Aoki Hamono Seisakusho Co., Ltd. 2022

“Sakai Forged Cutlery” with a History of Over 600 Years

Sakai is one of Japan’s six major cutlery-producing regions. With a history spanning over 600 years, “Sakai Forged Cutlery” boasts such popularity—thanks to its sharpness and ease of use—that it accounts for the vast majority of the domestic market share for professional chef’s knives. Furthermore, fueled by the recent boom in Japanese cuisine, these knives are now attracting attention from chefs around the world.

Knives are broadly categorized into “hand-forged knives,” crafted by artisans, and machine-produced knives, formed by punching through metal dies. Sakai has traditionally specialized in the former, hand-forged knives. The technique used is “forging,” in which the raw materials—soft iron or steel—are heated until red-hot and then hammered and stretched to shape. This hammering process densifies the metal’s internal structure, enhancing its strength and toughness, and resulting in superior sharpness, durability, and beauty.

One characteristic of “Sakai Hand-Forged Cutlery” production is its traditional division of labor. The process consists of three main stages—forging, sharpening (edge finishing), and handle attachment—which are carried out sequentially to complete a single knife. It is said that by having professionals in each field master their respective techniques, they are able to maintain a level of quality that sets them apart from other production regions.

New Knife Craftsmanship Utilizing Traditional Techniques

Aoki Hamono Seisakusho, one of Sakai’s leading knife manufacturers founded in 1947, operates under a unique system where these processes are handled in-house (for some products).

“We have a division of labor within the company, and specialized craftsmen constantly strive to improve in their respective fields. “Although we have a division of labor, we also function as a single team, so it’s great that each process can provide feedback to the others. Also, when we want to prototype something new, we can immediately bring it to life in-house, refine it together with the craftsmen, and commercialize it quickly—I believe that’s one of our strengths,”

say Executive Director Toshikazu Aoki (right in photo) and Sales Representative Fumiaki Yonezawa (left in photo). The two of them guide us through the various production stages at the “Sakai Kōkō Sanpō Factory” located in Midori-cho, Sakai City.

“Forging”: The More It’s Hammered, the Greater the Blade’s Strength and Flexibility

First up is “forging.” Forging refers to “shaping metal through hammering.” The material is heated until it glows red in a blazing fire, then hammered and stretched using a hammer or a power hammer. To achieve both strength and flexibility in the blade, the basic method involves bonding two materials: hard “blade steel” and soft “base steel.”

“Temperature control in forging is extremely delicate. While higher heat makes the metal easier to stretch, if the temperature is too high, the carbon—which determines sharpness—will escape, resulting in a poor-quality knife. Since the temperature can only be judged by visually checking the redness of the heated metal, it requires experience and intuition.”

These are the words of blacksmith Ryosuke Shibata. Watching him work alone in the dimly lit workshop, intently focused on the glowing-red knife, there is something almost otherworldly about the scene.

“Sharpening (Edge Finishing)” to Create a Sharp Cutting Edge

Once the knife has taken shape, it moves on to the “sharpening (edge finishing)” process. Through the work of a sharpening artisan, the blade is honed and polished to achieve a razor-sharp edge. First comes “rough sharpening,” where the blade’s surface is ground with a coarse whetstone to reduce the thickness at the tip and shape the blade. This is followed by “fine sharpening,” where the flat surface is ground to refine the tip.

“Once you’ve sharpened too much, there’s no going back, so I work carefully while constantly assessing the knife’s condition.

It requires a great deal of concentration, but seeing the blade take its final form is the true joy of this process. It feels truly satisfying when it’s finished with a beautiful shape and luster.”

Master sharpener Makoto Togawa gazes fondly at his prized knife.

Finally, the blade is finished with a fine-grit whetstone and sent to the handle-fitting craftsman to attach the handle.

Professional-Grade Sharpness for the Home

Aoki Hamono Seisakusho, which produces a wide variety of knives, created the “Sumikuro” Santoku knife for the Sakai Kitchen Selection. The handle, made of oak with a charred finish and coated in lacquer, catches the eye with its natural charm.

“To ensure it can be used in ordinary households, we focused on a stylish design that fits seamlessly into modern kitchens, and we’ve finished the blade with a sharp profile. “The handle may appear simple, but the wood grain and scorched finish give it a rich character. Applying lacquer not only adds an elegant sheen but also enhances practical features such as water resistance and防腐,” says Mr. Aoki.

It’s not just the design—the feel in your hand is also guaranteed to impress. With a sharp yet supple cutting edge that has garnered many fans not only in Japan but

around the world, the sensation is so satisfying that you’ll be hooked the moment you try it. We invite you to experience it for yourself.