Right from day one, we have worked hard to attain our dreams. The history of our company is testimony of our hard work and achievements we got in the journey:
1989: Our Kameoka factory was formed for roasting processing with the name, Nakai Genmaichaya Co., Ltd.
1993: The name of our company got changed to Kyoto Grain System Co., Ltd. for the purpose of business expansion to other industries.
1998: For roasting foreign wheat, we established the Meihan factory in Yamabe-gun, Nara prefecture. In the same year, an automated production line was also started at the Kameoka factory.
2000: To start the import business of oolong tea, we formed the joint venture company, Xiamen Yinhe Tea Co., Ltd. Further, its headquarters departments and trade section were moved to Kyoto Shimogyo.
2002: To efficiently complete roasting & processing tasks of domestic barley, we built the Ishikawa Factory in Kahokugata, Ishikawa Prefecture. We also received JAS organic certification for the Ishikawa Factory In the same year. The year also marked the inception of our tea bag import division with the name Jintan Maibao Foods Co., Ltd.
2006: In order to merge & integrate the Kameoka and the Meihan factory, we started the Nara factory.
2007: Our Nara factory received Japanese Agricultural Organic Standard (JAS) certificate. We also got the manufacturing license of a food additive.
2012: Our Nara factory received FSSC 22000 certification. In the same year, we also got permission for the Bonded Factory.
2017: We started our office in Xiamen City of China. The year also saw the acquisition of the manufacturing license in the Nara factory for pharmaceutical raw materials.
We are getting a high appreciation in the market because we take orders for OEM. We understand the requirements of customers and accordingly process agricultural products from raw materials.
We keep ourselves updated with the latest technology. At our processing unit, we have installed modern technology machines & tools for Steaming & Drying, Roasting, Puffing (Crisping), Pulverizing and Chopping of Raw Material for Herbal Medicines. We also have a dedicated Soybean line.
Steaming: We have maintained two large steaming machines and several dip tanks for doing required work.
Roasting: We have sound hot air roasting, direct flame drum type roasting, hot air drum type roasting and many other specialized roasting machines. With support of these machines, several types of roasting and scale-up / down of production volume are done at our premises.
Puffing (Crisping): Puffing is a heat treatment method in which pressure is released at high pressure on the raw materials, after which several small cavities are formed inside grains by swelling. And by this process, the hard ingredients get changed to a crispy texture.
Soybean Dedicated Line: To systematically do roasting, crushing, packaging and several other processing tasks of soybean, we have maintained specific facilities.
Pulverizing: At our company, we make use of airflow type pulverizing in which it is tough for heat to enter. The process is used for converting raw material input to powdered form within a few seconds. This process offers high hygiene as the machines used can be easily disassembled and cleaned.
Chopping of raw material for Herbal Medicine: In May 2017, our company received a license for processing pharmaceuticals and accepting contract processing of crude drug raw material.
Import And Export Business
In the business line, we have made our presence across the world. We have built a network to China and Southeast Asia because there are many joint ventures and cooperating companies in China. Apart from just importing Oolong tea, Jasmine tea and other types of Tea from China, we use its sales channels and supply raw materials overseas. Our company is also expanding its network from Asia to America and Europe. We also aim at becoming the top supplier of Fresh Roasted Barley Grain in the world.
With high pride we state that at our Nara factory, we have got approval from a bonded factory. Because of this approval, we can bring in foreign currency raw materials and complete commissioned processing work.
How We Deal With Customers, Our Inquiry Inflow
- Customers contact us by filling the inquiry form.
- We conduct a meeting in which our executive asks a few points such as the finished image, raw material information, usage, etc.
- We begin Trial Production work. In a laboratory machine or prototype in an actual machine, we make a simple prototype.
- We ask customers to evaluate products and share feedback. We further re-prototype to meet their requirements.
- We confirm customers about the estimated price and time of order delivery.
- We ensure that the production process will be completed on time and the delivery of orders will be promptly made.
Kyoto Grain Systems Co., Ltd. has received the international food safety system certification standard FSSC 22000 for its Nara Factory.
FSSC 22000 Certificate is given to companies that adopt food safety standards by the Global Food Safety Initiative (GFSI). This association is composed of food distribution companies and international food manufacturers.
