FERMENTATION
The oldest form of food preservation.
Encourage multiplication of m/o.
Definition
– Chemical conversion of carbohydrates into
alcohol or acids
Microbes
– Alter the texture of foods
– Preserve foods (product of alcohol/ acid)
– Produce subtle flavours and aromas
Alcohol
– Preservative effect
– Depends on concentration (12-15% by volume)
– Sometimes need pasteurization (increase
Starter
– Selected strains of lactic acid organism
– Quick & dependable acid production
– Specified culture are available
– Before put the starter, heated-- inactivate
other competitors
– Ancients times – naturally created
Temperature
– Depends on the ability of m/o. temp, acid
content.
– <37°C, more bacteria produce acid-- kill other
m/o.
O2
– Aerobic condition encourage development of
mold
– Mold oxidize acetic acid to CO2 & water
Salt
– Added to control/inhibit proteolytic organism &
spoilage types.
– Frequently added as water drawn from vege
will dilute brine solution.
Sauerkraut – 2.0-2.5% added into cabbage
Pickled olive – 7-10% added into olive
Pickled cucumber – 15-18% added
Eskimos
– Prepared fermented fish by digging a
hole about 2 ft in the ground.
– Put the freshly caught fish in the hole
– Covers with earth & let it buried for a
couple of weeks/> 1 month.
– After reaching the desired level of
fermentation – unearth – freeze
immediately eat
– Tastes best raw and frozen
African
– Fermented fish popular in Ghana,
Uganda, Burundi.
– However unclean practices may cause
dangerous consequences.
– Factors
Water
Cleaning practices
Gutting
Environment
Fish Sauce
Salty, smelly brown liquid made from
fish that is the single, most important
flavoring ingredient in Thai cooking
(Laos, Cambodia, Vietnam, Burma &
Philipines).
Called “nam bplah” in Thai, genuine
fish sauce is the water, or juice, in
the fish that is extracted in the
process of prolonged salting &
fermentation.
Processing
Small fish
- 2 step fermentation
PROCESSING OF SOY SAUCE
Traditional method
Modern method
produce high Q of soy sauce
fulfill the requirement in Food
Regulation 1985.
MODERN METHOD
washing
Soaking Boiling
Soy bean Cooling Mixing
(10 hrs) (20min,15psi) (Wheat Flour,20%
*remove seed Innoculum,0.1%)
coats/hulls *horizontal retort *Aspergillus spp.
Incubate in
Put In Koji Put onto
Koji Room
(greenish rack Put In Tray-2cm thick
Fiber Tank (30°C,RH 90%,
yellow) (stainless steel)
48 hrs)
+ brine(22%)
[1:3-koji wt :brine wt]
Moromi
*sampling for Kjeldahl
Fermentation method-not less than
2-18 months 0.9%N2
Pasteurization Mixing
Bottling (80°C,30min) Tank
PROCESSING PLANT
CRITICAL CONTROL POINT
STEP HAZARD
1. Ingredient of moisture
koji; soy bean, Insect
wheat flour. Microorganisms
STEP HAZARD
5. Concentration of brine less 20% - enhance
the growth of undesired
microorganism
Aspergillus oryzae
STAGE 1 :KOJI
The mixture is spread (2cm
thick) onto the stainless
steel tray (with hole).
These trays are covered
with muslin cloth.
Incubate in koji room–
30°C/48 hrs/RH 90%
At this stage – protein,
oligo and polysaccharides
are hydrolyzed –
Aspergillus enzyme
This results in production
of fermentable sugar,
peptides and amino acids.
Mould grow Koji formed
(greenish yellow - good Q).
Longer incubation – allow
the growth of undesirable
black moulds.
FERMENTATION
Koji - put into food grade fiber
tank – equipped with cover,
valve, pipe, filter, air flow.
Brine (22%) is put into this
tank. 1:3 (koji’s wt : brine’s wt)
– to kill the growth of
Aspergillus oryzae. moromi
formed
Lactic fermentation occurs
– Lactobacillus delbruckii &
Pediacoccus soyae
Followed by alcoholic
fermentation (by yeast) –
Zygosaccharomyces rouxii
Exposed to the sunlight –
Bright and sunny weather
tends to be more conducive in
producing soy sauce of better
Q and aroma.
Exposure for 2 months – to get
the min aroma of soy sauce
and continuously developed.
To ensure the conc. of
the brine not less than
20% - use brinometer.
Fermentation of
moromi within 45 days
(min period to dissolve
56%- 68% of total Brinometer
nitrogen from soy
bean).
EXTRACTION & FILTRATION
After fermentation, raw soy sauce
will be extracted and filtrated to
aging tank – using hydraulic/pump.
In aging tank – the mixture sunned
for a week– to develop aroma and
flavour.
SEDIMENTATIONS
The raw soy sauce will be pumped to
the sedimentation tank.
Sampling for the total nitrogen using
Kjeldahl method – the total nitrogen
supposed to at least 0.9% before
mixing with other ingredients and
pasteurization – may lost during
heating.
The processed soy sauce must
contains at least 0.6% total nitrogen
MIXING
Raw soy sauce with
sufficient nitrogen will be
pumped to the mixing
tank.
Brine (18%), sugar,
caramel and food additive
will be added in the ratio
1:2 (vol ingredient : vol
raw soy sauce).
Caramel and sugar to
condense and sweeten the
sauce.
Caramel calouring agent
Food preservative ;
eg : benzoic acid – not
more than 1000 ppm (Food
Regulation 1985).
Flavour enhancer also can
PASTEURIZATION
Raw soy sauce will be
pasteurized at 80°C/30
min in mixing tank
equipped with
stirrer and
jacketed thermal
oil (to prevent –
burnt and crusty),
or
Plate heat
exchanger.
BOTTLING
The processed soy
sauce will be filled
into sterilized
bottles using high
pressure vacuum.
Soy sauce –
capped, labelled
and distributed.
Conclusion
Allof the food potential to be
fermented (naturally/ modified), but
if there’s no controlled handling,
proteolitic and lipolytic will replace
the process and spoiled the food.
TODAY’S THORN
IS TOMORROW’S FLOWER
CHARACTERISTICS OF FIBRE
TANK
Food grade
recyclable and allows for easy
disposal
high-temperature performance
corrosion resistance