Yakult - Pioneer of Probiotics  
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Making Yakult
 
How is Yakult made in our modern, high technology factory?

Inside the Yakult factory

1. 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.

2. Sterilisation
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.

3. Culture Tank
The temperature of the tank is reduced to 37C 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.

4. 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.

5. Injection Blow Moulding Machine
The plastic bottles are produced on site. The bottles are made from polystyrene.

6. Bottling and Packaging
The bottles are wrapped with individual bottle labels. 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.

7. Refrigeration Room
Finished products are kept refrigerated before delivery to stores.

8. Yakult Quality Assurance
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.

Yakult Malaysia factory QC lab staff doing tests on Yakult Ace product Our 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.


9. Waste Management

Cleaning - 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.