Industrial Production Industrial Production Soy SauceSoy Sauce

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Group Members: Alexander EryuzluYathu KaileswaranHossam RefaeiJi XuCong Ying

Commonly used in Asia, becoming popular in Americas as a condiment

129 million litres annually produced in the U.S. (~$2 billion/year)

Kikkoman Foods Inc. is the largest producer in the world

Why soy sauce?

Ride the Kikkoman Wave

Popularity in the US

Koikuchi Shoyu PFD

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Koji Fermentation

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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

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

Koji Vats Perspective

Continuous Koji processing vats

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Temperature profile during incubation

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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

Brine Fermentation

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Brine Fermentation

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5 months ~ 6 monthsTake place in a fermentor

Fermentor properties 10, 000 Liters Closed tank reactor Atmosphere Pressure Varied temperature (15 28 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

reduction3. 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: 6.5 7.0

C6H12O6 CH3CHOHCOOH + C2H5OH + CO2 Glucose Lactic acid Ethanol

Carbon

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

Cost Estimation

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Floating head, shell and tube c/s

Cost Estimation: Heat Exchanger

Heat Exchanger ParametersSurface Area (m2)

100

Material Carbon steel

Temp. (K) 353

Pressure (Mpa) 3.2

Woods Correlations (Ch. 5.5)

Inflation factor: 4.756

Cost Estimation: Heat Exchanger

FOB c/s 8,000Co 38,051.83Fbm 3.14Fp 1.3204Fm 1(piping) 0.46 0.7Co(Fbm - 1) 81,430.91Co(FpFm - 1) 12,191.81Co(FpFm - 1)((piping))( )

3,925.761

Total Cost ($) 135,600.30Error (+/-) 40%

Operability

Fermentor

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Operability Window

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Process Operability

FlexibilityDegrees of freedom: temperature and

pressure

ReliabilityTemperature and pressure control for

production

EfficiencyProper management

DynamicsTemperature control (+/- 0.5 C)

Safety

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Safety Issue Basic Process Control Diagram

Pressure Safety Interlock System (SIS)

Temperature Safety Interlock System (SIS)

Safety Relief Valve

Workplace Containment

Emergency Response

Note:

Fermentor is very expensive Equipment!

Fermentation is a biological Process!

A A

Dissolved Oxygen Level DO2

Air Flow

P

PH

T

Heating Stream

Air Flow

Closed Tank

A A

Inlet Air Flow

PA1

Outlet Air Flow

PA2

PY

PC

PAH

Pressure HAZOP SIS

Fail Close Valve at Inlet Air Flow

Fail Open Valve at Outlet Air Flow

Filter at Outlet Air Flow Channel

Extra Pressure Sensor

Dissolved Oxygen Level DO2

A A

TA1

Heating Stream

TA2

TY

TC

Temperature HAZOP SIS

Fail Close Valve at Heating Stream Inlet Channel

Extra Sensor to Measure Temperature of Fermentation Tank

TAH

A A

Dissolved Oxygen Level DO2

Air Flow

P

PH

T

Heating Stream

Air Flow

Alarm !!

Pressure Exceeds

Maximum Allowable

Level!

A A

Air Flow

P

PH

T

Heating Stream

Air Flow

Safety Relief Valve

AA

Dissolved Oxygen Level DO2

PHA

Heating Stream

Air Flow

Overall SIS Diagram

Inlet Air Flow

PA1

PA2

PY>

PC

PAH

TA1

TA2

TY>

TC

TAHSafety Relief Valve

Workplace Containment

Fermentation is a biological process -- Employees should follow biosafety manual during operation and handling equipments and biological agents.

All microorganisms in soy sauce production belongs to Class I biological risk agent

Personal Protection: 1. Protective coating and gloves

2. Eye protection equipments

3. Mouth, nose covering

Class I Biological Risk Agent:

Has no or minimal risk to cause health problem to adult human

Workplace Containment Plant Environment Protection Safety Tank that covers the fermentation

tank

Emergency Response Shut down fermentation process

Isolate the problematic tank

If leaks to the work environment, evacuate all workers locate in workplace

Shut down all electric devices to prevent fire

Decontaminate the leaked liquid by killing all microorganisms with chemicals

Troubleshooting

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Process Flow

Not enough salt in Brine solution

Fermentor Temperature too high

Koji Vat

Temperature too low

Incorrect temperatures

Heat ExchangerTemperature too low

Koji vat

Contaminated

Fermentor

pH level changes not accounted

Faulty sensorsIncorrect readings

Incorrect calibration

Control ErrorsContaminated fermentor

Contaminated Soy Sauce

Incorrect fungi concentration

Heating coil damaged

Aerator damaged

Soy bean cooking temperature too low

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Questions?

Industrial Production Soy SauceWhy soy sauce?Popularity in the USKoikuchi Shoyu PFDKoji FermentationKoikuchi Koji OverviewAspergillus Sojae/OryzaePurpose of Koji FerminationKoji Vats PerspectiveContinuous Koji processing vatsTemperature profile during incubationBrine solutionBrine FermentationSlide 14Slide 15Slide 16Brine Fermentation Stage 1.Brine Fermentation Stage 2.Brine Fermentation Stage 3.Cost EstimationCost Estimation: Heat ExchangerWoods Correlations (Ch. 5.5)Slide 23OperabilityOperability Window Process OperabilitySafety Safety IssueSlide 29Slide 30Slide 31Slide 32Slide 33Overall SIS DiagramWorkplace ContainmentSlide 36Emergency ResponseTroubleshootingSlide 39Slide 40