Conclusion: Brown sugar is a traditional food with deep sweetness and richness, made from the squeezed juice of sugarcane through a simple but delicate manufacturing process of pressing, heating, filtering, and molding.
Manufacturing is divided into four major processes
Each process requires important technology that determines quality.
Minimize processing to bring out the natural flavor of the product.
Kaiho Shoji employs a manufacturing process that combines tradition and the latest technology.
Production process until brown sugar is produced
1. pressing (sugarcane juice)
A roller press squeezes out the juice.
Freshness at this stage determines the taste.
The first step in making brown sugar is to press the sugarcane. Because sugarcane loses its sugar content as time passes after harvest, the pressing process begins immediately after the sugarcane is brought in. Large rollers are used to press the stalks and extract the nutrient-rich juice. The freshness and sugar content at this stage directly affect the taste and aroma of the final product.
2. heating (boiling down)
Boil down while floating and removing impurities
The key is to cook over direct heat to bring out the flavor and aroma.
The next step is the heating process. While boiling the pressed juice in a kettle, the scum and impurities that float to the surface are carefully removed. In this process, the traditional heating method called "open-flame cooking" is important. Craftsmen carefully monitor the temperature and time to bring out the richness and aroma. Insufficient heating will result in too much moisture, while overcooking will cause burning and bitterness.
3. filtering
Removes scum and fine fibers
An important process for producing brown sugar that is smooth and pleasant to the tongue.
In the filtration process, scum and solids are removed from the boiled brown sugar solution. Physical filters such as wire mesh and cloth are used here. Careful attention is paid to clogging and passing time to maintain the proper concentration and clarity, making it ideal for later molding.
4. molding (cooling and solidification)
Solidification by natural cooling or air cooling
Cut and packaged for shipment as needed
The final step is to pour the hot brown sugar liquid into wooden or metal molds and cool to harden. Temperature control is an important factor in the factory, as cooling time varies depending on air temperature and humidity. The hardened brown sugar is cut into blocks and packaged by product for shipping. Here, the utmost care is taken to ensure the beauty and uniform quality of the product.
Supplement: Kaiho Shoji's particular manufacturing method
Selected sugarcane from Uruma City, Okinawa
Produced in our own factory with strict hygiene and quality control
The manufacturing process is the same for a wide variety of products such as flavored brown sugar.
Kaiho Shoji provides high quality brown sugar products by combining the manufacturing process that has been maintained since the company's founding with modern hygiene control technology. The Whipmichi brown sugar series, for example, is also based on the above process, while creating different flavors and textures.
summary
Although brown sugar is made from extremely simple ingredients, each manufacturing process requires advanced techniques and careful work.
Cooking over direct heat brings out the sweetness and aroma of the food.
Filtration removes impurities and ensures smoothness
Quality is improved by molding and cooling, and the product is completed as a finished product.
Kaiho Shoji's brown sugar is the result of these careful processes and is the pride of Okinawa.
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