Introducing Osaka Ohsho’s largest,
fastest gyoza manufacturing
factories in Japan
These are some of the largest and fastest gyoza factories in Japan, which also manufacture gyoza for Osaka Ohsho restaurants.
We actively adopt state-of-the-art facilities to utilize AI and IOT to bring even more, better-tasting products
to your table faster and at more reasonable prices.
This site also introduces our endeavors to address environmental and logistics issues.
Frozen Gyoza: The Manufacturing Process
This section explains the steps and particular processes involved in making Osaka Ohsho's frozen gyoza.
01. Wrapper Manufacturing Step
Wrapper manufacturing begins with mixing cold water and flour.
The cold water is mixed in to stabilize quality and prevent the flour quality from being affected by heat.
Feeding the flour mixture into a large, continuous rolling mill makes the springy texture of the wrapper possible.
02. Meat and Cabbage Processing/ Mixing Step
A large block of half-thawed meat is fed into a machine and processed into ground meat.
Cabbage, which comprises the majority of the gyoza stuffing, is checked to ensure it doesn’t contain any dirt or foreign substances, then cut into pieces to be fed into the machine.
Cabbage with a high sugar content is selected and purchased by production site according to the season. It is washed twice to thoroughly remove any foreign substances. After being finely chopped into approximately 7-mm pieces, the cabbage is drained of excess water for five minutes.
The meat and long-established, secret seasonings, which are key to the flavor, are mixed together.
The fresh cabbage that has been drained of excess moisture is added to the mixture.
Fully mixing together each of the fresh ingredients produces a rich flavor and juicy texture.
03. Gyoza Shaping Step/Freezing Step
Once the wrappers and ingredients are ready, gyoza with crispy wings are processed in one go using a single machine capable of wrapping 150 pieces of gyoza in one minute to seal in freshness and flavor.
The shaped gyoza are quickly and precisely placed in trays and undergo a visual inspection to make sure there is nothing amiss.
Furthermore, to fully elicit the flavor of the meat, and sweetness and texture of the cabbage without losing freshness, the gyoza are steamed for over five minutes at a temperature of over 95 degrees. The core temperature is checked every hour to confirm they are being heated.
The steamed gyoza are instantaneously frozen by passing through a machine for approximately 13 minutes at an extremely low temperature of minus 40 degrees. At the same time, they are exposed to strong blasts of air using super jets to seal in the flavor.
04. Wrapping Step/Packaging Step
The weight is precisely confirmed with a checkweigher, the secret sauce is added to the tray, and the product is wrapped.
Even after being wrapped, a metal detector and X-ray machine are used to thoroughly test for the absence of foreign objects.
Manufacturing Factory Locations Introduction
Gunma 374-0113
Gunma 374-0113
Gunma 374-0113
Osaka 573-0137
Okayama 714-0062
(inside Ajifuku Chugoku Logistics Center)
Utilization of AI and Robotization for Total Automation
Linking each device online enables timely management of manufacturing. The production speed and yield are automatically adjusted, and equipment failure is also sensed in advance.
When there is an abnormal interruption in equipment, products are temporarily diverted without slowing down the line speed, reducing product loss during disruptions. Gyoza ingredients and filling are also automatically conveyed using an automatic guided vehicle.
AI and sensing technology are utilized to prevent issues such as foreign objects being mixed in and insufficient product quantities.
Sustainability
At our factories, we promote the use of solar panels and freezers that use natural refrigerants. Our efforts also include limiting package wrapping and using thin trays for the frozen gyoza. We implement various endeavors in each of the manufacturing steps so we can make a large quantity of gyoza using less energy. Our aim is to reduce CO2 emissions by 46% over a ten-year period.
Our new distribution center, Kanto Logistics Base (KLB), will begin operations in September 2024. We use AI to manage products such as “Osaka Ohsho Gyoza with Crispy Wings,” a key company product manufactured at the adjacent factories, and have automated our systems and operations to maintain approximately one month’s worth of stock.
Automating the majority of warehouse operations reduces the need for personnel and minimizes human error in warehouse work. The KLB also addresses environmental issues by using natural refrigerants in its refrigerated warehouses. Altogether, the completion of the large-scale distribution facility has made it possible to promote planned production and reduce waste loss and opportunity loss at the factories.
We promote the active engagement of female employees and employment of non-Japanese individuals to harness the diverse perspectives, talents, and skills of each employee, creating new value and driving Group growth. Understanding of diversity promotion is spreading through environments in which diverse employees feel job satisfaction, pursue careers with a keen sense of growth, and have ample learning opportunities.
The Eat & Group contributes to everyone’s health through food and continues to support the health of employees. We are creating more pleasant office environments, offering health-conscious food choices to our employees, and creating systems and structures that allow employees to work with peace of mind. We believe that the continued corporate activities of our employees in good mental and physical health will drive business growth and benefit society.
