There are various traditional techniques that are still alive in Sakai City, Osaka Prefecture. Until now, it was only known to those in the know because it was difficult for consumers to see, such as OEM and B to B.It was launched as an initiative to improve the brand power of Sakai City's traditional industries and to get more people to know about them and use them.sakai kitchen(Sakai Kitchen)" project.This time we will be introducing one of those projects, Sakai cutlery, which is the envy of top chefs around the world.
Maintaining world-renowned quality
Delicate and dynamic "blacksmithing"
Japan's five major cutlery production areasSakai City, Osaka Prefecture is known as a production area.
Its origins date back to the 5th century.Nintoku Emperor Mausoleum, the largest keyhole-shaped tumulus in JapanIt is said to have originated from construction tools. Craftsmen who made plows and hoes continued to live in Sakai, and as swordsmiths, craftsmen who made guns and blades for chopping tobacco leaves brought over from Portugal, and parts for bicycles... Sakai's blacksmiths and cutlery continued to be used as appropriate to the times. It continued to spread. It is used by many top chefs in Japan, and has recently received high praise from overseas chefs.
Sakai knives are traditionally made of base metal (soft iron) and blade metal (steel).2train together, a single-edged knife.How to press and remove the moldAlthough it requires much more effort and skill, it produces a blade that is stronger and less likely to chip, so it stays sharp and lasts a long time.
The production of Sakai cutlery has traditionally been based on a division of labor. A knife is completed by going through three stages in order: ``blacksmith'' where it is forged, ``hazuke'' where the blade is sharpened, and ``wholesale'' where the handle is attached.
There is also a blacksmith shop in Sakai.10several housesThere's only one left. One of these is Tanaka Uchi Hamono Seisakusho, which was founded in 1896 and is run by Yoshikazu and Yoshihisa Tanaka. In fact, the name "TANAKA" is known among the world's top chefs. Unlike Japanese people who recognize the shop name of a store as a brand, overseas people often ask for a blacksmith's name to be engraved on the knife.More and more people are ordering. Carving the creator's name on a product is probably a sign of respect and trust in the craftsman.
Tanaka Uchihamono Seisakusho. A workshop covered in iron so that there is no place to step, a red-hot furnace, and the echoing sound of hammers.
To forge Sakai Uchihamono, first steel is placed on the base metal, put in a furnace and hammered, then steel is placed on top of the base metal, placed in a furnace and hammered. Once it is shaped, it is heated again and pounded to form it, and once it has cooled down, it is pounded again to remove the oxide film on the surface. Polish it with a grinder, pound it, pound it.
A strong blade is created by repeatedly using the furnace and hammer while gradually changing the shape. Hit, hit, organizationMake it fine.The characteristic of Sakai cutlery is not only its hardness, but also its strength, which gives it stickiness.
The cut steel is placed on the base metal and sent to a furnace at temperatures of over 1000℃. The temperature is too high to measure, so judge the appropriate temperature by the color of the flame.
In the past, it took two people to hammer, but after the war, it became possible for one person to do the work using a belt hammer operated by a foot pedal. Since it is not heavy enough to be placed in a high place, a hole must be dug to accommodate a person in a low place.
The state before forming, where the base metal and blade metal are blended together. The outline is still distorted and the surface is uneven.
Grind the molded material with a grinder to smooth the surface. A knife is forged by going back and forth between the furnace and hammer over and over again.
The parent and child change responsibilities every day of the week, but Yoshihisa says, ``It took about five years before I was allowed to touch the furnace.'' Once minor corrections such as distortions have been made, the product is quenched (heated to high temperatures and rapidly cooled) and tempered (heated to low temperatures) to make fine adjustments and complete the work. In fact, ``quenching'' and ``tempering'' are important and advanced processes that determine the hardness of the blade.
``This is where my father really shines. I do it sometimes, but basically he doesn't leave it to me yet. It's a very difficult and responsible process,'' says Yoshihisa. At the core of the world-famous "Tanaka" brand is a firm commitment to its products.
Traditional craftsman Yoshikazu Tanaka (middle). My son Yoshihisa (left), who just took over as the fifth generation in 2021, and his disciple (right), who has been in his seventh year,We are good at producing small quantities and a wide variety of products by hand.
The “blade attachment” does not overlook even the slightest distortion.
Determines sharpness and beauty
The “bladeless” created by a blacksmith, proceed to the next process, ``blade attachment''. Baba Knives Manufacturing Co., Ltd. was founded in 1916 as a wholesaler that handled the last stage of the division of labor: handle attachment. In recent years, in response to the aging of blade-making artisans, the second division of labor, the company started a one-company, two-process system in 2017.
