Yeah, mm So I've always wondered how a Japanese at train bento was made And luckily the folks at JR Tokai passengers oblivion and show me how it's made this video as part of my new series called Made in Japan, where I go in and show you how truly things are done here in Japan.

オラ、ずっと日本の駅弁がどうやって作られるのか 知りたかったんだよな

I'm so excited to show you this.

今回はJR東海パッセンジャーズの協力のもと 弁当を作る工程をみんなに紹介すっぞ

But before I start, if you want to see what I'm doing on the daily check on my instagram account, if you wanna help support the channel, definitely check out the Tokyo merch.

この動画は新シリーズ「MADE IN JAPAN」だ

And if you have any questions about Japan or your Japan travels, check out my discord community.

日本の高品質な商品やサービスの裏側を 見せちゃうシリーズだぞ

All right, let's go inside of the factory if you've ever eaten a japanese train bento.

オラ、ワクワクしてしかたがねぇぞ！

Good chances that was made by JR Tokai passengers, they sell bento boxes, only giddy.

始める前に、オラの日常はインスタでチェックしてくれ

And what's mommy says at Hokkaido Shinkansen stations employing about 530 staff to make this all happen.

チャンネルサポートはグッズ購入からお願いな

And today I'm taking you into the heart of it where trained bentos are made in Japan at the Tokyo Show me factory.

日本についての質問があるなら オラのDISCORDコミュニティをちぇっくしてくれ

So I've made it inside the building.

よっしゃ、早速工場に入ってみようぜ

Let's go see inside of the factory.

日本で駅弁を食ったことあるなら

Excuse me.

JR東海パッセンジャーズの工場で作られた やつかもしれねぇぞ！

Can I go in the factory with you?

ここでは、東海道新幹線の駅で売ってる弁当やおにぎり おつまみセットなんかを作ってるんだ

All right?

全地区で約530人のスタッフが力を合わせて作ってるぞ

We're in.

で、今日はその中心に突入するってわけ

So the factory is quite thorough and meticulous about preventing staff from introducing contaminants and bacteria, dust etcetera into the factory.

MADE IN JAPANの駅弁が作られている 潮見にある工場に来てるぞ

So they enforce strict policies on dress code, cleanliness and sanitation, which is, I'm sure comfort to many of their customers.

さぁ、建物の中に入ったぞ

To start the bento making process.

中に入らせてもらおうぜ

The ingredients are received in the loading dog.

すみません、オラも一緒に入っていいか？

Every single box from vendors must be inspected.

よっしゃ！入れた！

They inspect about 253 100 boxes every day.

ここの工場の衛生管理は厳しいぞ

So after the inspection boxes are brought to the refrigerators and freezers boxes are organized by category like meat and pickles, so that the staff can quickly access the ingredients.

スタッフが工場内に菌やほこりを 一切持ち込まないように衛生対策を徹底してるんだ

Now the preparation process begins wrapped packages like these are taken out of the boxes and sterilized.

服装や衛生面、消毒についての厳しいルールに従う

In this area, vegetables are fueled by hand, then there Washington, electrolyzing water tank.

客にとっちゃー間違いなく安心だよな

Finally their place in this machine to spin dry.

弁当を作るまず最初の工程は 仕入れた食材の荷下ろしだ

There's a door just behind me.

仕入れ先から届いた箱は、全部開けて検品すっぞ

Let's see what's in this room.

毎日２５０−３００箱も検品すんだって

Oh he's cutting fish.

検品が終わった箱は、冷蔵庫・冷凍庫に運ばれる

Apparently the ingredients are all cut by hand and each one is counted in order to prepare just the right amount based on how many bentos are being made that day.

カテゴリーごとに整理して、探しやすくしてるんだ

Now that all the ingredients are sliced up, the cooking process begins.

次は食材の下準備だ

This is the boiler area.

袋に入った食材は、外装を殺菌するぞ

Japanese boiled dishes are cooked in these giant bats.

