The Yakult cultured milk drink in Malaysia is Malaysian made. Yakult has applied 70 years of successfully promoting better health overseas, it is a new product to Malaysia. Yakult (Malaysia) Sdn. Bhd. commenced production in February 2004 and is owned subsidiary of Yakult Honsha (Japan).
Yakult has spent millions of ringgit to set up and run its Malaysian manufacturing operations in Seremban, Negeri Sembilan and head office in Glenmarie, ShahAlam.
The product that is marketed in Malaysia is Yakult Ace and Yakult Ace Light, an improvement version of Yakult cultured milk drink available in other countries worldwide. Yakult Ace has a higher concentration of the probiotics Lactobacillus casei Shirota and added nutrients such as calcium, niacin and vitamins B6, B12 and D.
Yakult (M) Sdn. Bhd. currently employs more 70 people throughout Malaysia. Their employees include production workers, sales consultants, customer service, accountant officers, administrative staff, managers and human resource personnel. Yakult (M) Sdn. Bhd. have more men workers than women.
PURPOSE OF VISIT
Our group chose Yakult (Malaysia) Sdn. Bhd. to meet the needs of the subject this time because we want to see the techniques of processing and production of Yakult drinks and to know the ingredients used to make the drink. We are also interested in knowing the work flow processing of the Yakult drink.
In addition, we would like to see the quality control and texture of the Yakult drink and the care of the drink during the drink. We also want to know how the packaging is done by the Yakult factory.
The following program trip on May 14, 2018
7.30am – All students gather at UiTM.
8.00 am – Bus departs from UiTM to Yakult Factory, Negeri Sembilan. 39 students were accompanied by a lecturer.
9.30am – Arrive at Yakult Factory, Seremban, Negeri Sembilan.
9.45am – All students and lecturers are briefed on factory backgrounds, according to the sequence of processing. After being briefed, students and lecturers are brought to visit around the factory to see the processes being carried out.
11.30 am – Completed tour session. Souvenirs are performed by Puan Nur Syuhada binti Muhammad.
OUTCOME OF VISIT
The founder of Yakult Honsha Co., Ltd was Dr.Minoru Shirota. He started developing Yakult in 1930 while he was with the Microbiology Department at Kyoto Imperial University’s School of Medicine. Dr. Shirota believed, rather than curing a disease, it better to build a strong antibody that was able to fight the disease.
This strain of Lactobacillus casei, was found to be the most acid and resistant was named Lactobacillus casei Shirota strain in honor of Dr Shirota’s research. It was the discovery of these bacteria that led to the birth of Yakult.
1935, Dr. Shirota began distributing Yakult from his clinic. After 20 years, Yakult was produced and marketed in Japan.
Finally, at 1955, Dr Shirota founded his own company, Yakult Honsha Co. Ltd., consolidating his business by taking control operations. His business plan had an objective were to promote health and bring happiness.
The Yakult headquarters was in Tokyo, Japan. Today, Yakult is available in 28 countries and consumed by more than 20 million people every day.
Yakult was produced in the form of food, beverages, cosmetics and in form pharmaceuticals. Food and beverage example are coffee, soy sauce, noodles, yogurt. Most doctors used Yakult at the hospital and put in patient’s meal.
There are two type of Yakult that have in Malaysia, Yakult Ace (red) and Yakult Ace Light (blue). Different taste between these two product is Yakult Ace Light are less sugar and a bit sour than Yakult Ace.
Every bottle of Yakult have 30 billion Shirota strain bacteria. Yakult can help digestion and stimulate immune cells. Harmful bacteria disturb the beneficial ones and produce harmful substances that affect your health. Unbalanced diet, high stress, less sleep, and lack of daily exercise can put your digestive system out of balance, which gives harmful bacteria the opportunity to multiply.
The Yakult factory produced only one flavor of the water, which is mix of orange and lemon. Yakult does not release other flavors because they want to keep up support health.
There are four benefits for drink Yakult. First, can add good bacteria and reduce harmful bacteria in the intestine. Second, can reduce toxic in the intestines. Third, smoother the intestinal tract it is suitable for anyone who has diarrhea or constipation. Last, enhance the body’s immune system to evade the body from any disease.
The three philosophies of Shirota are to prevent disease, healthy intestines longevity and good health for everyone at affordable. The intestines are longevity because the intestines are the largest organ in our body to absorb nutrients. Bacteria Yakult is in a drink that is easy to drink and is sold at a reasonable price.
This Yakult drink is recognized halal by JAKIM and probiotic drinks in the Malaysian food and regulation act. Official probiotic beverage to Malaysian Soccer Association.
