-art manufacturing facility, Kameoka FI plant, has two production lines that mainly produce functional food materials. These two lines are divided by the center wall and operated independently to prevent the contamination of allergic specific raw materials between eggs and milk.
In addition, the doorways of the staff to the production lines as well as the color of work clothes are separated to prevent egg powders and milk powders from crossing between two lines.