CHAPTER 1

INTRODUCTION

1.1 Briefing to industrial training

Every student of Bachelor of Food Technology Universiti Darul Iman Malaysia has to

undergo an internship program of fifteen weeks in any organization to get exposure to the real

time business environment. The real purpose of this internship program is to provide an

opportunity to the students to see the practical applications of their background professional

studies. The report is a reflection on my experience when I was interned in Zara Foodstuff

Industries, Johor Bahru.

1

I was assigned in Quality Assurance Department. This department is responsible in

controlling the quality of industry manufactured products and provide guarantee of safety of the

products. It covers the Quality Control Lab, Microbiology and Analysis Lab. In efforts to

improve the capability and quality of service, the this company has successfully obtained MS ISO

9001:2000 Quality Management Systems –Requirements in scope of manufacture of soy sauce,

chili sauce, tomato sauce and sri kaya.

My internship program in Zara Foodstuff Ind. was commenced on Monday, 4th January

2010. I was attached to the Quality Department for a period of 15 weeks. My supervisor, Mr

Fathuddin Hj Zakaria gave me a tentative outline concerning how my internship program would

be like.

1.2 Objectives of industrial training

The main objective of the Industrial Training is to experience and understand real life

situations in industrial organizations and their related environments and accelerating the learning

process of how student’s knowledge could be used in a realistic way. In addition to that,

industrial training also makes one understand the formal and informal relationships in an

industrial organization so as to promote favorable human relations and teamwork. Besides, it

provides the exposure to practice and apply the acquired knowledge “hands - on” in the working

environment. Industrial training also provides a systematic introduction to the ways of industry

and developing talent and attitudes, so that one can understand how Human Resource

Development works.

2

Moreover, students can gain hands-on experience that is related to the students majoring

so that the student can relate to and widen the skills that have been learnt while being in

university. Industrial training also exposes the students to the real career world and accustoms

them to an organizational structure, business operation and administrative functions.

Furthermore, students implement what they have learned and learn more throughout this

training. Besides, students can also gain experience to select the optimal solution in handling a

situation. During industrial training students can learn the accepted safety practices in the

industry. Students can also develop a sense of responsibility towards society.

In conclusion, there is strong evidence that industrial training is highly beneficial to

students’ development, and it is highly valued. The early exposure of real work life situation is

deemed necessary as this prepares students not only acquiring the theoretical aspects of the

knowledge, but far more important, is how this knowledge can be applied practically in real

workplace settings.

The students are well equipped to manage the period of industrial training successfully

and undoubtedly gain useful experience of applying their specialist and technical skills, as well as

developing their personal and communications skills. This internship also helps students to

prepare for the work environment and also teach the ergonomics of organizations in the real

world.

3

1.3 Objective of this report

This document provided details of my achievements in term of practical

implementation and understanding of working environment in Zara Foodstuff Industries for

about 3 and a half months. It also contains the findings on recent issues or problem that

occurred and must be confronted.

1.4 Scope of Industrial Training

The scope of my Industrial Training are basically on Quality Assurance officer duties

and responsibilities, the process flow of every product and its importance, knowing the ISO

amendment and the importance of Good Manufacturing Practice application in plant. Along

my internship period, I have to gain information from every step of production process and

relate them in term of food technology.

4

CHAPTER 2

ORGANIZATION BACKGROUND & STRUCTURE

2.1 Company profile

Zara Foodstuff Industries has in a relatively short period of time established itself as a

leading food product manufacturer. Commencing operations in 1987, when manufacturers

were trying to weather a period of recession, Zara Foodstuff Industries forged ahead, going

against the grain by expansion and astute business decisions. Its pioneer product which

provided the impetus for growth was soya sauce, deliciously thick and sweet or appetizingly

light and salty.

Today, Zara Foodstuff Industries has two technologically advanced manufacturing

facilities located at the Larkin Industrial Area, Johor, Malaysia, which produces four food

products under the Cap Kipas Udang brand, namely soya sauce, chili sauce, tomato sauce and

Sri Kaya (coconut bread spread).

5

There are about 105 staffs (local) in the whole factory (including office workers).

Operation starts from 8am – 5pm (Mondays – Fridays and half day on Saturdays) with lunch

break for 1 hour from 1pm to 2pm while operators operation hour start from 8am – 4.30pm

(Mondays – Saturdays) with half an hour lunch break. Tea breaks are scheduled at 10.15am and

3.15pm for 15 minutes.

Currently, soy sauce ‘Cap Kipas Udang’ and chili and tomato sauces had been exporting

to overseas markets such as Singapore and Brunei. They hope to expand their market to other

countries once they have improved their system by developing and implementing a food safety

system ‘HACCP’.

Their success has been rewarded with the certified ISO 9001 company in year 1999 by

SIRIM QAS for quality system management. They also won the ANUGERAH KUALITY

INDUSTRIES NEGERI JOHOR in year 2002 under category manufacturing organized by Johor

State. Currently they are in the process to get the HACCP certified from International body.

6

2.2 Organizational charts

Figure 2.3: Organizational chart

7

Group Executive Chairman

Plant Consultant 1

QA department

Plant Consultant 2

Plant Director

Production Advisor

Admin & Purchasing

Director

Human Resource Dept

Purchasing dept.

Admin and Legal Dept.

Group Finance Director

Managing Director

2.3 Quality Policy

To value customer needs and expectations by producing quality and safe product through

effective and continual improvement of world class Quality and Food Safety Management

System.