``In order to maintain the division of labor in Sakai, it is appropriate to have 10 to 20 bladesmiths for every 30 blacksmiths.I think it is originally taboo to have multiple blacksmiths, but we took the plunge and created a new bladesmith to fill the gap.'' Representative Takashi Baba talks about the circumstances.
Mr. Takashi and Mr. Sho Nishida, who was a candidate for the position as a craftsman, took the lead in establishing a ``blade'' workshop and a new knife brand ``Kagekiyo.'' ``Kagekiyo'' has been well-received by opening stores at events including those overseas, and in 2021, they started recruiting more staff. Thanks to Frank-Maximilian, a German, applying, Sakai cutlery is evolving into a global industry in both name and reality.
Shou Nishida (left), a blade craftsman, Takashi Baba (middle), a representative of Kagekiyo and also a master craftsman, and Frank-Maximilian (right), who came to Japan from Germany in 2019.
The process of "blade attachment" is called "sharpening""Distortion removal"It's a repetition. Start with a coarse whetstone, and while adjusting the shape, gradually level the surface with finer whetstones. To reduce frictional heat, the rotary whetstone first has grooves in it, and water is poured over it while sharpening. Sharpening is so intense that the large whetstone needs to be replaced every six months to a year.
To remove the frictional heat between the whetstone and the blade, which rotates at high speed, the blade is sharpened while being sprayed with water.
Distortion/twistCarefully sharpen and pound until there is no more residue. It is important not only to know the technique, but also to develop an eye for detecting discomfort.
The back of the blade has a very slight arc. ``Strain removal'' is a process that requires skill and skill, which involves placing the item on a mold and tapping it along the curve.
Fluorescent lighting does not allow you to see the subtle colors and shapes of the blade patterns, so only do this work under light bulbs.
On the other hand, when it comes to ``removal of distortion,'' it is important to check and touch the parts many times to make sure you don't miss distortions or twists that are so slight that they can't be seen. Hold the blade horizontally and tilt it little by little, so either the left or right end will come out first. It's high, which means it's not straight. Repeatedly making small adjustments until the head was in a straight line from one end to the other.
Finally, the ``Shinogi'', which is the boundary between the base metal and the blade metal, is shaved to create a blade pattern called ``Kasumi''. As Mr. Baba says, ``It's like makeup that improves the appearance.''Although it has no functional meaning, the hamon is an important point essential to the beauty of a cutlery.
First of all, Japanese people should know about the famous products that Japan is proud of.
The final step in making Sakai cutlery is attaching the handle. Insert the warmed knife into the handle and tap the butt of the handle, the knife will go in more and more. Again, check the twist and insert it straight and firmly and you're done.
Tap the butt of the handle to attach the handle and inspect it. The boxes in the back contain all sorts of knives.
Baba Knives Manufacturing has a wide variety of knives from all over Sakai. ``Sakai cutlery is an industry that grew together with Osaka's food culture,'' says Baba.
``Eating blowfish made ``fuguhiki,'' and eating conger conger eel made ``hamokiri.'' Even if you order a knife specifically for seasonal ingredients that are only made once or twice a year, Mr. They will understand right away and make it for you.”
This accumulation is Sakai's asset and the cornerstone of Japan's food culture.
Freestyle French is original, unbound, and constantly changing. It attracts attention not only from Asia but also from all over the world. Maintained two stars in "Michelin Guide Kyoto/Osaka + Wakayama 2022". He is a star chef that Osaka is proud of both in name and reality.
The person who understands Sakai cutlery the most is the chef. One of them is Chef Yusuke Takada of the French restaurant ``Rassim'', which has two Michelin stars and is ranked 8th in Asia's Best Restaurants. He is participating in sakai kitchen as an advisor.
"At the beginning of the project,
Sakai used to specialize in single-edged knives, but over the past 10 years, double-edged knives have also increased. It has been 10 years since Baba started selling Sakai cutlery to the world. ``I can feel the market growing,'' Baba says confidently.
Blacksmithing in Sakai is usually a one-person job, but Yoshikazu Tanaka wanted to increase the number of craftsmen, so he took on an apprentice seven years ago. This was because they feared that if the area continued to decline, it would become ``weak as a production area.''
His son Yoshihisa says, ``I want young people to try using a real steel knife at least once.'' Sakai cutlery, which has continued to advance with the times, is still in the process of evolving. Branded products that are highly praised around the world,sakai kitchenI want you to know through this.
(Titles omitted)
Photography by Noriko Kawase
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