Sakai Knives: A Legacy of Quality through Division of Labor

The manufacturing process of Sakai knives, which boasts a tradition of over 600 years, can be divided into three main steps: forging, sharpening, and handle attachment.

Forging involves shaping metal through hammering. The more the metal is hammered, the stronger and more flexible the blade becomes. Watching blacksmiths heat the material to a bright red in a roaring flame and then expertly hammer and stretch it is truly a sight to behold.

Sharpening is performed by skilled artisans who use honing and polishing techniques to create a sharp edge on the knife. First, the blade’s surface is ground with a coarse whetstone to reduce the thickness at the edge and shape it, a process known as rough sharpening. This is followed by fine sharpening, where the flat surface is polished to refine the edge.

Finally, there’s handle attachment, the last step in which the finely honed blade is fitted with a handle. This process takes place at the wholesale dealer that placed the order.

Sakai knives are distinguished by their traditional division of labor, where each step is carried out by a specialized craftsman. By honing their skills to a high degree, these artisans uphold a level of quality that is unmatched by other regions.

The Art of Infusing Life into Blades

Founded in 1962, Daikichi is a wholesale distributor specializing in the manufacturing of Sakai knives, various cutting tools, and kitchen supplies. The company is led by second-generation president Takayuki Harada and his brother Hirotsugu Harada, who serves as the executive director. Together, they highlight the unique appeal of Sakai knives. While their father focused solely on wholesale, he expanded the business to include processes such as handle fitting and other stages of production when leadership transitioned to his sons.

Let’s first explore Mr.Takayuki’s engraving technique, which involves inscribing the brand name onto the blade. Watching him skillfully strike with a hammer and chisel may seem effortless, but achieving balance while engraving delicate letters requires extensive experience and a keen artistic sense.

“The brand name engraved on the blade is like the ‘face of the knife’ that the user sees all the time. It’s not an exaggeration to say that the quality of the engraving significantly impacts the product’s value, so I engrave it intending to bring it to life at the end. While some engravings are done by machine, those done by hand have a unique shine and presence, don’t you think?” says Mr. Takayuki.

As he spoke, the letters of the brand “Sakai Ichimonji Yoshikuni,” selected for this Sakai Kitchen Selection, were expertly engraved.

The Final Touch That Affects Usability

Next, Mr. Hirotsugu heads to the sharpening area to perform “machi polishing,” which smooths the spine of the knife and the angle of the heel (the corner closest to the handle).

“This is a step that only advanced-class knives undergo. This extra effort makes the knife feel softer in hand, allowing you to hold it comfortably for longer periods. It’s something we often don’t think about, but having this finish makes a significant difference in usability,” says Mr. Hirotsugu.

In addition, Mr. Hirotsugi also handles processes like ” koba-tuke sharpening,” which enhances the blade tip by creating a double edge, and “uraoshi,” which helps the material separate more easily by adding a blade about 1 to 1.5 mm on the back of the knife.

“To sharpen the way I want, I make the whetstone myself. It can be a tense job since it’s the final step, but the best part is when customers tell me, ‘It cuts really well,’” says Mr. Hirotsugi.

A Heartfelt Creation by Two Brothers Working Together

The final step in the process is the handle fitting, performed by Mr. Hirotsugu. After heating the tang—the part that fits into the handle—he inserts it and taps the bottom of the handle with a wooden mallet, gradually pushing the blade into place. Achieving a vertical insertion of the blade without distortion and balancing the center of gravity highlights the craftsman’s skill.

“When you pick up the finished product, it should feel just right in the area of the blade that is most commonly used—the sweet spot. While it may seem straightforward, it actually requires a keen sense and involves a great deal of intricacy,” Mr. Hirotsugu explains.

The knives created by two artisans with different specialties, collaborating like a three-legged race, exude a genuine and authentic quality that truly represents a Sakai knife. Alongside their dignified craftsmanship, there’s a warmth that reflects human kindness.
‘I want everyone to experience the unique charm of handmade craftsmanship that machines simply can’t replicate. When knives are comfortable to use over long periods, cooking becomes more enjoyable, resulting in more delicious smiles. There’s nothing more rewarding than knowing our knives can bring happiness to others!’ says Mr. Takayuki.

edit/text Tomoyo Tsuchiya
photographer Yutaka Sato

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