Visiting the Producer of the Shirakabaha’s Curry
Isoyama Shoji Co., Ltd. (Hokota City, Ibaraki Prefecture)
Published in October 2014
When the Shirakabaha’s Curry Promotion Association decided to produce retort curry products, we prioritized not only deliciousness but also food safety. Through connections in the food industry, we arrived at Isoyama Shoji Co., Ltd. as one of the two trusted suppliers. At that time, there were discussions about outsourcing the production of Shirakabaha’s curry in Abiko City, Chiba Prefecture, to companies outside the prefecture. However, Isoyama Shoji was chosen because of its high-level manufacturing and safety technology, and their thorough understanding of the significance of Shirakabaha’s curry.
This time, we visited Isoyama Shoji and covered the actual process of retort curry production.
The Food Factory in the Fields
The food factory of Isoyama Shoji is located in the rural area of Hokota City, where vast fields stretch. We spoke with Mr. Naoki Oka (General Manager) to understand why they built the factory amidst the fields. “Isoyama Shoji processes agricultural products (cut vegetables), makes side dishes like Kinpira Gobo (braised burdock root), retort curry, and more. The company was established with the aim of expanding the use of local vegetables, so we built the factory near vegetable production areas. We purchase vegetables grown by the affiliated agricultural cooperative Hokota Nossan and local contract farmers. Even vegetables that may not sell well in the market due to their appearance are still suitable for processing, and their taste remains unchanged.”
Establishing a food factory among the fields was a great idea to cherish the locally grown vegetables. Few companies have an integrated process from vegetable production to primary processing (cutting), and then to side dish manufacturing. Mr. Oka proudly stated, “We don’t use chemical seasonings in our side dishes.” Not using chemical seasonings requires more effort and cost. By using chemical seasonings, it is possible to produce dishes easily and inexpensively.
The Handmade Feel in the Retort Curry Manufacturing Process
Isoyama Shoji produces 200,000 servings of retort curry annually, including the Shirakabaha’s curry (pork and beef). They have been responsible for manufacturing the Shirakabaha’s curry retort pork since 2008 and the beef since 2010.
“At Isoyama Shoji, we produce 2,000 servings of retort curry at a time. Compared to major food companies, the production quantity per batch is not large. However, small-batch production helps control temperature variations, and it reduces the transfer of retort odors to the curry, which is an advantage.”
During the factory tour, they were producing a different curry from the Shirakabaha’s curry. Five people were involved in the process of measuring the meat, putting it into the retort pouch, adding curry roux, and conducting inspections. Mr. Oka said, “We invest more effort compared to other companies, but it is necessary to maintain the quality.” Lastly, Mr. Oka gave us a hint, “Retort curry becomes more delicious with aging after production.”
JA Zen-noh Ibaraki’s Rose Pork
The pork in the Shirakabaha’s curry retort is made from the branded pig called “Rose Pork,” provided by JA Zen-noh Ibaraki. We asked Mr. Yonekawa from JA Zen-noh Ibaraki (General Sales Department, Section Manager) about the relationship with Isoyama Shoji and the story behind Rose Pork.
JA Zen-noh: The National Federation of Agricultural Cooperative Associations
JA Zen-noh Ibaraki had been commissioning Isoyama Shoji for primary processing of vegetables for school lunches. Due to the company’s honest work and the high quality of their products, they decided to entrust Isoyama Shoji with the production of retort curry.
“Rose Pork, the branded pork, is a special breed of pig. We designate the pig farmers, the raising of the pigs, the feed, and the sellers to maintain the quality. We are using this limited edition Rose Pork in the pork for the Shirakabaha’s curry.”
Rose Pork, local vegetables, miso and spices
In addition, the beef is also locally sourced from Ibaraki Prefecture and comes from a crossbreed of Japanese Black cattle and dairy cattle. “Using the unique meat quality of Japanese Black cattle allows us to provide it at a reasonable price.”
Challenges in Vegetable Production
We also spoke with Mr. Goto, in charge of vegetable production at Hokota Nossan Agricultural Cooperative.
Throughout the year, Hokota Nossan produces various vegetables such as carrots, onions, burdock roots, and sweet potatoes. Well-shaped vegetables are sold in the market, while the less visually appealing “B-grade” vegetables are used for cut vegetables. “Vegetables are vulnerable to weather conditions. Excessive heat can affect germination, and continuous rain can lead to disease and pests. Recently, due to the impact of global warming, new pests have emerged, making vegetable production more challenging.”
Through the cooperation of the parties involved, this coverage allowed us to once again realize that “Shirakabaha’s curry” is made deliciously. Next time, we plan to feature HUEJAY International, which produces chicken curry.
| Isoyama Shoji Co., Ltd. Business Description: • Primary processing of agricultural products, side dish manufacturing, pickles manufacturing, refrigerated and frozen food manufacturing, retort food, canned food • Research and development of bottled products, fresh, processed, and frozen foods • Manufacturing the Shirakabaha’s curry retort pork since 2008 and the beef since 2010. |