8

CHAPTER 3

PRODUCTS

3.1 Soy sauce

3.1.1 Introduction

Soy sauce production requires a complex fermentation process in which the carbohydrates

are fermented to alcohol and lactic acid and the proteins broken down to peptides and amino

acids. Soy sauce production is produced by solid state mold fermentation (koji) of raw materials:

soy bean and wheat followed by submerged high-salt ripening phase. During latter phase,

proteins and carbohydrates are hydrolyzed to amino acids and sugars and subsequent Mailard

reactions lead to the generation of a range of savoury aroma compounds.

9

3.1.2 Activities

During my industrial training, I have been placed at the fermentation area for 2 weeks to

learn more n details on the fermentation procedure and related action taken if any problem

occurs. The first thing that I have been introduced with is koji which I never saw before. Then,

further explanation on the process of making moromi is explained by Fermentation Leader, Mr

Shahrizal. Other than that, he also mentioned about the quality control plan that have been used

in order to overcome possible problem as the moromi is the ‘hardcore’ process to produce soy

sauce.

Within 2 weeks time, I have experienced on how to check the brine level, temperature

upper n lower part of moromi in the fiberglass and aroma of the moromi. These all parameters are

important as it will determine the quality of soy sauce later.

From my observation, the process shown only shows the physical appearance of the bean

water (moromi solution). My manager had asked me to reveal the story behind all processing step

in term of chemical and biological change during fermentation. The details are explained below.

10

3.1.3 Process Flow of fermentation

11

Cooking process (temp: 120ºC, 15-20 psi, 10 minutes (complete cooking period= 1 hour)

Soaking process: 4-18 hours

Washing bean with water(2 bag of bean/barrel for retort)

Koji preparation: Mixing bean with flour-starter and transfer it into wooden frame

Brine solution preparation: brine + 80ºB

Incubate the koji for 2-3 days in koji room

Transfer the incubated koji into the fiberglass

Addition of brine solution according to size of fiberglass

Spread thick salt: 3rd day of fermentation or after 3 times of mixing the koji with brine water

Figure 3.1.3: Fermentation Process Flow

12

Quality control

Fermentation process take place for 2 ½ months

Extraction of bean water: 1st extraction with specific amount according to size of fibreglass

Addition of brine solution: Brine: 74-76ºB with specific amount

2nd extraction of bean water

Addition of brine solution (74-76ºB with specific amount)into the fiberglass contains the remaining mash moromi

3rd extraction: (A) and (B)

Discard the moromi

3.1.4 Sequential Methods for fermentation process

i) Wheat- Starter production

Wheat flour must be dry fried at 60ºC to remove moisture and kill microorganism and

been cooled. The inoculums of Aspergillus sp. spores added and mixed well.

ii) Koji production

The soy bean has been cooked in a vertical retort for 5-10 minutes by maintaining the

temperature 110-120 ºC and pressure 10-15 psi. Mix well the wheat -starter with cooked bean in

the mixing tray by hand. The wheat-starter layer must not coated too thick. Mixture of soy bean,

wheat flour and fungal culture is placed on shallow flat wooden trays and incubated for 3-4 days

in shelf. They will be stored in koji room where the temperature and relative humidity are

controlled. Koji mold grows throughout the material becomes yellowish green as the result of the

sporulation of Aspergillus strains. They use of same trays to ensure that same organisms are

carried from one fermentation batch to another.

iii) Moromi and bean water production

Production of soy sauce starts with the fermented bean water which comes from moromi.

Once the fungus is well grown, usually after a few days, the koji is again mixed and placed in the

fibreglass for the second phase of the fermentation. Brine solution is added and it is from this

brine that the salty taste is derived. The fiberglass will be left open to sun light which to

encourage or enhance spontaneous fermentation by bacteria and yeast take place. After aging

13

period (2.5 months), the bean water (koji and brine solution) is siphoned off to give the first

extract for soy sauce production. The addition of brine water to the residue mash moromi will be

done as the bean water will be known as Bean water 2 as it is the second extraction. Addition of

brine will be repeated to the same fiberglass and consider the bean water as bean water 3 as it is

third extraction. The bean water is then transfer to the cook barrel for next process in producing

the soy sauce.

3.1.5 Chemical and Biological reaction during fermentation

i) Koji stage

Role of koji molds is to breakdown enzymatically the proteins and starches of the soy

beans and wheat in the koji preparation. The soy sauce koji contains proteases, amylases, and

lipases that hydrolyse their respective substrates in the subsequent submerged fermentation in

approximately 20% weight per volume salt brine. It was found that Aspergillopeptidase A

(molsin) was the most effective in improving the flavour of soy bean (Fujimaki et. al., 1968;

Noguchi et. al., 1970). During the submerged fermentation, some halophilic microorganisms such

as Pediococcus cerevisiae, Lactobacillus delbruekii, and salt-tolerant Saccharomyces rouxii

naturally developed, since in a fact that soy sauce fermentation depends on proteolytic enzymes

derived from those halophilic microbial strains to hydrolyze the proteins in the substrate to the

constituent amino acids and peptides. It was found that maximum proteolytic activity was

attained after an incubation period of 5-6 days at 37 ºC and that an acidic pH range induced better

growth and proteolytic activity. It is important that the fungus should grow over and through the

mixture, fully colonizing it and breaking down the component materials. However, it is also

important for the value of the product, that the fungus does not grow too much and begin to

produce spores in the koji. Additionally, patchy growth must be prevented.

