Factory introduction Introduces the manufacturing process and quality control until the product reaches the customer.

Hoyu has two factories in Japan and three overseas. Here, we will introduce the product manufacturing at the factory by taking the "Seto Factory" in Aichi Prefecture, Japan as an example.
Delivering safe, high-quality products where they are needed
Hoyu is committed to this "origin as a manufacturer" and is engaged in manufacturing.
We carry out strict quality control not only in Japan but also in all factories around the world, produce safe and secure products with high quality in any country and region, and meet the trust of customers all over the world.

01 Quality inspection and management

We inspect raw materials and products and check their quality in the following three processes.

1

Raw material acceptance inspection

Make sure that the raw materials you receive meet the standards set by Hoyu. If it is a raw material, we will inspect its properties and purity, and if it is a raw material, we will check its specifications and labels, and carry out functional inspections.

2

Bulk inspection

The bulk produced in the "preparation (see below)" process (the contents of the hair color product before filling in individual containers) is inspected for compliance with the standards set by the development department.

3

Product inspection

We confirm that the products we deliver to our customers are correct through package inspection and content inspection.

Thorough inspection for customer's safety and security

Hoyu sells products to 70 countries / regions from sales offices in 10 countries / regions around the world. Hoyu safety and security first in manufacturing because it is used by a variety of customers with different constitutions, and because it is a product that comes into direct contact with the skin of our customers. The key to this is "quality inspection and control," which inspects raw materials and finished products.

In the raw material acceptance inspection, we start production after confirming that it complies with strict raw material standards. We also carry out inspections again on bulk prepared from raw materials that have passed strict inspections to confirm the quality. In addition, we also inspect various parts and packages, and thoroughly inspect so that customers can use our products with peace of mind.

The standard of manufacturing refined in Japan is to the world

The Quality Assurance Department at the Seto Plant conducts quality verification inspections to ensure that Hoyu products are shipped to countries around the world. Stringent inspections are conducted to ensure that safe and reliable products are delivered not only to customers in Japan but also to customers around the world.

Hoyu Quality control is carried out in the overseas factories of "K" Line, Inc. under the same strict standards as in Japan, and the quality standards and inspection methods that have been developed over many years in Japan are practiced in the overseas factories as well. In order to create and maintain a system that enables manufacturing and inspection at the same quality level as in Japan, engineers from the Quality Assurance Department sometimes visit overseas factories to provide direct guidance and advice to overseas local staff (in Suzhou, Thailand, and Indonesia). These efforts ensure that strict quality standards are maintained at all Hoyu factories in Japan and overseas, and that products conforming to these standards are manufactured and shipped, allowing us to provide safe and reliable products to our customers around the world.

Analyze components with a heavy metal analyzer capable of highly sensitive analysis
Use a colorimeter to quantify the subtle shades of hair color

Analyze components with a heavy metal analyzer capable of highly sensitive analysis
Use a colorimeter to quantify the subtle shades of hair color

Analyze components with a heavy metal analyzer capable of highly sensitive analysis
Use a colorimeter to quantify the subtle shades of hair color

Analyze components with a heavy metal analyzer capable of highly sensitive analysis
Use a colorimeter to quantify the subtle shades of hair color

02 Preparation

We manufacture cream-type hair color products by performing a work called "emulsification" that mixes raw materials such as water and oil. The work is done in a huge "emulsifier" with a capacity of 0.25 to 2 tons.

Manufacturing process is automatically managed by the program

Emulsification is very delicate. If water and oil are not mixed well, they will separate and quality and safety will be compromised. In addition, it is necessary to ensure that the quality of the finished product is not uneven depending on the person who works. Therefore, at Hoyu, the preparation process is automatically managed by a program. I try to work at a fixed time and temperature.

Achieves the same quality as Japan, no matter which country in the world it is manufactured.

Product prototypes are made in very small quantities in a beaker. Therefore, it is necessary to verify at the actual manufacturing site whether stable production can be achieved while maintaining high quality even with a large emulsifier with a capacity of 0.25 to 2 tons. This is done by the production engineering department of the Seto Plant.

The production engineering department, which has abundant know-how in product manufacturing, tests prototypes with a device with a capacity of 40 kg, which is the same as the actual machine. After repeating verification until stable manufacturing is possible and deciding the manufacturing method, we will start manufacturing on the actual machine for the first time. Since the manufacturing method is transmitted to overseas factories, products of the same quality as Japan can be manufactured regardless of the country in the world.

In addition, like the quality assurance department, the Seto factory and production engineering department also provide technical support by telephone, email, and sometimes directly to the site, based on the know-how cultivated over many years.

