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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Microbiology of the Fermentation
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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Microbiology of the Fermentation
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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Microbiology of the Fermentation
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