Facility introduction

Facility introduction

Production/supply system that can handle small-lot productions

Sanshokaken has continued its research and efforts to improve its production technology so that it can continually and efficiently supply high quality products. Our flexible production system can handle small-lot productions resulting from diversifying consumer needs. We will continue our best efforts to satisfy our customers in all aspects of quality, quantity and cost. The minimum lot size that we accept is 1,000 units. (100 ml/unit)
Diverse lineup of products. Approximately 400 varieties (as of FY 2007)
Wide-ranging production capabilities
 Annual shipment volume: 5.4 million units
 Annual production volume: 590 t (as of FY 2014)

  • 秤量室

    (1)Weighing Room

    The room where ingredients are weighed as specified by the formula recipe.
    The weighed ingredients are then taken to the preparation process.
    [Environment]
    To maintain cleanliness, clean air is blown 24 hours a day nonstop into both the Filling Room and the Preparation Room.
    [Clothing]
    To prevent head or body hair from workers from becoming mixed in, the workers all cover their heads and wear work uniforms designed to prevent body hair contamination, masks and gloves.

  • 調整室

    (2)Preparation Room

    The bulk (the cosmetic solution) is produced here using vacuum emulsification equipment.
    [Environment]
    HEPA-filtered clean air is constantly blown into the room to maintain positive pressure. (24 hour operation)
    [What is positive pressure…?]
    The pressure in the room is increased by blowing in air in order to prevent external air (full of dust and germs) from entering the room.
    Bulk manufacturing equipment
     500-liter emulsifying kettle: 2
     200-liter emulsifying kettle: 1

  • 品質管理室

    (3)Quality Control Room

    [What is an acceptance inspection?]
    An inspection of ingredients, materials and packaging to be used in the cosmetic product manufacturing before they are accepted into the warehouse.
    [What is the bulk/product test?]
    Physical testing (pH, specific gravity, viscosity, etc.) and microbial testing (bacteria, fungi) of the bulk (the cosmetic solution) manufactured in the factory and the final product.

    Only products meeting the quality control testing are shipped.

  • バルク保管庫

    (4)Bulk Storage

    Storage for bulk (the cosmetic solution) that has been manufactured in the Preparation Room, before filling it in containers.

    [Storage conditions]
    Summer (June-September): 20-25 degrees Celsius
    Winter (October-May): 15-20 degrees Celsius

  • 充填室
    充填室

    (5)Filling Room

    The cosmetic solution is filled, measured, and capped/the pump dispenser is tightened.
    The half-finished product that has been capped travel on the conveyer belt to the Final Packaging Room.
    [Environment]
    This is a workplace where the cosmetic solution comes in contact with ambient air, so a certain level of cleanliness must be maintained. Therefore, HEPA-filtered clean air is constantly blown into the room 24 hours a day to maintain positive pressure. UV disinfection is simultaneously conducted in daytime.
    [Clothing]
    To prevent contamination with foreign substances or bacteria in the Filling Room, workers change into Filling-Room-specific work uniform and shoes in the changing room next to the Filling Room, wash and disinfect their hands and fingers, and wear masks and gloves before working.
     Filling machine for high viscosity products: 3
     Filling machine for low viscosity products: 4

  • 包装仕上室

    (6)Final Packaging Room

    Lot numbers are printed on the semi-finished products from the Filling Room, and after inspection, they are finished with packaging, such as in individual boxes or shrink-wrapping. The finished products are temporarily stored in the warehouse, after which they are shipped out to the markets.
    [Clothing]
    To prevent head or body hair from workers from becoming mixed in, the workers all cover their heads and wear work uniforms designed to prevent body hair contamination.

Production capacity of Sanshokaken K.K.

Production capacity
Annual shipment volume 6.5 million
Annual production volum 650 t (FY 2016)
Bulk manufacturing equipment
Vacuum emulsifiying apparatus 150L、400L、1000L
Bulk production capacity 12 lots (about 5 tons) / Production / day
Capsule manufacturing apparatus 1 type (about 80 kg) / Production / day
Various mixers for each purpose Disper Large 1, Dispersonal 1, Homo Mixer 1, Agitator 4, Turbine Mixer 1
Filling and packaging equipment [Osaka Ikeda Factory]
Cosmetic line 2 lines
Quasi-drugs line 1 line
One liquid filling machine (4 stations) 1 unit
Cream filling machine 1 line
High-viscosity filling machine (semi-automatic) 1 unit
Cappers 3 units
Capping machine 1 unit
Bottle vacuume cleaning machine (semi-manual) 1 unit
Weight checkers 3 units
Labellers 3 units
Pillow Shrinker 1 unit
Tornado shrink tunnel 1 unit
Filling packing capacity Liquid automatic filling machine line 10000 ~ 15000 / Production/ day
Cream automatic filling machine line 8000 ~ 10000 bottles / production/ day
Semi-automatic filling line 5000~ 8000 bottles/ Production/ day
Filling and packaging equipment [Abiko factory]
Cosmetics line 1 line
Quasi-drugs line 1 line
Filling machine (semi-automatic) 3 units
cappers/th> 3 units
Capping machine (semi-automatic) 1 unit
Bottle vacuume cleaning machine (semi-manual) 1 unit
Weight checkers 1 unit
Labellers 2 unit
Lister 1 unit
Filling and packaging capacity 10000 to 15000 bottles/ production/ day