14

ii) Mash Moromi stage

Fungal strains are important in hydrolyzing the raw material, bacteria and yeasts take over the

fermentation in the mash stage. Growth of bacteria in the mash was found to give rise to the

formation of organic acids, thereby making acidic conditions which was considered to be

necessary to remove undesirable flavours and add indispensable good flavours to the soy sauce.

(Sakaguchi, 1959). During fermentation process, there are some enzymes that will decompose

carbohydrates, protein and lipids content in soy bean such as amylolytic, proteolytic and lypolytic

enzymes. At this stage it is usually inoculated with yeasts and/or bacteria which grow well in

high levels of salt (osmophilic species) and are also able to grow under low levels of oxygen.

Inoculation with Saccharomyces rouxii (osmophilic yeast) and Lactobacillus delbrueckii (a lactic

acid bacterium) ensures that the process continues, although traditionally this part of the process

was probably more of a chance event. In the secondary phase of the fermentation therefore,

anaerobic conditions quickly develop and further growth of Aspergillus oryzae is prevented. The

sugars in the mixture are fermented by the yeast and lactobacilli so that after about a month, a

sour (pH 4.5), dark coloured liquid is formed which contains large amounts of amino acids,

particularly glutamic acid, simple sugars and a range of vitamins. Subsequently, the brown liquid

is drained off from the moromi and gently filtered. All the residual bean fibre and residue is

removed. It is then boiled to inactivate the degrading enzymes and kill the microbes.

3.1.6 Problems and suggestions

As we know, fermentation is a crucial process in soy sauce making. There must be a zero

problem and error to get high quality soy end product. But, there still some problems that can

contribute to contamination. Firstly, during koji making process, the cooked bean will be mixed

with the wheat-starter in a huge tray bare handed. This may introduce contamination to the soy

15

bean. As a suggestion, the workers may wear single use hand glove or in advance technology use

mixer, eg: ribbon mixer for more hygienic process.

As wooden trays are use in making koji, the condition of the tray must be care of.

Moisture must be avoided to prevent other microorganism grow on the frame of trays. This may

contribute a problem in quality of soy sauce later. As a suggestion, stainless steel trays may be

used but further research and observation must be taken to ensure the quality of koji is same or

better than present. The koji room must be in clean and free from any possibilities of rodents or

insects present. The utensil of making koji must be specifically store in specific place.

3.1.7 Soy sauce manufacturing

3.1.7.1 Activities

Along the internship period, I have been given a chance to check the soy sauce samples

along the process of manufacturing. The parameters that must be checked are pH, saline, brix,

taste, specific gravity and temperature.

3.1.7.2 Functional ingredients

Sugar is added to enhance flavor and also act as antimicrobial. Salt is also added for the

same purpose. The high salt concentration is necessary to help protect the finished product from

spoilage. Monosodium glutamate is use in enhancing the flavor and adds umami taste to the soy

sauce. Other than that, sodium benzoate is added to help inhibit microbial growth in finished soy

sauce.

16

Sugar syrup

Extraction

Palletizing

Sealing

Traying

Shrink wrapping

Capping

Labelling

Cooking95-105°C 60 min

Storage

Sugar, Caramel, MSGMixing

Sodium benzoate, HVP, Salt, Acetic acid, Caramel

Finished goods storage

Loading

Filtering and Cooling (PHE)

Filling

Bottle

Heating and Rinsing(>60°C)

Water

Salt WaterSugar

Blending

Cap

3.1.7.3 Process Flow of soy sauce manufacturing

Figure 3.1.7.3: Process flow of soy sauce

3.2 Chili Sauce and Tomato sauce Production

17

Garlic Dried chilli

Peeling

Grinding 1

Weighing

Blanching

Grinding 2 Rinsing

Tomato sauce*

Garlic, Onion, Papaya

Course grinding

Fine grinding

3.2 1 Introduction

Chili and tomato sauce are another products that been manufactured in this factory. Both

products undergone same process and only differs on ingredients and parameters on quality

checking. The products are categorized as shelf stable product.

3.2.2 Functional ingredients

These are the ingredients that contribute in giving the preferable flavor, texture and other

parameters that must be complied to produce the products. Modified starches are used in all

starch applications: in food products for example as a thickening agent, stabilizer or emulsifier, in

pharmaceuticals as disintegrant, in paper as a binder and many other applications. In tomato and

chili sauce modified starch contribute in giving the viscous texture and bind the excess moisture.

This may help in reducing the possibilities of microbial spoilage.

Other ingredient is xanthan gum. It has properties that have ability to produce a large

increase in the viscosity of a liquid by adding a very small quantity of gum, on the order of one

percent. The viscosity of xanthan gum solutions decreases with higher shear rates; this is called

pseudoplasticity. This means that a product subjected to shear, whether from mixing, shaking or

even chewing, will thin out, but once the shear forces are removed, the food will thicken back up.

Sugar is important in giving flavor and taste for the sauces and also reducing the chances of

microbial spoilage.

3.2.3 Tomato and chili sauce process flow

18

3.3 Seri kaya Production

3.3.1 Introduction

During my internship, I have observed the production flow of Sri kaya making from the

raw material to final product. I have been introduced to observe and analyze the raw material

sample to ensure the quality of the raw material. The specification for every raw materials differs

and all observation must be recorded in the specific form.

3.3.2 Functional ingredients

The oil from the coconut milk powder must be emulsified with all ingredients. By adding

whole raw egg, it will provide moisture to a mixture and holds the ingredients together. As the

food is heated, egg protein coagulates, thus binding ingredients together. Egg yolk contains

lecithin which acts a an emulsifier. Egg yolk prevents the two liquids from separating; the

emulsifiers in the yolks are liaisons between the two liquids and serve to stabilize the mixture.

