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

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

C
Anaerobic

Initial Pediococcu
pH value: 6.5 7.0
s

C6H12O6
Glucose
Carbon

CH3CHOHCOOH + C2H5OH + CO2

Lactic acid
Ethanol

dioxide
18

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

Reactions
(T = 28 C)
S. rouxii
Amino acid
S.
rouxii
Maillard reaction:
Amino acid + Glucose

19

Alcohol + Water
HEMF

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

Safety Issue

Basic Process Control Diagram

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

PAH
PA1

Fail Open Valve at

Outlet Air Flow
Filter at Outlet Air
Flow Channel
Extra Pressure Sensor

PA2

PY

AA

TAH
TY
TC

TA1

Temperature HAZOP SIS

TA2

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

Air Flow

Maximum Allowable
Level!
T
P

Heating Stream

PH

Air Flow

AA
Air Flow

Safety Relief
Valve
T
P

Heating Stream

PH

Overall SIS Diagram

Dissolved Oxygen
Level DO2
Inlet Air Flow

Air Flow

AA
>
TAH

TY

TA1

TC

TA2

Safety Relief
Valve

PC

PAH
PA1

PA2
Heating Stream

PHA

PY

>

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

Temperature too low

Heat Exchanger

Soy bean cooking temperature too low

Koji Vat

Process
Flow

Incorrect fungi concentration

Incorrect temperatures
Aerator damaged

Fermentor

Temperature too high

Heating coil damaged
Temperature too low
Not enough salt in Brine solution

Contaminated
Soy Sauce
Koji vat
Contaminated
Fermentor

Control Errors

Contaminated fermentor
pH level changes not accounted

Incorrect readings

Faulty sensors
Incorrect calibration

Questions?
40