this is the day in life of a japanese
panko factory owner
[Applause]
[Music]
this is show 43 years old living in
tokyo
he wakes up earlier than most japanese
to start his work day
he lives with his wife and two daughters
in this two-story house
but sleeps in a separate bedroom so not
to wake them up in the morning
show and his wife both work full time so
he shares the house chores like doing
the dishes
[Music]
damn you have a lot of records how many
do you have and you say
which one is your favorite
wow lyrics are screen pitted on the
fabric he says this diy spirit is the
same spirit he tries to capture when
creating his punko
[Music]
do you always eat bread in the morning
oh he's working already being a father
and a business owner himself it's
important for him to wake up early to
maximize his day
reading stretching and organizing his
daily tasks
interesting his house has an addict
looks like he's preparing rain boots for
his daughter
[Music]
sho's office is only a 10-minute walk
from his house pretty rare in japan
every morning on his commute he stops by
the inari shrine this particular one is
called
boga inari which is believed to protect
its visitors from fires
quite important for someone who runs his
own factory
[Music]
good morning everyone i'm back with
another day in the life
this one i'm super excited for because
we're going into a japanese factory
show should be coming around the corner
just now let's see how his morning is
good morning did you sleep
was a third generation owner of the kaya
panko factory a family run business
started in 1948 by his grandfather it's
only truly made in tokyo panko factory
baking their own bread to create a flaky
breadcrumb commonly used as a crunchy
coating and fried japanese food their
panko is so highly acclaimed it's used
by 60
of the tonkatsu restaurants listed in
japan's michelin guide as well as chains
like yutan negishi
and even mom and pop stores many in the
industry believe that panko alone will
make the restaurant popular
hello
[Music]
right after he arrives he starts to
organize today's orders since clients
place their orders overnight in many
different ways online phone call
messages
emails line messenger sms and even fax
it's amazing how flexible he is with his
customers and shows how committed he is
to customer service did you originally
want to inherit the business
he would even sit in the truck with his
dad during deliveries the panko factory
was such a large part of his life when
he was a kid he drew a layout of it
which still hangs in the office today
and that's his brother he's the kojocho
aka factory manager
after he finalizes today's orders he
assigns delivery drivers drivers locate
the products on the shelves and
refrigerators and load their trucks
accordingly
[Music]
this machine prints out the tempio in
english an itemized sales slip which is
given to customers at a time of delivery
in japan
many businesses are still paper-based so
this form of receipt is absolutely
necessary
now show prepares cash for delivery even
these days
many of his clients still prefer to pay
in cash so all of his delivery drivers
must carry enough to make change
wow that looks so old are you still
using this
a japanese family crest passed down from
his ancestors
now the morning workers are lining up to
stamp their time cards a
very common practice in traditional
japanese companies
while they're doing that show works on
organizing stock in the factory as an
owner
it's important for him to be involved in
all aspects of the business large or
small he
even makes time to clean toilets despite
daily cleanings by staff some japanese
believe that the active cleansing toilet
also cleanses one's malevolence so
you'll find many successful business
owners participating in this activity
what did you do before becoming a punko
factory owner
now show goes back to his office
replying to emails and texts
as well as other administrative work so
it looks like show has a little bit more
office work to do so while he's doing
that
let's take advantage of this time and
explore this place
so let's go up to the second floor and
let me show you where
all the magic happens but in order to do
that i'm gonna need a change so let's do
that right now
all right good to go let's go do this
now that i'm all set it up let me show
you how the bread making process begins
150 years ago from the meiji period
japanese used sliced bread to make panko
a japanese word pan meaning bread and co
meaning powder
many panko producers use commercially
made bread but nakaya punk will craft
their own bread at their factory
creating 50 different types of honko
every year with their own unique
textures and flavors
first step is to make the dough the
workers mix water yeast and flour
then add salt and sugar and then knead
the mixture after that they add oil and
knead it again
interestingly depending on the weather
that day the workers adjust how long the
dough is fermented as well as the amount
of yeast added in order to produce an
identical product
also since flower producers update their
harvest each year the factory needs to
readjust their ingredients and process