Coconut emulsion is the main flavor source that gives the taste of natural Seri Kaya.

19

Eggs Modified starch

Heating and Rinsing

Cooking

Glass bottle

Breaking

Homogenization

Weighing

Washing

Coconut powder Filtered water

Homogenization

FiltrationSugar, Salt

Filling

Capping

Retorting

Cooling

Labelling & sealing

Traying

Top sticker

Wrapping

Palletizing

Finished good storage

Loading

Cap

Cap seal & label

Tray

Top sticker

Sleeve wrapper

Xanthan gum Colour and Flavour

Water

3.3.3 Process Flow of Seri Kaya production

Figure 3.3.3 Process Flow of Seri Kaya production

20

CHAPTER 4

QUALITY CONTROL PLAN

4.1 Fermentation

I have been given an exposure to explore the quality control method for moromi solution.

As we know, moromi solution is a hardcore product as it is the starter to produce soy sauce. From

koji making to moromi production, strict observation and control system has been done. Koji

must fulfill the specification before proceed being used to produce moromi. The percentage of

spore growth and its colour are the parameters taken.

The bean water has been control its quality since the first day of fermentation. The brine

degree of brine solution must be at least 80- 90 ºB as this degree range is the best for moromi

fermentation. Moromi in the fiberglass will be exposed to sun light every morning for browning

process and drying the surface of moromi as the UV light from the sun kill the mold and other

pathogen microoraganisms on the surface.

To ensure the quality of the bean water, gradual checking applied. The observation and

check is done for every 2 weeks, 1 month and 2.5 months old moromi. The observation

parameters are same but with differs range of specification. The parameters are temperature of

21

the upper and lower part of moromi, aroma, colour, pH, salinity and brine level of moromi

solution. The equipments uses are pH meter, salinometer and brinometer.

During the fermentation period, the moromi must be treated with salt to avoid any

possible contamination from insects, animal and microorganism. The method of spreading the

salt onto the surface of moromi depends on level of contamination and condition of bean water

and moromi. Normally, the stiring is done after 2,4 and 8 weeks of fermentation period to help

and enhance aeration. Expose the moromi to sun light everyday if good weather and spread thin

salt if there is any contamination at early stage.

For extraction and addition of brine solution, the same hose will be used as moromi can

not contain excess water as moisture will spoil the moromi.

4.2 Soy sauce

Numerous analytical tests are conducted to ensure the finished sauce meets minimum

quality requirements. For example, in brewed sauces, there are several recommended

specifications. Total salt should be 10% of the final product; the pH level should be 4.6-4.85; and

the total nitrogen content should not be less than 6%. The fermented sauce must be made from

fermented mash, salt brine, andpreservatives (either sodium benzoate). This specification also

states that the final product should be a dark brown liquid and met all quality parameters. The

qualities parameters of soy sauce are the sensory characteristics such as taste, odor, as well as

analytical values for nitrogen content, alcohol level, and soluble solids.

22

4.3 Chili and tomato sauce

Laboratory analysis is needed to control the quality of the product and maintain the shelf

life duration time to time. There are some specifications that must be complied such as pH, Brix,

viscosity, consistency, cadmium presence, Total acidity as chemical analysis, Total plate count

and yeast and mold count for microbiological analysis.

4.4 Sri Kaya production

The incidence of spoilage in Sri Kaya products is very low, but when it does occur, it is

important to proceed with the investigation. Most of the problems may occur on bloated cap,

undesired colour and undesired texture. Abnormalities on bottle cap usually indicate improper

capping. The problem may due to the present of ‘air space’ and not vacuum capped. The texture

of Sri kaya must be fine and not lumpy and color is natural color of Seri Kaya. The specifications

that must be complied are brix, preservative present, cadmium presence as chemical analysis,

total plate count, yeast and mold count and Salmonella and E.coli detection as microbiological

analysis.

4.5 Corrective action

23

There are some steps and procedures taken if any non-conformance occurred. If there is

any problem with the products, the batch is not released. The must be keep in view (K.I.V) for at

least 2 weeks. During that time duration, the product will be check regularly to ensure that the

standard is complies. Before releasing each batch, some samples will be taken for company’s

observation. This is necessary when any complaints about the product are received from either

the customers or the retailers. Traceability of product is a vital to assist in identify which batch of

product have a problem that mentioned or complaint by the customers and helpful for product

recall.

The corrective action required to prevent recurrence is evaluated, documented, and its

effective implementation is monitored. All rectification is subsequently re-inspected to ensure

complete customer satisfaction.

4.6 Quality control equipment

Production and measuring equipment held is maintained in good condition, and capable

of safe and effective operation within a specified tolerance of accuracy. Test and measuring

equipment is regularly inspected or calibrated to ensure that it is capable of accurate operation, by

comparison with external sources traceable back to National Standards.

Equipment that used in quality checking for all product are refractometer, brinometer, pH

meter, viscometer, consistometer, hydrometer and thermometer.

4.7 Raw materials

24

The raw materials received will be placed in the warehouse which the temperature and

moisture is controlled (suitable to control any possible spoilage). The raw material will be placed

accordingly and well-arranged. The raw materials like onion and garlic which are not suitable to

be placed in open area, they will be stored in cold room. All raw material received will be check

its quality by Quality Assurance Officer following the standard specification and all data must be

recorded in specific document. Raw materials and finished good must follow the ‘First in first

out’ system. Use the “first in, first out” rule meaning that foods should be used in the order they

are delivered for raw material or produced for finished goods.

