About the soybean flour processing line

Introduction of Soybean (soybean flour) line

Under the FSSC 22000 food safety management system, we conduct a series of “roasting, grinding, and packaging” processes exclusively for soybean
allergens.
Although the quality of the raw materials we purchase varies because they are agricultural products, we fine-tune the intensity of the fire and roasting
time according to the quality of the raw materials to maintain a constant quality of the finished product. We are also able to process organic JAS
ingredients on consignment because of our JAS-certified organic line.
We also procure soybean raw materials, so please feel free to contact us for inquiries regarding raw material procurement and production requests.

Soybean flour production method

STEP 01

Sorting process

Sorting out stones, wood chips, and other foreign materials derived from raw materials.

STEP 02

Roasting process

Soybeans are roasted in a batch-type semi-direct roasting machine and are
cooled over time after roasting.

STEP 03

First crushing process

The roasted product is crushed in the first crusher. At this point, the product has not yet
reached the size of soybean flour.
After the first crushing, the peels are blown away by wind power.

STEP 04

Second crushing process

A pin mill is used to grind the material to a fine particle size.
The pin mill is equipped with a screen to maintain uniform particle size.

Allergen Control in the Production Line

The item as an additional FSSC 22000 requirement includes the control of allergens. Allergens present in the product, either by design or by cross
contact during manufacturing, must be clearly identified. Products must also be protected from unintentional cross contact due to cleaning, washing
and line changeover procedures and production sequence. Food handling employees should receive specific training in allergen awareness and
production procedures.
Under our strict 12-point hygiene management standard, we have established rules regarding allergens to prevent cross-contact during receiving,
manufacturing, and shipping of raw materials.

【Allergen control/operation rules for soybean flour line】
Dedicated entrance/exit and changing rooms for soybean-only lines.
From receipt to shipment, the product is segregated from other raw materials, and storage outside of designated areas is prohibited.
Full-time production line personnel are assigned to the production line, and entry by anyone other than the full-time line personnel is prohibited in principle.
Full-time workers are required to wear static-eliminating clothing during production, and full-time workers are prohibited from working on a separate line in the same state of dress.
Properly implement all items in accordance with the cleaning manual for switching cleaning after production of products containing allergenic substances. At this time, the person in charge of the line checks the cleaning condition by checking for residual protein. At the same time, the quality control staff conducts a cross-check to ensure that there are no problems with the cleaning condition.

Advantages of the KGS Soybean Dedicated Line

Mass production is possible	In order to adapt to mass production, we have improved and modified our original roasting machines, cracking machines, pin mill type crushers, etc. Currently, we are capable of producing 3-4 tons of soybean flour per day. If you wish to produce large quantities, we can offer cost reduction proposals.
Organic crops can be produced	Due to the Organic JAS certification line, contract processing of organic agricultural products is available. Application is required for each item, so please consult with us.
Workers are young	Since soybean flour has a long history of use in food, there are many companies and factories that have been manufacturing soybean flour for a long time. However, we often hear that our suppliers are considering alternative factories due to concerns about aging workers. In the case of our factory, the largest percentage of workers are in their 20s and 30s, and young human resources are active.
Obtained FSSC22000 certification	Our Nara Plant is FSSC22000 certified and produces under a food safety management system. Few factories that produce soybean flour have obtained FSSC22000 certification, and our factory is one of the few that has.