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    Soy Sauce Production Final

    Uploaded by

    Konpal Pali
    This document discusses the industrial production process for soy sauce. It begins by introducing soy sauce and its popularity and production levels. It then describes the key steps in the production process, which include koji fermentation using Aspergillus fungi to produce enzymes, and subsequent brine fermentation over 5-6 months to produce soy sauce. The document provides details on process parameters, equipment, safety systems, and potential troubleshooting issues for each major step.

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    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    Soy Sauce Production Final

    Uploaded by

    Konpal Pali
    491 views40 pages
    This document discusses the industrial production process for soy sauce. It begins by introducing soy sauce and its popularity and production levels. It then describes the key steps in the production process, which include koji fermentation using Aspergillus fungi to produce enzymes, and subsequent brine fermentation over 5-6 months to produce soy sauce. The document provides details on process parameters, equipment, safety systems, and potential troubleshooting issues for each major step.

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    This document discusses the industrial production process for soy sauce. It begins by introducing soy sauce and its popularity and production levels. It then describes the key steps in the production process, which include koji fermentation using Aspergillus fungi to produce enzymes, and subsequent brine fermentation over 5-6 months to produce soy sauce. The document provides details on process parameters, equipment, safety systems, and potential troubleshooting issues for each major step.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    491 views40 pages

    Soy Sauce Production Final

    Uploaded by

    Konpal Pali
    This document discusses the industrial production process for soy sauce. It begins by introducing soy sauce and its popularity and production levels. It then describes the key steps in the production process, which include koji fermentation using Aspergillus fungi to produce enzymes, and subsequent brine fermentation over 5-6 months to produce soy sauce. The document provides details on process parameters, equipment, safety systems, and potential troubleshooting issues for each major step.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 40
    At a glance
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    Some of the key takeaways are that soy sauce is commonly used in Asia and becoming popular in other regions like the Americas. It is produced through a fermentation process involving fungi and bacteria. Kikkoman is the largest producer globally.

    The main stages of soy sauce production are koji fermentation, where fungi produce enzymes to break down nutrients, followed by a long brine fermentation process involving lactic acid bacteria and yeasts to further break down proteins and starches and produce flavors.

    The main microorganisms involved are the fungi Aspergillus oryzae/sojae during koji fermentation to produce enzymes, and the bacteria Pediococcus and yeast Saccharomyces rouxii during brine fermentation. They break down nutrients and produce acids, alcohols and flavors through their metabolic processes.

    Industrial Production Soy Sauce

    Group Members: Alexander Eryuzlu Yathu Kaileswaran Hossam Refaei Ji Xu Cong Ying

    Why soy sauce?


    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 Ride the Kikkoman Wave

    Popularity in the US

    Koikuchi Shoyu PFD

    Koji Fermentation

    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

    Aspergillus Sojae/Oryzae
    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
    7

    Purpose of Koji Fermination


    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


    8

    Koji Vats Perspective

    Continuous Koji processing vats

    10

    Temperature profile during incubation

    11

    Brine solution
    20-24% NaCl To kill off Apergillus Oryzae/Sojae fungi

    and its spores


    Adds a salty taste

    12

    Brine Fermentation

    13

    Brine Fermentation
    5 months ~ 6 months Take place in a fermentor Fermentor properties 10, 000 Liters Closed tank reactor Atmosphere Pressure Varied temperature (15 28 C)

    14

    Brine Fermentation
    Fermentor

    15

    Brine Fermentation
    3 Stages in Brine Fermentation
    1. Protein and starch hydrolysis 2. Culture of lactic acid bacteria and pH

    reduction 3. Growth of yeasts and alcohol fermentation

    16

    Brine Fermentation Stage 1.


    Protein and Starch Hydrolysis

    17

    Brine Fermentation Stage 2.


    Culture of Lactic Acid Bacteria and

    pH Reduction
    C Anaerobic
    s

    Pediococcus bacteria
    Growing in a 24% salt solution, T = 15

    Initial Pediococcu pH value: 6.5 7.0


    C6H12O6 Glucose Carbon dioxide
    18

    CH3CHOHCOOH + C2H5OH + CO2 Lactic acid Ethanol

    Final pH value : ~ 5.0

    Brine Fermentation Stage 3.


    Growth of Yeasts and Alcohol

    Fermentation
    Saccharomyces rouxii

    Growing in a 24% salt solution, T = 15 C Anaerobic

    Reactionsrouxii = 28 C) S. (T
    Amino acid S. rouxii Maillard reaction: Amino acid + Glucose Alcohol + Water HEMF

    19

    Cost Estimation

    20

    Cost Estimation: Heat Exchanger


    Floating head, shell and tube c/s

    Heat Exchanger Parameters


    Surface Area (m2) Material Temp. (K) Pressure (Mpa) 100 Carbon steel 353 3.2

    Woods Correlations (Ch. 5.5)

    Cost Estimation: Heat Exchanger


    Inflation factor: 4.756
    FOB c/s
    Co Fbm Fp Fm (piping) Co(Fbm - 1) Co(FpFm - 1) Co(FpFm - 1)((piping)) () Total Cost ($) Error (+/-)

    8,000
    38,051.83 3.14 1.3204 1 0.46 0.7 81,430.91 12,191.81 3,925.761 135,600.30 40%

    Operability
    Fermentor

    24

    Operability Window

    25

    Process Operability
    Flexibility
    Degrees of freedom: temperature and

    pressure
    Reliability
    Temperature and pressure control for

    production
    Efficiency
    Proper management

    Dynamics
    Temperature control (+/- 0.5 C)

    Safety

    27

    Basic Process Control Diagram

    Safety Issue

    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!

    Dissolved Oxygen Level DO2

    AA
    Air Flow Air Flow

    T P Closed Tank
    Heating Stream

    PH

    Dissolved Oxygen Level DO2

    AA
    Outlet Air Flow Inlet Air Flow

    PC 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 PA2 PAH PA1 PY

    AA

    TAH TY TC TA1 TA2

    Temperature HAZOP SIS Fail Close Valve at Heating Stream Inlet Channel Extra Sensor to Measure Temperature of Fermentation Tank

    Heating Stream

    Dissolved Oxygen Level DO2

    A Alarm !! A Pressure Exceeds


    Air Flow

    Maximum Allowable Level! T P

    Air Flow

    Heating Stream

    PH

    Air Flow

    AA
    Air Flow

    Safety Relief Valve T P

    Heating Stream

    PH

    Overall SIS Diagram


    Dissolved Oxygen Level DO2 Air Flow Inlet Air Flow

    AA > TAH TY TC TA1 TA2 PA1 Safety Relief Valve

    PC

    PAH PY

    >

    PA2
    Heating Stream

    PHA

    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

    38

    Heat Exchanger

    Temperature too low

    Soy bean cooking temperature too low

    Process Flow

    Koji Vat

    Incorrect fungi concentration Incorrect temperatures Aerator damaged Temperature too high Heating coil damaged Temperature too low Not enough salt in Brine solution

    Fermentor

    Contaminated Soy Sauce


    Koji vat Contaminated Fermentor Contaminated fermentor pH level changes not accounted Incorrect readings Faulty sensors Incorrect calibration

    Control Errors

    Questions?
    40

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