4.8 Personnel hygiene

Personnel hygiene is very important. All workers who have direct contacts to the products

must wear mask, head cover and glove to minimize the contaminations. If hand glove is not

practical, they must wash hands regularly. However, there are still workers who not wearing

mask and head covers in the production and packaging areas. Strict implementation must be

applied to ensure the safety and hygiene of the products.

4.9 Packaging system

25

All products have primary and secondary packaging. For soy sauce, the primary

packaging are glass bottle, crown cap and cap seal. Same goes to tomato and chili sauce but have

an addition of plastic bottle (HDPE) for 2.3 kg packing. While Ser kaya use glass bottle, twist cap

and cap seal for primary packaging. The secondary packaging is same for all products. They are

corrugated cardboard and plastic shrink wrap.

The principle of plastic shrink wrap is when heat is applied to this material it shrinks

tightly over whatever it is covering. Heat can be applied with a hand held heat gun (electric or

gas) or the product and film can pass through a heat tunnel on a conveyor. A shrink film can be

made to shrink in one direction (unidirectional or mono-directional) or in both directions

(bidirectional).

Films are stretched when they are warm to orient the molecules from their initial random

pattern. Cooling the film sets the film's characteristics until it is reheated: this causes it to shrink

back toward its initial dimensions.

26

CHAPTER 5

LABORATORY ACTIVITIES

5.1 Microbiology lab

5.1.1 Introduction

During my practical period, I have spent most of my time in microbiology lab to learn

more on starter culture for koji been made and practice ‘hands-on’ to produce the starter culture

called inoculums. Other than that, the inoculation of Aspergillus oryzae in a Petri plate must be

conducted to produce the inoculums. The lab is equipped with the basic equipment like oven,

laminar-air flow, utensils for inoculation, petri plates and analytical balance.

5.1.2 Preparation of Microbial Culture Media

27

As Aspergillus oryzae is the starter culture use to make the koji, Potato Dextrose Agar

(PDA) is use to inoculate the strain in petri plates. PDA recommended for plate counts of yeasts

and moulds in the examination of foods and dairy products. It is also used for the stimulation of

sporulation (slide preparations), maintenance of stock cultures of certain dermatophytes and for

differentiation of atypical varieties of dermatophytes by pigment production. PDA is a fungal

media (common organisms that can be cultured on PDA are yeasts such as Candida albicans and

Saccharomyces cerevisiae and moulds such as Aspergillus niger) and does not contain agar. The

nutritionally rich base (potato broth) encourages a very rich fungal and mold growth. Dextrose is

the fermentable carbohydrate as carbon and energy source.

5.1.3 Inoculums Production

Spores of Aspergillus oryzae grown on PDA agar are introduced into sterilized koji

materials, which consist of coarse blended soy beans and been incubated for 5 days in trays. The

tray are covered with aluminum foil and few small hole have been made to provide aeration and

oxygen for fungal to grow. This can also called starter. The colour of high quality

starter/inoculums is yellowish green and the growth must be at least 80% throughout the tray.

5.2 Analysis Lab

28

Food analysis was run to ensure every product conformed Food Act 1983. Many type of

analysis must be conducted to assure the product quality. Some of the necessary analysis are salt

content, 3-MCPD test, Total Nitrogen Content, Benzoic Acid content for soy sauce, Total acidity

and benzoic acid content for chili and tomato sauce, and Preservative detection for Sri Kaya

product. But, there is only one analysis that have been conducted in this lab which is Total

Nitrogen Determination for soy sauce. Others analysis have been conducted by external lab.

Analysis lab is equipped with complete Total Nitrogen Analysis Unit and chemical solutions that

requires for the analysis.

5.2.1 Total Nitrogen determination

5.2.1.1 Introduction

The purpose of conducting the experiment is to determine the nitrogen content

(percentage of nitrogen) in the soy sauce. The amount of nitrogen must not less than 0.6 per cent

w/v of total nitrogen according to Food Regulation 1985.

A food is digested with a strong acid so that it releases nitrogen which can be determined

by a suitable titration technique. The amount of protein present is then calculated from the

nitrogen concentration of the food. The whole experiment of determination can be divided into

three phases that have to be performed in a day. The three phases are The Kjeldahl method can

conveniently be divided into three steps: digestion, neutralization and titration.

Along my industrial training in the company, I have performing the similar experiment

eight times, each time with slightly different procedures. From the three phases of the

29

experiment, I was mostly involving directly in all phases by starting with preparation of the

chemical reagents and samples to be used in the experiment. The summary of the whole

experiment is described in Figure below.

Figure 5.2.1.1: Main process of experiment

5.2.1.2 Principles of analysis

i) Digestion phase

The sample (bean water or soy sauce) to be analyzed is weighed into a digestion flask and then

digested by heating it in the presence of sulfuric acid (an oxidizing agent which digests the food),

anhydrous sodium sulfate (to speed up the reaction by raising the boiling point) and a catalyst

(selenium) to speed up the reaction. This phase conducted use Kjeldaltherm unit. Digestion

converts any nitrogen in the food (other than that which is in the form of nitrates or nitrites) into

ammonia, and other organic matter to C02 and H20. Ammonia gas is not liberated in an acid

solution because the ammonia is in the form of the ammonium ion (NH4+) which binds to the

sulfate ion (SO42-) and thus remains in solution:

