Jepsen Soy Sauce Corporation (Jsc) Bioreactor

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    JEPSEN SOY SAUCE

    CORPORATION (JSC) BIOREACTOR

    DESIGNAlmeda. Ngo. Tiongco. Wu.

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    Product Identification

    Naturally brewed soy sauce

    There are two distinct types of soy sauce on the market today: naturally

    brewed (or "fermented") sauces and non-brewed products.

    Naturally brewed soy sauce is translucent, with a reddish-brown color and a

    wonderfully balanced flavor and aroma.

    Non-brewed soy sauce is often opaque and has a harsh, overpowering flavor

    and pronounced chemical aroma.

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    Raw Materials Soy beans

    Wheat

    Aspergillus Sojae/Oryzae

    Produces Amylolytic, Proteolytic, Peptidolytic, and Lypolytic enzymes

    Bacteria Culture

    Brine Solution

    Kills off Aspergillus Sojae/Oryzae fungi and its spores

    Adds a salty taste

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    Process Overview1. Protein and Starch Hydrolysis

    i. Incubate mixed Aspergillus Sojae/Oryzae fungi, cooked soybeans

    and roasted wheat (50/50 concentration with 40% moisture

    content) aerobically for 3 days at 25C in shallow vats withperforated bottoms such that air is forced through the solution

    - Gives rise to enzymes such as proteases and amylases which

    breaks down the proteins in soybeans and the starch in the

    wheat forming amino acids and sugars

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    Process Overview2. Add brine solution with 22-25% salt (salt by weight volume) to the mixture

    3. Culture of lactic acid bacteria and pH reduction

    i. Grow Pediococcus bacteria in 24% salt solution at 15C anaerobically with

    initial pH value of 6.5-7 having a final pH value of 5.

    ii. Add lactic acid bacteria to mixture

    - Converts glucose to lactic acid, ethanol and CO2

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    Process Overview4. Growth of yeasts and alcohol fermentation

    i. Grow Saccharomyces rouxii in 24% salt solution at 15C anaerobically.

    ii. Add yeasts to mixture

    a) Reaction takes place at 28C

    b) Converts amino acid to alcohol and water

    c) Converts amino acid and glucose to 4-hydroxy-2(or 5)-ethyl-5(or 2)-

    methyl-3(2H)-furanone (HEMF)

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    Process Overview6. Ferment for around six months

    7. The mixture goes through a mechanical press separating solid residue to the

    soy sauce

    8. Heat the resulting raw soy sauce to 70-80C

    i. Eliminates active yeasts and molds left in the mixture

    ii. Develop its color and aroma

    7. Packaging

    i. Pump liquid soy sauce to specified packaging stations

    8. Storage

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    Process Summary

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    Equipments Continuous Koji Processing Vats

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    Equipments Brine Fermentor

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    Equipments Storage Tanks

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    Equipments Bottle Blowing/Filling/Packaging

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    References

    Berk, Z. (1992). Technology of Production of Edible Flours and Protein Products from

    Soybeans(Vol. 97). FAO Agricultural Services Bulletin, Rome.

    Eryuzlu, A., Kaileswaran, Y., Refaei, H., et al. (n.d.) Industrial Production Soy Sauce.

    Retrieved on September 20, 2013 from

    http://www.docstoc.com/docs/77586737/Soy-Sauce-Production

    Iino, Hisakazu. (n.d.) Fermented Foods of Japan: Soy Sauce. Retrieved on September

    20, 2013 from http://www.kikkoman.com/foodforum/

    thejapanesetable/25.shtml#header

    Kikkoman.Art of Natural Brewing. Retrieved on December 18, 2013 from

    http://www.kikkomanusa.com/homecooks/soysaucebasics/artofnaturalbrewing.php

    Maruso Soy Sauce. Process of Making Soy Sause The Maruso Way. Retrieved on

    December 18, 2013 from http://marusoy.com/process