BUSINESS ASSURANCE How traditional Japanese Tea pursued the 'modern' food safety approach Hiroshi Izuta F&B Manager DNV GL Business Assurance Japan Koji Tategai Product Management Dept. Manager Kyoeiseicha Co., Ltd. 11 th of November, 2015 SAFER, SMARTER, GREENER
Topics 1) Overview of Food Companies in Japan 2) History of Japanese Tea production 3) How "Traditional food company" harmonized with "the Latest food safety standard 4) From FSSC 22000 Certified Organisation
Overview of SMEs in Japan
Most of Food companies are SMEs in Japan Large Small and Medium(3-299people) Very small 1% 29% 70% *Ministry of Economy, Trade and Industry Census of Manufacturers (2010)
Background Food Safety in Japan HACCP & Specific PRP have been introduced 80% of large companies. On the other hand, only 75% of small and medium sized companies have not still introduced. *HACCP survey (MAFF, 2012) They wish specification defined for small and medium sized company by food categories. *Material for Act on Temporary Measures concerning Sophistication of Management of Food Manufacturing Process (MAFF, 2013)
Obstacle on Food safety activities for SMEs 1. There are no personnel instructing development of HACCP in the company. 2. There are no enough knowledge and experience for hazards and control measure. 3. They are apt to think buildings and facilities are necessary for HACCP. 4. Companies not yet tackled HACCP are hard to recognize an effect of HACCP 5. It is difficult for them to documentation. (can do it, but cannot described it well) 6. HACCP is not well known to downstream of food chain (e.g. region, industry) Monthly HACCP April, 2015
History of Japanese Tea production
Tea manufacturing (Matcha) Incoming Selection Blending Crude tea/steamed green tea Sterilization (For Ingredient of confection) Grinding Shifter, Magnet Packaging Foreign matter detector Powdered Green tea(matcha) Release
Matcha manufacturing in Edo Period (18 th C) From Nihon-Sangai-meibutsu-Zue (a guidebook for special products)
Grinding Process in Taisho period (20 th C) Ancient stone mill Characteristic of Matcha is Bright Green. But there is the weak point that fading color by heat and light. Grinding Process in Taisho period (hand made) From Study of the matcha Hideki Kuwabara
Grinding Process in Taisho period (20th C) Machine for Grinding Process using stone mill From, Act of tea Yasumitsu Waki
Current Grinding Process Machine for Grinding Process using stone mill
Current Grinding Process Machine for Grinding Process (Dynamic mill)
Increasing interest in Matcha for Foreigner Confectionary using green tea (Matcha) is increasing. Furthermore, Export of Japanese Green tea and confectionary using Matcha is increasing year by year by Japanese foods boom and Healthy foods boom.
Export of Japanese tea (Y2012) Hongkong 3% other Thai 12% 4% Canada 5% Taiwan 6% Germany 9% Singapore 15% US 46% Export of Japanese tea 2,351t 5 billion JPY Tea export strategy, MAFF, 2013
Strategy of Export of Japanese tea Billion JPY 16 14 12 10 8 6 4 2 0 2011 2012 2013 2016 2020 Year From Tea export Expansion policy, MAFF, 2014
How "Traditional food company" harmonized with "the Latest food safety standard"
Established 1836 Kyoto Uji Ogura
Harmonized with Traditional and Innovation Agriculture/ Agrochemical/ Fertilizer -Quality -Food Safety -Food defense -CSR etc. Changing Area Innovation Technology/ Knowledge GMP/SSOP Supplier/ Sales area Objective Strategy Policy Direction of Growth Not Changing Area Traditional Experience/ Develop own skill Based on Tradition, growing with innovative creation Primary business Mission Bland/Trade name
Food safety/buildings Uji Kubo Plant Numbers of years after the construction of buildings: Unknown Uji Higashiyama Plant Numbers of years after the construction of buildings: 30-50 years Buildings become deteriorated over time. However, they have been maintained for preventing food safety hazard.
Food safety/equipment Traditionally, storage and distribution for tea leaf have been used Tea Box made of Wood. However, they are replaced made of plastic and/or stainless.
Food safety/food safety Policy and Objective
Food safety/tea manufacturing (Matcha) Incoming Selection Blending Sterilization (For Ingredient of confection) Grinding Shifter, Magnet Packaging Foreign matter detector Release
Food safety/traceability Incoming Selection Incoming inspection (Tea leaf producing record, sensory evaluation, Physicochemical inspections) Sorting (Sorting machine, visual inspection, magnet) Blending Packaging Packing Foreign matter detector Release Selection Record Sorting process Daily Report Blending Record Weighting/Packaging/ Packing Record Foreign matter detector Record Release Record
Food safety/training (Competence and Awareness) Monthly planed training (e.g. HACCP, label, allergen, Internal auditor etc.)
Food safety/communication
Food safety/inspection [Main Inspection activities] Bacteria (Coliform, general viable bacteria, yeast and mold, thermoduric bacteria, Staphylococcus aureus), Color-difference, moisture contents, particle size distribution, component, residual agricultural chemicals, radiological dosage, electron microscope
Food safety/risk based Food defense
Food safety/risk based Food defense Surveillance camera RECEPTION OF VISITOR Waste control Access control for water tank Access control for chemicals
Certified FSSC 22000 Uji Higashiyama Plant Uji Kubo Plant
From FSSC 22000 Certified Organisation
What do you think effectiveness of FSSC22000 Certification for your company?
How do you think Food Safety of traditional companies and contribution of FSSC22000
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