10. soy sauce production

8/12/2019 10. Soy Sauce Production

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SOY SAUCE PRODUCTION

Indah RiwayatiProdi Teknik Kimia Unwahas

2012


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Soy sauce

Soy sauce is the most popular flavoring used inJapanese and other oriental cooking

Japanese consumption being very high (estimated

to be 10L/head of population per year)

The product is well known to consumers in the

West as a condiment for addition to Chinese foods


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Soy Sauce

The product contains a high saltconcentration so that consumption of large

amounts can lead to high blood pressure and

associated health problems

Recently, steps have been taken to produce

soy sauce with a lower salt content

Originally, soy sauce fermentation wascarried out on a small scale in households,

today much of it is manufactured on large

scale using highly mechanized processes


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Manufacture of Soy Sauce

Fermentation

Pressing & Refining

Pasteurize

Bottle

During fermentation, which takes 6-8

months or longer, koji mold enzymes

continue to breakdown starch and

protein. Sugars are converted by

lactic acid bacteria and yeasts to

lactic acid and alcohol. Flavoring

constituents are formed

At 70-80oC destroys any organisms

remaining in the soy sauce,

preventing any further fermentation


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Koji Process

The process converts a substrate that isunavailable to lactic acid bacteria and yeasts

into a material that can be used by these

organisms in further fermentations

Koji production is used as the foundation for

the manufacture of a number of products,

including soy sauces, miso and rice wine(sake)


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Koikuchi Koji Overview

1. Cooked soybeans and roasted wheat at

50/50 conc. (40% moisture content)

2. Inoculated with Aspergillus Sojae/Oryzae

3. Incubation within the perforated vats

4. Salt solution is added

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Aspergillus Sojae/Oryzae

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Release enzymes to digest material

Material is absorbed by hyphae

Types of Enzyme produced during Koji

Fermentation

Amylolytic, Proteolytic, Peptidolytic, and

Lypolytic enzymes

Reproduces by sporulation


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Purpose of Koji Fermination

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1. Maximize enzyme production

2. Prevent denaturation of the enzymes

3. Avoid the presence of undesirable micro-

organisms

4. Minimize the utilisation of nutrients by the

Koji molds


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Koji Vats Perspective


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Koji Process

Raw Materials

Cook

Inoculate with

Aspergillus oryzaeorAspergillus sojae

Soybeans, wheat, barley, rice

Cooking reduces the number of

contaminants in the raw material and

introduces the necessary moisture

required for mold growth. Proteins are

denatured and starches made more

soluble so that they can be digested by

the mold


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Koji Process

Incubate at 25-30oC

Koji

The inoculated substrate is packed into

shallow trays or baskets and aerated for 2-3

days with temperature and moisture controlledair. The mold grows throughout the substrate

breaking down starch, protein and other

materials into soluble products

Koji containing sugars and

amino acids is used for further

fermentation by lactic acid

bacteria and yeasts


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BRINE FERMENTATION

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Brine solution

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20-24% NaCl

To kill off Apergillus Oryzae/Sojae fungi and its

spores

Adds a salty taste


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Brine Fermentation

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5 months ~ 6 months

Take place in a fermentor

Fermentor properties

10, 000 Liters

Closed tank reactor

Atmosphere Pressure

Varied temperature (1528 C)


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Brine Fermentation

Fermentor


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Brine Fermentation

3 Stages in Brine Fermentation

1. Protein and starch hydrolysis2. Culture of lactic acid bacteria and pH

reduction

3. Growth of yeasts and alcohol

fermentation


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Brine Fermentation Stage 1.

Protein and Starch Hydrolysis


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Brine Fermentation Stage 2. Culture of Lactic Acid Bacteria and pH Reduction

Pediococcus bacteria

Growing in a 24% salt solution, T = 15 C

Anaerobic

Initial pH value: 6.57.0

C6H12O6 CH3CHOHCOOH + C2H5OH + CO2

Glucose Lactic acid EthanolCarbon

dioxide

Final pH value : ~ 5.0

Pediococcus


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Brine Fermentation Stage 3.

Growth of Yeasts and Alcohol Fermentation

Saccharomyces rouxii

Growing in a 24% salt solution, T = 15 C

Anaerobic Reactions (T = 28 C)

Amino acid Alcohol + Water

Maillard reaction:

Amino acid + Glucose HEMF

S. rouxii

S. rouxii


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Microbiology of the Fermentation

Salting the Koji helps to prevent furthermold growth and produces ideal conditions

for growth of organisms active in the

fermentation

Mold enzymes continue to digest the

substrate and release nutrients for the

growth of lactic acid bacteria and yeast


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The fermentation follows a successionstarting with Pediococcus halophilus

This organism produces lactic acid causing

the pH to drop from 6.5-7.0 to 4.8-5.0

These conditions favor the growth of

Saccharomyces rouxii, an osmophilic yeast,

that carries out an alcoholic fermentation


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The yeast Torulopsisspp., also an alcoholproducer, finally dominates the fermentation

process

The final product has a pH of 4.7-4.9, a saltconcentration of about 16% and contains a

wide variety of flavoring components

About 300 flavoring cmpds have been

identified in soy sauce


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Flavoring cmpds in soy sauce includescarbonyls, organic acids, esters, alcohols

(including aromatic alcohols), acetals,

sulphur and nitrogenous cmpds The product is highly stable and not subject

to microbial spoilage or the growth of

pathogens Attempts to isolate mycotoxins from these

products have proved negative

10. soy sauce production

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