All preparation processes are managed by the program
Verify in the same environment as the actual machine and decide the manufacturing method

All preparation processes are managed by the program
Verify in the same environment as the actual machine and decide the manufacturing method

All preparation processes are managed by the program
Verify in the same environment as the actual machine and decide the manufacturing method

03 Filling / packaging

The bulk produced in the "preparation" process is placed in a container such as a tube, packaged, and packed in a box.

To deliver safety and reliability as well as safety

No matter how high the quality of the product, if the contents are different from the box, customers will not have confidence in the product. For this reason, in the "filling and packaging" process, we work not only to ensure product safety, but also to give customers a sense of security and trust in our products when they see and hold them in their hands.

We put special emphasis on "preventing the mixing of different products" to ensure that the wrong product is not included in the package. For example, to prevent boxes from being filled with instructions that differ from those of the product, bar codes are printed not only on the container and box containing the product, but also on the instructions, and sensors and cameras are used to confirm that there is no mixing of different types of products.

In addition, weight checks are performed multiple times to weigh the containers filled with the contents and check for any errors in the filling volume.

High-speed line that simultaneously improves quality and productivity
Carry out multiple weight checks during filling, packaging, and boxing

High-speed line that simultaneously improves quality and productivity
Carry out multiple weight checks during filling, packaging, and boxing

High-speed line that simultaneously improves quality and productivity
Carry out multiple weight checks during filling, packaging, and boxing

High-speed line that simultaneously improves quality and productivity
Carry out multiple weight checks during filling, packaging, and boxing

04 Storage / Shipping

By being managed and shipped by an automated system such as loading on pallets, carrying in to high-rise automated warehouses, and carrying out to shipping workshops, it will be lined up at retail stores and delivered to customers.

Managed by an automated system

Managed by an automated system

Managed by an automated system

Managed by an automated system

Introducing factories that support product production

Japan

Seto factory

Mother factory and command post that transmits technology to manufacturing bases around the world

This is the main factory responsible for the production of hair color, which is Hoyu 's main business.
We actively introduce the technologies of the times and accumulate abundant technologies and know-how such as manufacturing tests, production, and quality assurance. It is a mother factory that sends them to manufacturing bases around the world, and is a control tower for manufacturing.
GMP voluntary standards, strict quality control at the pharmaceutical level (although the products handled are quasi-drugs). In addition, we have acquired ISO9001 and maintain a global standard quality management system.
In 1999, we obtained ISO14001.

Japan

Sakuragaoka Factory

Manufactures mainstay hair color products with the same quality control as the Seto Factory

Together with the Seto Factory, we produce our main product, hair color. GMP voluntary standards, quality control at the pharmaceutical level, and acquisition of ISO9001/14001 are the same as the Seto Factory.
Established in 2000, it is a new factory among Japanese manufacturing bases, but Hoyu 's products are committed to the "origin as a manufacturer" to reliably deliver to the place where it is needed, and honest and thorough quality control. The spirit of craftsmanship has certainly been passed down.

China

Hoyu Cosmetics (Suzhou) Co., Ltd.

A historic manufacturing base that advocates "the same thing as Japan with the same quality"

Established in 2001, Hoyu 's oldest overseas manufacturing base. We mainly produce products for East Asia and provide products not only to China but also to Japan.
Under the slogan "The same thing as Japan with the same quality", we have acquired ISO9001 and introduced an automatic packaging line to provide products for Japan. The local staff also have a good understanding of Hoyu 's strict quality control stance and commitment to manufacturing, and their work skills are at a high level.

Indonesia

PT Hoyu Indonesia

Received halal certification and provided products to Islamic countries around the world

Established a new factory in 2017. Equipped with the latest equipment such as automatic production lines, the factory is capable of efficient mass production.
The biggest feature is that in addition to considering the usual safety and quality as a hair color, we also manufacture products that are halal certified and can be used safely by customers in the Islamic world. We strictly comply with halal not only in raw materials and materials, but also in the process, and provide products to Islamic countries around the world, mainly in the Middle East.

Thailand

Hoyu Cosmetics (Thailand) Co., Ltd.

Manufacture various products to meet global needs

Based in Thailand, we supply products to Africa, Europe, Southeast Asia and the Americas. In addition to cream type, we also produce powder type hair color. Another feature is that the packaging process is done manually, which makes it possible to flexibly meet various needs.
The current factory was established in 2010, but Thailand has expanded its manufacturing bases before that. Rooted in the region, the retention rate of local staff is high, and high quality and stable manufacturing is possible.

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