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
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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

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Koji Vats Perspective

Continuous Koji processing vats

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Temperature profile during incubation

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

and its spores

Adds a salty taste

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Brine Fermentation

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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)

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Brine Fermentation
Fermentor

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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

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Brine Fermentation Stage 1.

Protein and Starch Hydrolysis

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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
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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

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Cost Estimation

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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

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Operability Window

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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

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 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

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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?
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