このエリアでは野菜は手で一枚一枚めくって

Oh that's to Conoco in english bamboo shoots.

電解水で洗浄する

Let's talk to that guy.

最後にこのマシンを使って、水分を篩い落とすぞ

Excuse me going to ask you a question how much food is made at one time.

この後ろのドアが何か入ってみようぜ

What is your favorite food to make?

あ、魚を切ってる！

What is that?

食材は基本的に手で下準備するんだって

They also boiled daikon, radish, Kornienko and sata Imo.

その日に作る弁当の数に合うように 数も数えるんだ

Yeah.

食材の下準備が完了したら

To cook the pumpkins.

次は調理開始だ！

The workers also use a special oven.

ここは煮物のエリア

So this is where they grill the fish and check it out.

いわゆる和食の煮物みたいなのは ここで作られるぞ

Mm hmm, mm.

あ、これはたけのこ！ 英語だとBamboo Shootだな

The temperature and duration the food is cycled through the grill are precisely said to ensure food is cooked perfectly each and every time, but just in case the temperature is also checked when it comes out and this is the fried section, definitely my favorite place in the factory right now, pork katsu is being tried for the spicy masala katsu curry sandwich, wow, that looks so crispy.

あの人に話しかけようぜ

Immediately after frying the cuts is dipped into the curry sauce.

質問していいか？

I can watch this all day.

一度にどのくらいの量を作るんだ？

Other foods like karate fried shrimp and karaoke are also cooked in this fried oasis.

中でも作るのが好きなものってあるのか？

After all the food is fried, it's then cut into pieces and ready for the bento boxes.

なんで？

All right, So this is where all the rice has made impact.

他にも大根やこんにゃく、里芋も作ってるな

A bento box wouldn't be complete without rice.

このカボチャはオーブンを使って調理するみたいだ

So, it's no surprise that this factory makes 260 kg of rice about £570 every day.

ここでは焼き魚が作られるみたいだぞ

I guess workers here always have a rice day.

毎回、パーフェクトな焼き加減に仕上げるために 温度やグリルを通過する時間を調整するんだ

Look at all these machines.

さらに魚の温度は確認すっぞ

This giant pot itself can make up to 13 kg, about 28 a half pounds of rice.

ここは揚げ物を作るエリア！

So in order to fill the day's demand, the factory utilize a team of rice cookers.

間違いなくオラの一番好きな場所だな

The rice is then spread out by hand to help eric out.

今はロースカツを揚げてるところだ

So it's nice and fluffy when it goes into the bento boxes.

これは「スパイシーマサラカツカレーサンドイッチ」に 挟むやつ

The factory will also produce a flavored rice.

わ〜なんてこんがり美味そうなんだ！

This one in particular is a sarin attack economic johan clam flavored rice.

揚げてすぐにカレーソースにディップする

It's using one of their popular bentos.

一日中見てられるぞ

Futagawa May she Rice isn't just for Bentos, but it's also used to make only Geary the Japanese rice ball.

他にも、唐揚げやエビフライ、コロッケなども この「揚げ物オアシス」で作るぞ

If you don't already know Japanese love their own a giddy.

弁当箱に入れるために 揚げ終わったらカットをするものもあるぞ

The factory make about 2000 only kiddies every day.

ここはご飯を炊くエリアだ

So this machine makes the square rice beds and then the feelings are added on top by hand.

米なしじゃ〜弁当は語れねぇよな！

Afterwards, the machine takes the field rice beds and presses it into a triangle ship and finally add the wrapping.

この工場では毎日260kgの米を炊いてるんだ

Yeah.

大体570ポンドくらいかな

Mhm.

ここで働けば、毎日が 「ライスデイ」（ナイスデイ）に違いねぇ！

Depending on the type of only guilty though, the seaweed is sometimes done by hand.

炊飯器がいっぺーあんぞ！

I think this one is gonna chicken ball.