Main features of FSSC 22000:
Interactive communication: The norms of the certificates state that all the companies involved in the food industry must communicate and share reliable information.
System management: As per the norms of the certification, companies must ensure that food safety measures are taken not just at the food production site but throughout the organization including management.
HACCP principles: Companies must set management standards according to HACCP 12 procedure, when important management is required.
Prerequisite programs: In accordance with the ISO / TS 22002-1 guidelines, hygiene must be maintained in food production premises and all the prerequisites must be followed.
Food safety measures: Matters related to food safety like raw materials, food defense and allergens are crucially handled by us.
Activities of The Project Team
We aim at becoming better with every passing day. For this, by selecting appropriate people from each department, we have formed a special team and sincerely work with its support. At our company, meetings are conducted by every team, atleast once a month to check the status of initiatives and bring improvements. Below mentioned are the specific teams:
Food Safety Team: To handle tasks related to hygiene management and hazard analysis, this team works hard. This team keeps in mind our own food safety manual and checks 5S patrols, reviews the rules, adaptation status of hygiene standards in the premises and strives to ensure that food safety standards are maintained at all levels.
Health and Safety Committee: This committee is dedicated to mainly reviewing & revising the risk assessment and improving the work environment. By taking special efforts related to employee training, conducting factory tours and employee health promotion campaigns, the team works towards ensuring no occupational accidents happen at our premises.
Energy Conservation Team: In order to to reduce the usage of energy & natural resources, this team makes several efforts at our factory. Further, experts at our company are focused on reusing and recycling the resources.
About Hygiene Management
As a company which deals with food products, for us, maintaining hygiene standards is of utmost importance. We have set strict hygiene control standards that include 12 original items. The hygiene management program at our unit covers various things, right from production to purchase, shipment, waste and buildings, workplace layout, utilities like raw materials and products, etc.
Prevention of Contamination
Entry Control: We have restricted the entry of people in our premises. Right at the entrance, we have a changing room, where everyone has to change to work clothes, disinfect and wash hands. A proper record of name, carry-in items, entry and exit time, physical condition report etc. is maintained. At the entrance of our factory, we have installed adhesive rollers and air showers that prevent the entry of dust and fine foreign substances including hair in the premises. The above restrictions have been maintained not just for employees but also for visitors including customers.
Management Of Carry-On Items: A proper list of items that have been brought by people into the factory is maintained. In our factory, we have such stationery items that do not contaminate products.
Efforts on Hazard Analysis: For each line, we periodically conduct hazard analysis. We also check as well as work in bringing improvement in the operation status to meet guidelines set down by the Food Safety Team.
Introduction of Surveillance Camera And Alarm System: At the entrance to the premises of our factory, we have installed a surveillance camera and an alarm system. We do surveillance by specifically allocating helmets of specific colors to employees and visitors.
Control Of Pests / Allergen Countermeasures
Measures against insects and rats: We have made an association with a specialized insecticide dealer, which regularly conducts visits to our factory and conducts study sessions. We have also placed seat shutters everywhere, done installation of various traps, blocked approach paths by coking, etc. We also conduct periodical drug spraying sessions.
Allergen management: For the smooth management of allergens in the factory, we have set some rules.
Confirmation when raw materials are accepted: We conduct tests on raw material at the time of receipt and entrance in our premises.
Retention of records: For all the processes from receipt to production and shipment, we maintain proper records. Every record is double checked by two or more and multiple departments to avoid errors.
Information On Raw Materials & Packaging Materials: From the first day, we work hard to acquire information related to raw material such as origin, allergen, etc. and maintain a safety data sheet (SDS) about packaging materials, raw materials, chemicals etc. At our premises, we periodically conduct residual pesticide tests and radioactivity tests on every batch of crop to supply safe items.
In accordance with the standards of each product, at our manufacturing site and quality control division, proper quality tests are conducted. Once we are assured about high quality, we ship the orders. For quality evaluation, below mentioned Analytical Instruments & Inspection equipment are used:
- Infrared aquameter
- Near-infrared spectrometer
- Digital denistometer
- Magnetostrictive sieve shaker
- Water activity measuring instrument
- A set of microorganism analysis equipment
- Wet type particle size distribution measuring instrument