each time it's very much an art of its
own to craft a consistent
and high quality panko each and every
day this machine receives a kneaded
dough and separates it into smaller
clumps
and then the dough rests here for about
15 to 20 minutes
after it cycles through it then drops
down this shoe to be flattened
finally the dough is rolled and placed
in the metal pans by hand
[Music]
now the dough needs to sit in a
fermentation room which is set to 90
humidity i guess my camera's not going
in there after this
the baking process begins how long does
it take to bake this bread
the factory produces 1800 loads of bread
per day
and the lows vary in texture and shape
depending on the end product for this
particular cycle before the bread gets
shredded into small pieces of panko the
workers must remove the crust by using
an automatic slicer
[Music]
the bread itself doesn't come out of the
oven in perfect form so usually
there will be crusted sections like this
so workers remove these spots by hand
[Music]
now that all the crust has been removed
the bread is processed through the
specialized machine
it shreds the bread into small pieces
which are passed through these metal
nets
the holes in the nets vary in size which
ultimately determine the size of the
punko
[Music]
apparently they use about 1.3 tons of
flour to make 800 kilograms or about
1760 pounds of panko
each day
[Music]
so they not only sell panko here but
they also provide an assortment of
ingredients so that when their customers
come
they can buy punko as well as cooking
ingredients kind of like a one-stop shop
pretty convenient
just over there it looks like they have
some deliveries let's go check it out
the factory ensures that the crust
doesn't go to waste and donates it to be
useless food to raise pigs and chicken
[Music]
oh a typical japanese meeting held every
morning before work starts in this
meeting the factory staff review tasks
for the day as well as any issues that
need to be addressed
[Music]
now show goes around the factory floor
to perform a quality inspection
it's important for him to talk directly
with the workers to get feedback on the
condition of the breath
sure can i make panco today you so check
it out y'all they actually
let me make my own panko so you gotta
break it up just like this
that's awesome wow i made the perfect
panko
they even have students visit once a
year
today chefs from an italian restaurant
noc are visiting to learn about sho's
panko
oh they brought temiage a gift to say
thank you
in japanese business culture it's
customary to give such a gift when
someone is doing something for you
that's one of his latest creations
godspeed you black punk oh
[Music]
during the factory visit show's brother
details how the ponco is produced
explains the different types as well as
shares tips on how to use it during
cooking
now it's time for the tasting what is
your favorite food
[Music]
are you going somewhere
[Music]
do you always have to eat lunch in the
truck
is a food that you don't eat just itself
but it's combined with other ingredients
to produce an end product like katsu
and fried fish so show works diligently
to understand his customers needs in
order to produce the highest quality
product possible to do this it's
critical for him to often meet with
customers to see how his punko is being
sure
the first stop is in the high-end area
of nishizawa
[Music]
the next stop is a wood-fired oven wagyu
steak restaurant for no initiative
what are you doing now
foreign
[Music]
not only does he deliver orders but he
also provides a private instructions at
the customer's request
he knows his panko better than anyone so
he's able to share detailed preparation
methods to chefs from high-end
restaurants to mom and pop tonkatsu
shops
in order to bring out the full potential
of his panco's taste and texture
during the instruction they use his
ichiko mix which is a blended powder to
coat food before dipping it into the egg
as well as special techniques on how to
produce a crispier and ultra textured
minty crust
[Music]
wow that looks so crispy you can even
see that the punko with added technique
produces a unique
spiky stalagmite-like crust
now back at the office he needs to
refocus on sales
wow it seems like he missed many calls
while he was out
after finishing his sales task he has a
strategy meeting with his brother about
new business opportunities
apparently they started an
anti-microbial and anti-virus coding
service for restaurants as well
yay finally finished
oh is it for the dusty
[Music]
[Applause]
ah so cute his girls sure miss daddy
he usually can't make it home on time to
have dinner with his family so he has
dinner alone but that karage his wife
made
sure looks good though and it looks like
his girls love to share in daddy's meal
[Music]
so after dinner show will probably go
and hang out with his family
take a bath play with his daughters and
probably then just go to sleep at 11 30.
so that's pretty much the day in life of
a japanese panko factory
owner what do you guys think let me know
in the comments if you guys
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