N(food) (NH4)2SO4 (1)

ii) Neutralization phase

30

Preparation of samples and

reagent

Digestion process

Neutralization process

Titration process

After the digestion has been completed the digestion flask is connected to a receiving

flask by a tube. The solution in the digestion flask is then made alkaline by addition of sodium

hydroxide, which converts the ammonium sulfate into ammonia gas:

(NH4)2SO4 + 2 NaOH 2NH3 + 2H2O + Na2SO4 (2)

The ammonia gas that is formed is liberated from the solution and moves out of the

digestion flask and into the receiving flask - which contains an excess of boric acid. The low pH

of the solution in the receiving flask converts the ammonia gas into the ammonium ion, and

simultaneously converts the boric acid to the borate ion:

NH3 + H3BO3 (boric acid) NH4+ + H2BO3

- (borate ion) (3)

iii) Titration phase

The nitrogen content is then estimated by titration of the ammonium borate formed with

standard sulfuric acid, using a phenolphthalein as indicator to determine the end-point of the

reaction.

H2BO3- + H+ H3BO3 (4)

The concentration of hydrogen ions (in moles) required to reach the end-point is

equivalent to the concentration of nitrogen that was in the original food (Equation 3). The

following equation can be used to determine the nitrogen concentration of a sample that weighs m

grams using a xM HCl acid solution for the titration:

31

(5)

Where vs and vb are the titration volumes of the sample and blank, and 14g is the

molecular weight of nitrogen N. A blank sample is usually ran at the same time as the material

being analyzed to take into account any residual nitrogen which may be in the reagents used to

carry out the analysis. Once the nitrogen content has been determined it is converted to a protein

content using the appropriate conversion factor: %Protein = F %N.

5.2.1.3 Reagent preparation

For this experiment, I was assigned with tasks of preparing the reagent the day before the

analysis was carried out. The reagents that I need to prepare were Sulfuric acid concentrated

(H2SO4) 0.01N, Sodium hydroxide 40%, 20% and 10% and boric acid 2%. All these reagents

will be needed in the coming extraction process. Some of the reagents have to be prepared by

dissolving them in water while some other reagents have to be diluted in water. Since most of the

reagents are corrosive chemicals, therefore it must be handled in the fume hood and I was

required to wear a respirator (mask) and safety glove while performing the preparation, as well as

during conducting the digestion phase.

32

After all the reagents had been prepared, the experiment will be carried out on the

following day. I was involving directly in the whole phases of experiment and be monitored by

my supervisor.

5.2.1.4 Result and discussion

The samples used in this experiment can be sweet soy sauce and salty soy sauce. I will

show the result of four (4) experiments out of eight (8) that have been done in the Appendix. The

enclosed results are followed with the discussion and conclusion of each experiment.

33

CHAPTER 6

PROJECTS AND TASK DURING INTERNSHIP

6.1 HACCP documentation

6.1.1 Task description

The hazard analysis critical control point concept is a systematic approach to the

identification, assessment and control of hazards. It is very simple because it only identifies

potential food safety problems and determines where they could be controlled and prevented.

6.1.2 Methodology

I have been collecting the information of all possible hazards that may be present in

manufacturing soy sauce product by observing the working culture of the workers and how they

practice in limiting any possible hazard to the food products. I also used discussion method with

34

the other staffs to gather information. Finally, I gather information through the online journals

and books too. Since I was provided a computer with internet access therefore browsing the net

for information was indeed very easy.

6.1.3 Hazard Analysis

Hazard analysis has been conducted in a table form with specific information related. The

tables are enclosed in Appendix section of this report.

6.1.4 HACCP Plan Form

HACCP plan is a form where determine the Critical Control Point of the whole process. It

is including critical limits, corrective action and verification. These analyses has been

documented and attached to the Appendix.

6.1.5 Summary

From the HACCP Plan Summary, I have determined some Critical Control Points (CCP)

of soy sauce products in term of ingredients and processing steps. All Critical Control Points

must be control to ensure the hazard that may come across will be inhibited. There are two (2)

CCP that have been identified.

35

6.2 Waste water treatment plant analysis

Major aim of wastewater treatment is to remove as much of the suspended solids as

possible before the remaining water, called effluent, is discharged back to the environment.

6.2.1 Objective

The purpose of this observation is to find the best treatment medium to treat the waste

water in Zara Foodstuff Industries.

6.2.2 Methodology

The observation has been conducted for a months and the results are shown in the table

and graph below. The treatment of the waste water has been treated using two type of medium.

They are Active Orange, a brownish orange solution contain active microorganisms that will

digest the microorganism that give bad odour and acidic condition and Active Ball, a mud-like

composite that contain active microorganism that will play the same role like Active Orange.

The observation is based on the ratio of sample to treatment medium (sample: treatment

medium) as we do not know the exact amount of treatment medium to be used to treat the waste

water. Each treatment is represented by seven (7) samples and each sample represents each ratio.

The samples are labelled with A, B, C, D, E, F and G with different ratios. All ratios represented

with duplicate samples.

36

Label Ratio

(sample: treatment medium)

A 1 : 1

B 1 : 2

C 2 : 1

D 1 : ¾

E ¾: 1

F 1 : ¼

G ¼ : 1

Table 6.2.2: Samples ratio

The treatment using Active Orange was conducted with a total amount of waste water use

in each sample is 200ml. The amount of Active Orange is based on the ratio above. On the other

hand, usage direction of Active Ball has been stated on the packaging. The application of 1

Active Ball can be used to treat 1 m3 or 1000 litre waste water. For the observation, the sample

with a ratio 1: 1 is followed the application direction amount. The average weight of each Active

Ball is 190 grams and it can be used for 1000 litres waste water. The observation sample only

used 100 ml waste water. The treatment medium use is too little and the Active Ball must have to

be crashed into powder to be easily weighed.

