The motivation for introducing

Up until ten years ago, we were using a batch sterilization method for tofu, which often resulted in inconsistent sterilization effects and high product damage losses. The working environment was also challenging, hot and steamy, requiring manual handling of containers under strenuous conditions. Unable to enhance our capabilities due to these limitations, we considered switching to a conveyor-style continuous sterilization machine but lacked the necessary factory space.It was then that we were introduced to the continuous steamer sterilizer, which, we found, could fit within our existing space and meet our desired capacity.

After implementation

After implementation, the sterilization and cooling performance exceeded our expectations, increasing efficiency by over 30%. Consequently, we have completely phased out batch sterilization in favor of continuous steam sterilization, allowing us to operate up to 18 hours a day. This has enabled us to work at a pace unimaginable with the old manual batch method.

We decided to upgrade our packaging machine as the old equipment showed significant wear, especially in the rotating shafts, which resulted in a notable decline in performance. In addition, a single machine could no longer meet our capacity needs, so we added another machine and introduced a new one for different product sizes. Tokyo FooD's design fully understood the required standards and provided machines with solid specifications. Since the installation, we have experienced no discrepancies or issues with the specifications, and we are very satisfied with the performance.

When it comes to packaging materials, opting for cheaper products often leads to functional, printing, and quality inconsistencies, causing issues both in the factory and the market, and placing additional strain on the packaging machines. In the long run, I find it more cost-effective to choose materials that may have a slightly higher upfront cost but are stable in quality and less prone to issues.

The motivation for introducing

Our packaging machines operate for extended periods, and when we consulted with them about this, they proposed a high-level packaging machine (DAISAY brand) that prioritizes functionality and usability based on North American standards. Since the electrical and safety standards align with North American regulations, they made sure to adapt everything accordingly, providing us with the appropriate solutions.

After implementation

We introduced the steam pasteurizer for the third line of our new factory to sterilize tofu packaged in vacuum bags. The steam pasteurizer operates with horizontal movement, ensuring that the packages do not deform, and the sterilization and cooling efficiency have been impressive. The on-site staff are astonished, asking, 'Why does it cool down so well?' In fact, we had considered introducing a steam pasteurizer for the first and second lines as well, but since we had no prior experience with steam pasteurization, we opted for the conventional continuous boil-and-cool system (Taiwan-made), using hot water and cooling water as we had always done. The result has been a complex workflow, frequent bottlenecks, entry and exit troubles leading to downtime, over-sterilization, under-sterilization, and insufficient cooling, all of which are daily issues. After introducing the steam pasteurizer for the third line, we now realize we should have taken the risk earlier and implemented steam pasteurization for the first and second lines as well.

【Sterilization Efficiency and Quality】 The efficiency of the sterilization process and the quality of the product after treatment are of the utmost importance. The ability to effectively eliminate bacteria while maintaining the safety and quality of the product is our top priority.

【Safety】 Features and designs that minimize machine malfunctions and reduce maintenance frequency are essential to ensure the safety of operators and the safety of the product.

【Cost Efficiency】 It is important to consider not only the initial investment cost but also the operational costs. This includes energy consumption, water usage, maintenance costs, downtime losses, and product losses.

【Energy and Water Consumption】 Efficient use of energy and water is crucial from both an environmental perspective and for reducing operational costs.

【User-Friendliness】 Machines with high usability are essential, featuring ease of operation, simple maintenance, and an intuitive interface design.

【Space Efficiency】 Compact designs and efficient layouts that fit within the available space in the factory are highly valued.

【Reliability and Durability】 Durability and reliability that ensure stable operation over a long period are essential.

【Technical Support and After-Sales Service】 Excellent customer support and technical assistance are essential for product installation, operation, and troubleshooting.

【Regulatory Compliance】 Compliance with food safety regulations and industry standards is essential. The equipment must meet local laws and industry guidelines.