Yakult in Malaysia is bottled in 80ml and has 30 billion Shirota bacteria. The expiration date of this drink is 45 days and this drink is free from any coloring. Yakult Ace has calcium, niacin, bacteria Shirota and vitamins B6, B12 and D. while, Yakult Ace Light only has a Shirota bacteria. Yakult are suitable for every level of age include children and adult. Yakult can only last for 8 hours. Yakult Ace using sugar cane while, Yakult Ace Light uses fruit sugar.
Mixing of Raw Ingredients
Live Lactobacillus casei Shirota strain is cultured in a ‘seed tank’ in laboratory. Skim milk powder is mixed with sugar, glucose and filtered, sterilized water to make a sweet milky solution.
The sweet milky solution is sterilized at a high temperature for a short time for destroying any bacteria that may be present. There is 500-litre culture tanks via a closed system of pipes and valves.
The temperature of the tank reduced to 37°C and live Lactobacillus casei Shirota
strain is added. The solution allowed to ferment for one week until the number of Lactobacillus casei bacteria reaches an ideal concentration.
Mixing and Storage Tank
The concentrate is transferred to the 12,000-litre mixing and storage tank. The temperature of tank is around 2° C. Sterilized flavors, syrup solution, vitamins and calcium are added to the concentrate. Prior to bottling, the concentrate is diluted with filtered, sterile water.
Injection Blow Moulding Machine
The bottles of Yakult are produced on site. The bottles are made from polystyrene. There are 4 machine that are produced 70,000 bottles per hour for each machine.
Yakult Quality Assurance
To maintains a comprehensive quality assurance program to ensure that Yakult at the highest quality. For this stage, samples are collected for laboratory analysis throughout the production process to confirm that the quality measures in place have been effective. The testing involves more than 150 samples per production run. Quality assurance measures are to maintain standard for personnel and factory hygiene, equipment cleaning, processing methods and parameters, and product handling.
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.
Finished products are kept in refrigerator before delivery to stores.
Waste Management Cleaning
Yakult check to a comprehensive hygiene and sanitation program, following a cleaning program that is governed by cleaning in place. Steam, an environmentally friendly cleaner, was used to sterilize the pipes and tanks. Chemical cleaner is used, reducing the numbers of chemicals introduced into the drains. Solid wastes, the amount of solid waste is comparatively small. Liquid wastes goes into a holding tank in our water treatment facility. The acidity of the water is adjusted with acid or alkaline before being released into the sewage system.
Yakult Sdn. Bhd. should added more choices for customers in terms of flavors. There are only two flavors available which are Yakult Ace and Yakult Ace Light. Unlike its competitors, such as Vitagen and Nutrigen, these two brands come out with variety of flavors which will attract more people to buy their products especially children because children more attracted with color.
Yakult should provide a refrigerator to the retailers because if the temperature increases, the bacteria will eventually become inactive that will turn the taste sour. This is because the bacteria will begin to make lactic acid when the temperature drops. It will a lead to a storage difficulty for retailer outlets with little storage capacity as they still have other products brand they need to keep. This will cause an imbalance of stock availability during different time of the outlets. This problem also influences consumers’ purchase intention that does not have a refrigerator.
Yakult should consider to produce big packaging because its not enough for people who love to drink yakult. One bottle of Yakult contains 80ml cultured milk drink while competitors such as Vitagen and Nutrigen serve in 125ml per bottle . Moreover, another country such as Japan have large amount of contains cultured milk compared to Malaysia.
Yakult also need to consider cost of selling Yakult. Yakult offered to market with higher price compared to competitors.Yakult products are sold in a bundle of 5 bottles, which is the same with Vitagen and Nutrigen. However, the Yakult cultured milk drink’s price is higher than the competitors, who offer their drinks in bigger bottles too.
Yakult should do aggressive marketing plan to compete with competitors that uses aggressive marketing plan to promote their products such as advertising in traditional media like television advertisement, radio, social network sites and forth, especially Vitagen. With this, competitors are more recognizable to consumers than Yakult. As Yakult does not usually do aggressive advertisements to promote their brand, consumers are likely to be aware of competitors’ brand. Sometimes people are unknowing brand Yakult. Besides that, the marketing plans are not heavily invested. Usually advertisements are easily to duplicated.
Yakult Malaysia is produced from high quality, selected ingredients and packaged in a technological advanced local manufacturing facility, incorporating some of the latest food processing equipment. The factory was maintains the highest quality standards throughout the process, equivalent to the Yakult manufacturing in Japan. Through their planning, they are able to produce output with maintain high quality product and are able to gain more consumers than competitors.