Next-generation bottling line
In designing a new bottling line, Daishichi chose to focus not on short-term maintenance of freshness, but on long-term, stable and reliable quality maintenance. It was this concept that led to the creation of a unique bottling line, unlike any other in Japan.
Japan's first anoxic bottling system
We focused on the fact that conventional bottling lines in clean rooms cannot prevent the exposure of sake to the air, resulting in oxidisation and a loss of fragrance. Daishichi's solution was to create a new bottling system that eliminates all contact between sake and worker, and between sake and air. We introduced Japan's first counter-pressure filling machine equipped with a nitrogen replacement system. Bottling takes place in anoxic, hermetically-sealed conditions. This prevents any contamination or oxidisation of the sake, adding to long-term quality assurance.
1. The filling nozzle descends and seals the mouth of the empty bottle.
2. The air in the bottle is removed to create a vacuum.
3. The bottle is filled with nitrogen.
4. The sake is introduced, forcing out the nitrogen.
5. The nozzle leaves the bottle mouth, which is swiftly capped.
Fail-safe mechanism gives high integrity
Differences in quality that occur during bottling are due to problems on the production line that cause a back-up of sake flow, allowing it to oxidise and overheat. It is of course practically impossible to prevent all unpredictable line stops. So Daishichi added its own back-up system, based on fail-safe principles, to cover for any unforeseen problems. Line control of unprecedented precision ensures that should any problem occur, the back-up system will automatically kick in, allowing the filling machine alone to continue stable production.
Like no other: Japan's first, next-generation bottling line.
The effect of the anoxic bottling line on sake quality
Previous bottling machines bottled sake at a warm temperature when it is most susceptible to chemical reactions. The sake was also exposed to the air. As a result the sake would become slightly oxidised during the bottling process. Abruptly-oxidised sake develops a spiky quality, and it takes weeks of rest before the original sake quality re-establishes itself. The excess oxygen that enters the sake leads to faster degradation over time.
In contrast, an anoxic line where the sake is never exposed to air means no oxidisation takes place and the sake is amazingly smooth even immediately after bottling. The absence of oxidisation also means that there is no degradation over the long term.