FACTORY VISIT – YAKULT SEREMBAN

The History of Yakult ~

Talking about the company , we have been explained briefly how and when it was built . Firstly ,
we are informed that Yakult is a world pioneer in the field of probiotics . Born from the research
of a doctor in 1935 , we have over 75 years of research experience . Yakult has spread around the
world , and is loved by 28 million people from 32 countries and regions .

Next , move on to history of Yakult product . Yakult is a high quality probiotics in the form of a
cultured milk drink . Yakult contains the probiotic bacteria "Lactobacillus casei Shirota"
(popularly known as the "Shirota strain") . With over 30 billion live Shirota strain in each bottle ,
Yakult has among the highest concentrations of probiotics compared to other probiotic products
on the market (most probiotic drinks and supplements claim to contain at most 1 to 10 billion
live probiotic bacteria per serving or per capsule) . The Shirota strain is scientifically proven to
be among the 'strongest' strains of beneficial bacteria , and has been shown to benefit human
health . In Japan , Yakult is acknowledged by the Japanese Ministry of Health as a "Food for
Specified Health Usages" with approved health claim "The Lactobacillus casei Shirota strain
reaches the intestines alive , so this product maintains good health by increasing beneficial
bacteria , decreasing harmful bacteria and improving the intestinal environment" . Free of
preservatives , colourings and stabilizers , Yakult is the right choice for those looking for high
quality probiotics for good health .
Manufacturing of Yakult Product ~

How is Yakult made in our modern, high technology factory?

Firstly , we are introduced to the first step that is mixing of raw ingredients . Live
Lactobacillus casei Shirota strain is cultured in a 'seed tank' in our laboratory . Skim milk
powder is mixed with sugar , glucose and filtered , sterilised water to make a sweet milky
solution . Secondly , the step of sterilization . The sweet , milky solution is sterilised at a high
temperature for a short time , destroying any bacteria that may be present . The solution is
then transferred to a 6,500-litre culture tank via a closed system of pipes and valves . Thirdly ,
the activities done in culture tank . The temperature of the tank is reduced to 37°C and live
Lactobacillus casei Shirota strain is added . The solution is allowed to ferment for about one
week until the number of Lactobacillus casei bacteria reaches an ideal concentration .
Fourthly , we also can observe what the products have been done in mixing and storage tank .
The concentrate is transferred to a 12,000-litre mixing and storage tank . The tank is chilled to
around 2° C . Sterilised flavours , syrup solution , vitamins and calcium are added to the
concentrate . Prior to bottling , the concentrate is diluted with filtered , sterile water . Next ,
the machine of injection blow play its role where the plastic bottles are produced on site . The
bottles are made from polystyrene . The bottles are wrapped with individual bottle labels for
bottling and packaging step . Then , they are filled with Yakult , capped with a foil lid , sealed
and transferred along the conveyor belt to the packaging facility . Single bottles of Yakult are
sorted into groups of five and shrink-wrapped in polypropylene film . Ten "5-packs" are
grouped together and wrapped again in polyethylene film and then heat shrunk , forming a
'carton' of 50 Yakult bottles . Lastly , the finished products are kept refrigerated before
delivery to stores .

We are also take additional notes about Yakult Quality Assurance which is said that Yakult
maintains a comprehensive quality assurance program in order to ensure that our product is of
the highest quality . For this reason , samples are collected for laboratory analysis throughout
the production process to confirm that the quality assurance measures in place have been
effective .

Their testing involves more than 150 samples per production run , upon which a total of more
than 200 tests are conducted . These determine Lactobacillus casei numbers , check for potential
contaminants , microbiological quality , composition , acidity , physical attributes and taste . In
addition , each bottle is inspected for undesirable markings and incorrect printing . Quality
assurance measures are in place to maintain standards for personnel and factory hygiene ,
equipment cleaning , processing methods and parameters , and product handling . Yakult's
quality assurance utilizes a system called "Hazard Analysis and Critical Control Points"
(HACCP) . The principles of HACCP are internationally recognised as an excellent method for
assuring stringently high standards .

Before we going out from the process room , we are told briefly about the way of waste
management used in Yakult production . For cleaning section , Yakult adheres to a
comprehensive hygiene and sanitation program , following a cleaning program that is
predominantly governed by CIP (Cleaning in Place) . Steam , an environmentally friendly
cleaner , is used to sterilize the pipes and tanks . A single phase chemical cleaner is used ,
reducing the numbers of chemicals introduced into the drains . Chlorine based chemicals are not
used . Solid wastes - The amount of solid waste is relatively small . Liquid wastes - Any liquid
waste goes into a holding tank in our water treatment facility . The acidity (pH) of the water is
adjusted with acid or alkaline before being released into the sewage system .
Probiotics ~

What are Probiotics ? Probiotics are foods containing beneficial living microorganisms which
we consume to benefit our health by improving the balance of our intestinal flora . The majority
of probiotic bacteria used in food production are 'Lactic Acid Bacteria' such as species of
Lactobacillus and Bifidobacteria . Yakult contains Shirota strain, a strain found only in our
product . The Shirota strain has been specially selected for its "strength" - in other words , its
ability to survive through our stomach and bile acids to reach the intestines alive to deliver its
health benefits .

A probiotic must meet these strict requirements :

• Proven to be safe for human consumption
• Able to live and multiply in our intestines
• Be able to survive the gastric and bile acids to reach the intestines alive
• Scientifically proven to have a beneficial effect on our health
• Be available in sufficient numbers throughout the 'shelf-life' of the product
• Affordable and easy to consume

The Shirota in Yakult are scientifically proven to :

1. Help regulate our bowel movement to avoid constipation and diarrhea
2. Help maintain the balance of good and bad bacteria in our intestines
3. Help to reduce production of toxins in our body
4. Help enhance our body's immunity to reduce risk of infections and reoccurrence of
cancer cell
Drinking Yakult daily helps to top up our beneficial bacteria . In our busy lives , managing our
bacteria is a smart , easy way to help take care of our bodies .
JOB COSTING