It's the HALAL POLICY with our halal objectives The factory has secured 500-600 halal-certified ingredients. All products made by them can be sold as Halal products. We'd show visitors documents proving
only halal ingredients are used This is a log book to see that production is hygienic with records of ingredient lots, process, sterilizing temperatures, procedures We pasteurized unfrozen goods So, we check if it's pasteurized properly via the graph This is the storage room for ingredients. All of them are Halal. (showing a few variety of Halal-certified soy sauce) There are many soy sauce flavours,
so this is *dark soy sauce Japanese vinegars made from alcohol, so we can't use them.
This is Indonesia's DIXI vinegar. We'd dilute it with water, add yeast extract, other umami ingredients to make our own rice vinegar. Then, we use that vinegar to make like Ball-shaped Sushi. We aim to meet international standards, therefore we are very careful about the vinegar we use. This is breadcrumbs of Indonesia's MUI. A fat called shortening is used in breadcrumbs
to make them flakier. In those shortenings, most contain pig-derivatives. But, this Indonesian one is Halal with certification
that the shortening uses plant-based only.
So we must also check that all secondary, tertiary
ingredients included in them. It can't be used unless you check it. We only use ones that are confirmed safe. Chicken stock and beef stock too, all are certified. chili sauce Otafuku sauce halal-certified olive oil Originally we wholesaled foodstuff to hotels Now, hotels are swamped catering for allergies. In cases like Tokyo Olympics, where multi-national
people come for a brief visit, it's hard to cater for allergies or religious dietary. If so, our products that also cater for religious dietary, can be enjoyed by everyone—Americans,
Japanese, Europeans, Muslims, which may help hotels to operate easier. That's why we opted for Halal. It's said that 1/4 of the world's population is Muslim. Regular goods in Japan today only target
75% of the world's population. So we decided to create our goods with a 100% target.
At international conferences, there are many
that don't have the same meal. The same for universities' welcoming events
for foreign students, only Muslims would have like a different meal. At international events, it should be a basic fact
of everyone enjoys the same food in harmony That is what I aim to do when I started this. Since we're doing this, we have to meet international standards that cover Malaysia, and even the
stringent Middle-East's standards. Recently, certification bodies certified
by Malaysia's JAKIM are increasing. Also from the Middle East's ESMA, GAC. We have MUIS [Singapore] certificate too. This is a Turkey's halal tomato Ingredients would come from here, then we sort them into freezers here.
This is fridge for ingredients Fridge for defrosting For food in-progress (ongoing prepped food) For finished/cooked food Example, if contaminated ingredients are
store together with food-in-process, they can be contaminated by air. Plus, it's not hygienic to store defrosting goods with goods in cooling phase together, so we separate like this. Here is where we prepare meat, fish and vegetables. We don't prepare meat and fish together. Chopping boards are divided into use for
meat, fish, vegetables Same with knives: meat, fish, vegetables.
Everything is separated. We prep with colour-coded boards, exclusive knives,
different prepping time slots to avoid contamination risks. Prepping meat and fish simultaneously is very unhygienic. We maintain a thorough hygiene by separating chopping boards, knives and cooking times. Things prepared here moved to the production room We do all kinds of work here like packaging the cooked food or arranging the bento [packed meal]. We're about to cook *Kinpira Burdock (see description👇) There's no flight right now, but we do have some orders
for in-flight catering company at Narita Airport.
Arima Onsen have the same one for their breakfast. This is a measuring room, so there's a scale. Here are seasonings This is Koujin's halal product There are some certified products that
don't mark halal on them. For such products, we have their halal certificates Bonito Stock Kuki Sesame's oil also has no halal mark on it, but it has a halal certification by Japan Halal Association We measure seasonings here. This is where we put used seasonings. Over here is the freezer. This is chicken certified by Thailand's CICOT Minced chicken There is a declaration basis. For a non-certified product, you must submit a full specification of manufacturing process and ingredients.
If the association confirms it is halal, then we will use it. For that, a pledge is important. And we make sure to only use items that have those pledges. It's a food processor for mixing. A cutter mixer. This machine is for grinding coarse pieces into micro-paste. It has a millstone in it Here is the cooking section. This is the pasteurizer This is to make *dashimaki egg (see descrip.👇) Our dashimaki egg has been used by Emirates Airlines.
We have 13 inns of Arima Onsen that
use our dashimaki egg too Many people think that Halal=Not Tasty. Japan has a lot of dashimaki egg shops, but ours are recommended by chefs, that are halal and delicious. Our kinpira burdock are made a lot like that to supply
to Narita Airport and Arima Onsen We used to fry 40 tons a year here
of fried food for in-flight meals. It can fry 100kg an hour. We used 2 of them, 200kg per hour, 8 hours a day, 20 days a month for 12 months. It would fry about 40 tons a year. We cook and fill in curry here. It's an insulated tank. Temperature is kept at 90°C while we fill food (into packs) there. There is a magnet of 10,000 gauss at the protruded point. It can absorb all the fine iron powders that don't react to metal detectors. Grinded curry spices also have finely iron powder in them, which can be removed with it.
If the filling temperature is above 80°C and pH is kept below 5.2, bacteria will not grow between the filling and sterilizing time,
even after half a day. Its temperature is controlled to be safe. Of course, we process them as quickly as possible. There will be about a 1hour difference between the first and the last filling. During this time, we try to avoid bacteria forming in the first filling.