一つのお釜で（炊き上がり）12~13kgの米が炊けるんだ

I hope you're enjoying the tour.

28.5ポンドくらいだな

But before I continue on, I want to give a quick shout out to our sponsor for this video books.

さっきの炊飯器たちに頑張ってもらって

Do if you don't already know books to provide a gourmet experience of japanese snacks delivered to your front door.

その日に必要な米を炊き上げるわけだな

They work with traditional japanese factories over 100 years old to provide you with unique snacks.

炊き上がったご飯はこのトレイに入れられる

And each monthly box has its own unique theme.

人の手で米をふんわりさせるんだ

So you get new snacks each and every time.

炊き込みご飯も作るぞ

First time users will get a seasons of japan box and after that you'll get a theme box like this on this month is books is fifth birthday.

これはアサリの炊き込みご飯だな

So it includes staff's favorite snacks, which takes you on a tour of five japanese prefectures off the beaten path.

人気の弁当「深川めし」にいれるためのやつなんだ

As always, you get 10 to 25 snacks in your box depending on the package you choose and they're all hand picked from all over japan to deliver your unique and local japanese flavors.

ご飯を使うのは弁当だけじゃねぇ

So get 10% off your own authentic japanese snack box from books to and save up to $47 using Michael peloton and link in the description that said, let's continue on with this tour, wow, look at that guy over there.

日本人が大好きなおにぎりを作るのにも使うぞ

I wonder what he's doing.

ここでは、毎日2000個のおにぎりを作るんだって

Let's go ask him.

まず、この機械でごはんを四角く平らにする

Excuse me, Can I ask you a question?

具は人の手で乗せていくぞ

What are you doing?

その後、機械が三角に丸めるんだ

How often did the machines break down?

で、最後に包装！

So it looks like everything's been refreshes.

おにぎりの種類によっては

So now all we have to do is wait till this evening.

手で海苔を巻くこともある

Alright, we're back.

これはつくねかな！？

It is after one a.m. In the morning and look at all of these people hard at work.

あの人は何してるんだろう

Let's see what they're doing.

話しかけようぜ

Now.

すみません

It's time to finish up the plating and complete the final product to ship out the bentos as fresh as possible.

質問してもいい？

On the day, the factory plays all of the bento boxes.

何してたんだ？

After midnight, each worker is responsible for one task on the production line.

どのくらいの頻度で壊れるんだ？

It's amazing to see how many different dishes are all packed into one bento box and the factory makes different kinds of bentos every night.

食材は全部作り終わって、冷やす段階に入ったぞ

So when one mental product is completed, the workers we stock a different set of dishes in preparation to box.

よっしゃ、戻ってきた！今深夜1時だ

The next one.

スタッフがたくさん頑張って働いてんぞ！

In total, about 8000 bento boxes are made at the factory every day.

何してるのか見に行こうぜ

But due to coronavirus is about half that.

ついに 盛り付けをして、弁当を完成させるぞ！

Now, holidays are the most busy, as that's when customers are traveling the most on trains.

作りたての弁当を届けるために

So during this time They make up to 10 bentos per day.

深夜0時を過ぎてから盛り付け作業が始まるんだ

At the end of the production line to workers are paired to inspect every single product before final packaging.

ライン作業では、一人一人担当業務が決まってる

What do you look for during the inspection?

一つの弁当箱にこれだけたくさんの 具が詰まってるって考えるとスゴイよな

What's a common issue with the bedroom box?

工場では、毎日何種類もの弁当を作るから

So what happens to the ones that don't pass after the inspection that bentos are cleared for the automatic packaging machine?

一種類の弁当が全部完成したら

Yeah one's package the finished products and then moved to the shipping prep area.

次の弁当の具材をセットして、 また詰める作業をするんだ

Each product has a barcode which needs to be scanned into the system.

通常は1日8000個の弁当を生産するんだけど

When scanned the system notifies the worker by a flashing number above the shelves in which basket.

コロナの影響で今はその半分くらいなんだって

To stop the product.