6.2.3 Observation

After 3 weeks, the sample using Active Ball changes into dark colour (black) and odour-less and

this shows that the microorganism has been fully breakdown and digested while the samples

using Active Orange still have same colour like on Day 1 and have bad odour (stingy). The pH

change is obviously differs within a week where Active Ball treatment increase the acidity level

to a natural level.

37

6.2.4 Errors and problems

There are some errors occurred during the analysis. There is no control sample to compare

the result and the best control sample is distilled water. The other obvious error is the amount of

Active Ball may not be accurate as the amount use for each sample is too little that make it

difficult to measures accurately.

The most important thing is to first know the composition of waste water and examined

its BOD/COD level to determine the level of contamination. From the BOD level, we can find

the best treatment for the waste water. But in this analysis, there is no study run before conduct

the analysis.

38

Medium Sample Day 1 Day 7 Day 14 Day 21

1 2Averag

e1 2 Average 1 2 Average 1 2 Average

Active orange A 3.66 3.67 3.67 3.70 3.71 3.71 3.73 3.67 3.70 4.55 4.50 4.53

B 3.65 3.66 3.66 3.49 3.58 3.54 3.44 3.44 3.44 4.14 3.96 4.05

C 3.70 3.69 3.70 3.76 3.81 3.79 3.99 3.88 3.94 4.86 4.62 4.74

D 3.69 3.69 3.69 3.71 3.72 3.72 3.71 3.69 3.70 4.39 4.33 4.36

E 3.67 3.68 3.68 3.58 3.57 3.58 3.47 3.53 3.50 4.17 4.23 4.20

F 3.73 3.75 3.74 4.04 4.39 4.22 3.18 6.18 4.68 5.05 6.77 5.91

G 3.67 3.67 3.67 3.60 3.63 3.62 3.45 3.45 3.45 4.06 3.98 4.02

Active ball A 3.82 3.82 3.82 7.57 7.56 7.57 7.64 7.77 7.71 7.91 8.42 8.17

B 3.80 3.85 3.83 6.99 7.73 7.36 7.71 7.78 7.75 8.23 8.50 8.37

C 3.82 3.81 3.82 7.48 7.86 7.67 8.00 7.88 7.94 8.44 8.51 8.48

D 3.81 3.81 3.81 7.47 7.40 7.44 7.78 7.90 7.84 8.44 8.38 8.41

E 3.80 3.80 3.80 7.51 7.38 7.45 7.79 7.98 7.89 8.34 8.36 8.35

F 3.81 3.79 3.80 7.44 7.16 7.30 7.88 7.66 7.77 8.33 8.07 8.20

G 3.82 3.83 3.83 7.65 7.53 7.59 8.11 8.04 8.08 8.41 8.29 8.35

Table 2: Result on pH changes based on two type of treatment medium within 3 weeks

39

40

6.2.5 Conclusion

We can conclude that Active Ball is the best treatment medium to treat the waste water as it gives

higher rate of reaction with obvious changes after 1 week of treatment than treatment with Active

Orange. But further observation must be conducted to ensure the effectiveness of the treatment

medium application.

6.3 Findings on ‘white flakes’ issue

I have been given a task on finding the possible reason of the phenomenon of ‘white

flakes’ on the surface of soy sauce. The possible reason of this ‘white flakes’ to be appeared is

maybe caused by yeasts due to lack of brine percentage during fermentation. I have found some

facts that support the reason that I have stated above by reading of journals and books and also

have some ideas from my Dean. In traditional products, non-pasteurized products or products

with a low salt content, aspergilli, film and pellicle-forming yeasts may cause spoilage (Roling et.

al., 1994). In low-salt (<15%) sauces, some types of spoilage bacteria may also grow unless the

pH is low or preservatives (e.g. sodium benzoate) are present.

The principal contaminants of koji are coagulase-negative Staphylococcus spp. And B.

subtilis (Chiba, 1977). The contaminating Staphylococcus spp. grow symbiotically with koji

mold, and the combination becomes a problem when koji fermentation takes place at low

temperatures (at or below 25°C), whereas B. subtilis grows in competition with koji molds,

especially at higher temperatures. Wild salt-tolerant lactic acid bacteria may grow in soy sauce

and produce biogenic amines such as tyramine and histamine (Uchida, 1982; Stratton et.al.,

1991). Some wild salt-tolerant lactic acid bacteria may produce ornithine by decomposing

arginine in an abnormal fermentation, resulting in the accumulation of citruline as an

41

intermediate product. When such raw soy sauce is pasteurized, ethyl carbamate can be produced

by the reaction between citrullin and alcohol ( Matsudo et. al., 1993).

A salt-tolerant wild yeast Z. rouxii var. halomembranis can grow in moromi that has

progressed to the maturation process. This wild yeast is harmless to health, but has a high salt-

tolerance, and grows to form a membranous film on the surface of moromi or soy sauce resulting

in deterioration of the soy sauce aroma and flavour.

6.4 3-MCPD findings

3-MCPD (3-monochloropropane-1,2-diol) is the most common of the group of food

contaminants called chloropropanols. 3-MCPD can cause cancer in laboratory animals fed large

amounts over their lifetime. Although people usually consume chloropropanols only at low

levels, there is still concern that these chemicals may be a health risk. 3-MCPD has been detected

at low levels in many foods and food ingredients, such as breads, savory crackers, toasted

biscuits, cheeses, doughnuts, burgers, salami, malts, and modified starches. 3-MCPD is found at

higher levels in some soy sauces and the savory food ingredient, acid-hydrolyzed vegetable

protein (acid-HVP).

