Jepsen Soy Sauce Corporation (Jsc) Bioreactor
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Transcript of 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