Stable supply
In food manufacturing, a stable supply of ingredients is an important factor that influences product quality and production plans. At Kobayashi Foods, we have built a stable supply system for bonito flakes, dashi ingredients, seasoned dried products, and dashi packs, utilizing the procurement network and manufacturing know-how we have cultivated over the 40 years since our founding. We support our customers’ food manufacturing with a reliable supply of ingredients.
Three foundations that support stable supply
1. Reliable raw material procurement capabilities
Kobayashi Foods has built long-term relationships with reliable suppliers both in Japan and overseas, securing multiple procurement routes. Bonito, the main ingredient in katsuobushi, is particularly susceptible to fluctuations in season and catch, but we have secured import routes from major domestic fishing ports as well as from overseas. We also have a system in place that allows us to check the origin and quality of ingredients at any time, ensuring a stable supply of the optimal ingredients to meet our customers’ needs.
Procurement capabilities in numbers
[Annual raw material handling volume]
about2,000ton
[Procurement Network]
Domestic6fishing port,
overseas3countries
[Raw material suppliers]
20A trusted partner
for over 100 companies
2. A comprehensive manufacturing and inventory system
Our own factory in Yaizu City is equipped with the latest manufacturing equipment and a production system staffed by experienced technicians. We also maintain sufficient stock of regular products at all times to be able to respond to fluctuations in demand. Furthermore, the dried bonito flakes that we use as raw materials are always stored in temperature-controlled refrigerators, so we are well-equipped to handle sudden orders. Furthermore, we can handle everything from small lots to large orders with flexible production plans tailored to our customers’ needs.
Seasoning and drying line
The seasoning and drying line at the Oshima Factory can season, mix and dry approximately 1 to 1.5 tons of furikake per day.
Dried bonito flakes production line
The bonito flakes production line has four rooms for thin shavings (general shavings) and one room for thick shavings (shavings specifically for making dashi). With a total of five production lines, we are able to flexibly respond to production requests.
Liquid dashi line
The liquid dashi line can produce approximately 1 to 1.2 tons of dashi per day.
Product formats include crimp cans (refrigerated), BIB (room temperature), and aseptically filled aluminum bags (room temperature).
Our own factory production capacity (annual)
| Thinly shaved dried fish | Approximately 600 tons |
|---|---|
| liquid dashi | Approximately 180 tons |
| Dashi powder for extraction | Approximately 200 tons |
| Dashi pack | 100,000 packs per month |
| Seasoned furikake | Approximately 300 tons |
| Always-on inventory | More than two months’ worth of main ingredients |
| Shipping | Ships as soon as the next business day |
3. Thorough quality control system
We have established a consistent quality control system from receiving raw materials to manufacturing and shipping. We supply safe, high-quality products through hygiene management based on HACCP and regular quality inspections. In addition, our raw material traceability system allows us to track the raw material history of all products. We also issue quality certificates upon request from customers.
Quality Control Initiatives
| Sanitation Management System | HACCP certified |
|---|---|
| Daily quality inspection items | 10 items or more |
| Traceability | Compatible with all products |
| Annual quality-related investment | Continuous equipment updates and technical training |