3-MCPD has probably been present in foods for a long time, but it was only recently that

scientists were able to detect it reliably. Its occurrence in hydrolyzed vegetable proteins is related

to the production process that uses acid hydrolysis. The source and formation of 3-MCPD in soy

sauces are still being studied. There are several hypotheses on the origin of the compound in soy

sauces, including the addition of acid-HVP as a savory ingredient or the use of acid hydrolysis in

the food’s manufacture. Not all soy sauces contain 3-MCPD. Only about 22 percent of soy sauces

42

tested were found to have detectable levels. The traditionally brewed soy sauces did not contain

the contaminant. The Joint FAO/WHO Expert Committee on Food Additives (JECFA) has

concluded that 3-MCPD is an undesirable contaminant in food and recommended that its

concentration in hydrolyzed proteins should be reduced to the lowest level technically feasible.

3-MCPD in soy sauce is produced as a contaminant by-product of a flavour enhancer

known as acid-hydrolysed vegetable protein. Flavour enhancers are commonly added to

commercially produced food products (for example frozen dinners, instant soups, snack foods)

and some soy sauces to make them taste more 'savoury'. 3-MCPD was originally detected in acid-

hydrolysed vegetable protein (HVP) and was subsequently found in HVP-containing soy sauces.

It is important to remember that not all soy sauces contain 3-MCPD. It is not present in

fermented soy sauces. Therefore, most of the mitigation measures employed by industry centre

around the careful control of the acid hydrolysis step during production of soy sauces.

6.5 Moromi mash waste – useful or useless?

Moromi mash waste is the residue after final extraction of moromi solution. It is a useful

byproduct containing nutritive ingredients of soybeans and wheat as well as functional

ingredients generated in the process of brewing. For example, it contains rich fat, highly

antioxidant fat-soluble Vitamin E, as well as Vitamin K1 which is indispensable for blood

coagulation and a lot of isoflavone that is antioxidant and acts like a female hormone. Through

the work of microbial enzymes, isoflavone is disconnected from malonic acid and sugar and

becomes aglycon.

43

Low quality waste of moromi mash is used to make into soy sauce oil for lamps through

elaborate processes, and used also as fertilizer. Other than that, the waste has long been used as a

safe feed for livestock in general. Analyses of the basic components, and the functional

components of lipophilic vitamins (E, K1) and isoflavones were made in November 2004 by

Kikkoman. Result shown in Appendixs.

44

CHAPTER 7

SUGGESTION AND RECOMMENDATION

Based on my 15 weeks experience, I’ve concluded that Quality Department of Zara

Foodstuff Industries are on the right track achieving their short and long term goals; provided that

they continues to cater client’s request on the timely manner, consistently improve workflow

efficiency by optimizing the usage of information and communication technology (ICT) and

available laboratory hardware, and strengthening knowledge and skills of its members through

professional consultation or training programme.

For laboratory facilities, there are still rooms for improvement especially in terms of the

quantity of basic equipments. For example, the loop for streaking strains is not in a good

condition. The most important things, the hygiene of workers must be enhanced and avoid any

possible cross contamination.

During this internship period, Quality department have gave me many valuables

knowledge, experience, and hence I would like to highly recommend any particular whom are

interested in gaining real-life working experience, knowledge which are in-accessible in

45

reference books and lecture, and last but not least to be skilful in lab work to pursue job in this

department.

46

CHAPTER 8

CONCLUSION

During 15 weeks of industrial training at Zara Foodstuff Industries, I have learned a lot of

things that prepared me with working experiences such as how microbiology laboratory operates,

how to do chemical analysis and how to test and check the products based on rules and regulation

in Food Act (1983) and Food Regulation (1985) and company’s specification. All analysis were

run to ensure locally-distributed or exported products are safe and in good condition.

I also learned how to work as independently and other practical and real-world situation

of which are not taught in the classroom. The objectives of industrial training are all achieved.

47

REFERENCES

1. Catharina Y.W. Ang, Catharina Yung-Kang Wang-Ang, KeShun Liu and Yao-Wen

Huang (1999). Asian foods: science & technology : Technomic Publishing Company Inc.

2. Stephen A. Osmani, Gustavo Henrique Goldma. (2008). The Aspergilli: genomics,

medical aspects, biotechnology, and research methods : CRC Press

3. KeShun Liu. (1997). Soybeans: Chemistry, Technology and Utilization : Aspen

Publishers

4. Yiu H. Hui (2006) Handbook of food science, technology, and engineering, Volume 1 :

CRC Press

5. T. Boekhout, Vincent Robert . (2003). Yeasts in food: beneficial and detrimental aspects :

Behr’s Verlag

6. Barbara M. Lund, A.C. (Tony) Baird-Parker, G.W. (Grahame Warwick) Gould,

GrahameW. Gould. (2000) .The Microbiological Safety and Quality of Food 

7. S. J. Forsythe, P. R. Hayes. (2000). Food Hygiene Microbiology and HACCP: Aspen

Publishers (Original work published 1998)

48

8. http://www.bellaonline.com/articles/art32465.asp

9. http://www3.interscience.wiley.com/journal/119439828/abstract

10. http://www.springerlink.com/content/t22g2u4805171034/

11. http://www.bd.com/ds/technicalCenter/inserts/Potato_Dextrose_Agar.pdf

49

50