年末や連休は旅行者が多いから繁忙期にあたるんだけど

The number on the display represents how many items the stock and each basket on the shelf represents a store location.

その期間は1日10,000個も作ることもあるんだぞ

This is amazing!

ラインの最後では完成品の検品をする

There's just so much food here.

最終の梱包をする前に、二人がペアになって 具材が全部入ってるか確認するんだ

Let's go check out some more.

特に何に注意して検品するんだ？

Yeah.

検品にひっかかるのに一番多い理由は何？

Yeah after midnight bentos are not the only product being made.

その商品はどうなるんだ？

Foods like sandwiches and only giddy are also being ready for morning delivery.

検品の後、弁当は自動の梱包マシンを通る

Let's have a look at the sandwiches first, cutting the bread crust by machine.

商品が出来上がったら 弁当は配送仕分けエリアに移動する

Mhm.

商品のバーコードを読み取ると

Mhm.

棚の上に数字が点滅する仕組みになってて

And spreading the margarine as well.

スタッフはこれを見て配送先に仕分けするんだ

Other ingredients like mustard, katsu and lettuce are added by hand.

数字は出荷個数を表してて

Once the sandwiches completed its process through an automatic slicer, Then package one x 1 again by hand.

棚のバスケットが発送先店舗別に別れてるんだ

Then the sandwiches are wrapped by machine to complete the process.

とにかく食いもんがいっぺーだ！

Mhm.

他に何があるか見に行こうぜ

Oh and someone needs some extra topping love So this is done by hand as well.

深夜、スタッフが作るのは弁当だけじゃねぇ

Yeah.

早朝の配送のために サンドイッチやおにぎりも用意するぞ

Yeah.

サンドイッチがどう作られるか、見てみようぜ

This made in Japan tour wouldn't be complete if I didn't show you the back office, wow.

まずは機械がパンの耳をカットして マーガリンを塗る

Even all of the office workers are suited up.

他の具は人の手でやっていくぞ

It's pretty awesome.

マスタードを塗ったり、カツをはさんだり

Excuse me, What are you doing?

具を全部入れたら、自動のスライサーに通すんだ

How do you decide what goes into a bento?

パッケージ詰めは人の手

How did you get this job during the interview?

最後に機械で梱包したら完成だ

Did they test you by making you taste food blindfolded?

トッピングが必要なおにぎりは、手で作るぞ

How?

MADE IN JAPANシリーズはバックオフィスを 見せないと終われねぇよな

So this is where all the new products are born.

オフィススタッフも完全装備だぞ

The development room, the team comes up with new ideas, creates test products and conducts Taste us.

すげーな！

They'll even create products many times until it's perfect and ready for mass production.

すみません、今何してんだ？

One of the most important things to check is whether or not the food tastes good when it's cold because bento boxes are made to be eaten cold.

どうやって弁当に何を入れるか決めるんだ？

What are you testing today?

どうやってこの仕事を選んだんだ？

How, how is the prototype coming along all of us?

面接で目隠しテストはあった？

So back to the factory finally from three a.m. Delivery workers start to load the trucks for morning deliveries so that the bentos are ready in stores for customers just before the earliest bullet trains start running.

この部屋は新商品が生まれる、開発をする部屋だ

Mm hmm.

新しいアイディアを出しあったり

All right.

試作品を作って、味見をしたりするんだ

So that is how a Japanese trained bento is made.

大量生産できるレベルの完璧な商品に仕上げるために

Let me know what you thought in the comments.

何度も何度も試作品を作り直すんだぞ

Also, let me know what you thought of my made in Japan series.

試食するときに見る重要なポイントは 冷めても美味しいこと

I'll be doing more if you guys like this is going to help me out and hit that like button.

弁当は冷めた状態で食うからな

And if you want to see more Japan videos or anything related to Japan, hit that subscribe button and the button and I'll get you guys in the next one.

今日は何の試作を食ってんだ