JEPSEN SOY SAUCE CORPORATION (JSC) BIOREACTOR DESIGN

Almeda. Ngo. Tiongco. Wu.

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.

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

Process Overview
1. 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 with perforated 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

Process Overview
2. 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

Process Overview
4. Growth of yeasts and alcohol fermentation
i. ii. Grow Saccharomyces rouxii in 24% salt solution at 15C anaerobically. 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)

Process Overview
6. 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.
ii.

Eliminates active yeasts and molds left in the mixture

Develop its color and aroma

7. Packaging i. Pump liquid soy sauce to specified packaging stations

8. Storage

Process Summary

Equipments
Continuous Koji Processing Vats

Equipments
Brine Fermentor

Equipments
Storage Tanks

Equipments
Bottle Blowing/Filling/Packaging

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