It can take 1-2 hours (from filling to sterilization) as long as the temperature and pH are controlled. Here is for simmering food like cooking curry. We can cook roughly about 150kg at a time. This is an oven. We're baking meringue now. Nice! Looks good! This one uses steam, food won't get burnt like when cooking vegetables. But for strong heat, we use copper kettle with high thermal conductivity
over direct heat. For precise temperature control to the nearest degree, we use induction. It's for making custard cream. There is high demand for sweets among Muslims Our financiers are also made with a machine like this
while controlling the temperature A steam-heated oven Electromagnetic waves are applied to raise the steam to about 400°C Normally steam only rose to about 150°C, but because it rose to 400°C, imported chicken can be as juicy as domestic ones. We are particular on heating and freezing, thus we can make delicious food Food heated here are then vacuum-packed here.
Line up the products and pack them up It's vacuum-packaging Non-vacuum-packed products are lined up here, then sent to the other side About 1000 pack a day can be packaged. Vacuum packaging machine, decompresses as the air in the bag is let out. The air leaks at 30°C, just like how water boils at 80°C on Mt.Fuji What you should do during that time? If a pot is about to overflow, you can lower the heat and it will boil without spilling. This is a 'Low Heat Function' that can be switched automatically. That's why it can vacuum-pack liquids, even though it's horizontal. Most factories use the vertical type to vacuum-pack liquid. It rotates in a loop, with a tank on top to vacuum-pack vertically. That (type) won't overflow but it tends to produce for larger batches like 1 ton and above. As you've seen, our equipment allow us to handle small quantities.
In other words, for thousands or 10 thousands packs, it's cheaper to order from larger factories. But, considering the current Muslim demand and so on, you don't need such huge quantities. If a hotel wants to show its originality, features or have specific requests, a factory like ours is perfect A large factory is not quite viable if it becomes an exclusive Halal factory. It's easier to meet demand with this scale of equipment. This is a pack-sealer This is a proton freezer It's a bit unique It's like having a microwave oven inside a refrigerator. It lets out electromagnetic wave. It's now at -34°C, yet it's not frozen because the molecules vibrated by waves. Once it reaches -40°C, the waves will stop.
Unfrozen items go through ice crystallization temperature range at once, down to -40°C. So there's no droplets when you defrost fried food or chicken steak. It doesn't get dry or less juicy. Even our fryers are electrically charged. We take great care in heating, freezing our food, thus it tastes delicious. Regardless of Halal, other freezer manufacturers may focus on freezing, but not on heating. No matter how good the freezing process is,
if the food is not tasty before it's frozen, it won't taste any better. Here's the storage for finished product. thinly sliced and dried radish [kiriboshi daikon] Fried shrimp, chicken skewer [yakitori] Grilled beef There's a lot here like fried rice, yakisoba [fried noodle] For unfrozen goods, they are pasteurized in a sealed pouch like this. It's pasteurizing. Pasteurize meaning we control the time and temperature, so it can be used as a cooking tool. It's vacuum packed with fresh cut vegetables, meat, seasoning sauce and cooked in a pouch. It's called sous vide. It's sterile, ingredients are measured first and distributed evenly, so it's the same in every pouch.
There are many sous vide variations including *chikuzenni, roast beef We won the gold award in the Emergency Foods Award for our halal set It's preserved at 50°C. What do you think is the basis for setting, example,
a shelf life of 5 years We actually let it sit (for that period). At 20°C, objects deteriorate at double the rate of every 10°C increase. doubles at 30°C, quadruples at 40, eightfold at 50. A year of preservation at 50°C gives the same test data as 8 years of preservation. Multiply by safety factor of 0.7 and you'd get 5 yrs shelf-life. Here's the date we put it in. We keep this to know the date These are stored from 2018. Now it's 2021, a little over 2 years (passed), so they would be about 16 years old (in reality). We would open it (to verify). Actually it will bulge out if there's abnormality We're checking for spoilage, taste however is a different story. Finally, we do sensory tests to check colour, appearance and how its taste. The tests are to see whether the product can last up to 7 or 10 years Standard pre-packaged meal can only be set for up to 3 years.
There's academic proof that products made with
soy sauce, mirin, other fermented seasonings, example: soy sauce darken as it oxidizes, miso emits fermented smell. That's roughly 3 years, they say. In terms of its ingredient processing, only possible for
3 yrs is common knowledge. To set a longer shelf-life, you can't use fermented seasonings. Why our emergency food can be set for 5, 7 years We have a patented non-fermented seasonings By using halal engineering, we can make our own Halal goods like mirin, etc.
We add yeast extract, guanylic acid, succinic acid and other mirin's umami factors to Japanese syrup [mizuame] to make mirin-like-seasoning. Like that soy sauce, it's for general use. Soy sauce for emergency food, we made soy sauce-like-seasoning,
a non-fermented one. It's a non-fermented, soy sauce-like-seasoning. It's a blend of soy sauce's umami ingredients, same way as our mirin. Just as salt-sugar are still salt-sugar after 5 years, our non-fermented soy sauce also stays the same
as it was freshly made even after 5 years.
It doesn't change over time. That's why it can lasts to 5 or 7 years. The product is preserved to a quality that you wouldn't even know the difference between the same product made today and 5 years ago. If we're going to make something, we want it done thoroughly Our emergency food is as good as fresh food, even after 5 years. We want to increase the variety of our emergency food, but it has to be well validated, so we have to let it sit for at least a year before we can test it. This is a tensile tester. We seal it here. To make sure it's properly sealed, we cut 1.5cm wide. Open like so, pinch it here. If it can't withstand a pull of 23kg, you know it's not sealed properly. To verify, we would cut 1.5cm wide, open, pinch and pull (there). When we found out it's not sealed properly, the batch is thrown away. That is how far we check. We set the sealing temperature and timing
to make sure there's no improper sealing. This don't happen, but we test and check it regularly just to make sure.
Here's a financier. We don't use like vanilla essence in our financiers. We use real almond powder with no artificial substances Really delicious! We use really great butter too That's what this factory is all about!.