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Industrial Production Industrial Production Soy SauceSoy Sauce
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Group Members: Alexander EryuzluYathu KaileswaranHossam RefaeiJi XuCong Ying
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
Why soy sauce?
Ride the Kikkoman Wave
Popularity in the US
Koikuchi Shoyu PFD
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Koji Fermentation
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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
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Aspergillus Sojae/Oryzae
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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
Purpose of Koji Fermination
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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
Koji Vats Perspective
Continuous Koji processing vats
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Temperature profile during incubation
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Brine solution
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20-24% NaCl
To kill off Apergillus Oryzae/Sojae fungi
and its spores
Adds a salty taste
Brine Fermentation
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Brine Fermentation
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5 months ~ 6 monthsTake 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 hydrolysis2. Culture of lactic acid bacteria and pH
reduction3. 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– Pediococcus bacteria
Growing in a 24% salt solution, T = 15 °CAnaerobic
– Initial pH value: 6.5 – 7.0
C6H12O6 CH3CHOHCOOH + C2H5OH + CO2 Glucose Lactic acid Ethanol
Carbon
dioxide
– Final pH value : ~ 5.0
Pediococcus
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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) Amino acid Alcohol + Water Maillard reaction: Amino acid + Glucose HEMF
S. rouxii
S. rouxii
Cost Estimation
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Floating head, shell and tube c/s
Cost Estimation: Heat Exchanger
Heat Exchanger Parameters
Surface Area (m2) 100
Material Carbon steel
Temp. (K) 353
Pressure (Mpa) 3.2
Woods’ Correlations (Ch. 5.5)
Inflation factor: 4.756
Cost Estimation: Heat Exchanger
FOB c/s 8,000Co 38,051.83Fbm 3.14Fp 1.3204Fm 1ƒ(piping) 0.46ψ 0.7Co(Fbm - 1) 81,430.91Co(FpFm - 1) 12,191.81
Co(FpFm - 1)(ƒ(piping))(ψ) 3,925.761Total Cost ($) 135,600.30Error (+/-) 40%
Operability
Fermentor
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Operability Window
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Process OperabilityFlexibility
Degrees of freedom: temperature and pressure
ReliabilityTemperature and pressure control for
production
EfficiencyProper management
DynamicsTemperature control (+/- 0.5 ºC)
Safety
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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!
A A
Dissolved Oxygen Level DO2
Air Flow
P
PH
T
Heating Stream
Air Flow
Closed Tank
A A
Inlet Air Flow
PA1
Outlet Air Flow
PA2
PY
PC
PAH
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
Dissolved Oxygen Level DO2
A A
TA1
Heating Stream
TA2
TY
TC
Temperature HAZOP SIS
• Fail Close Valve at Heating Stream Inlet Channel
• Extra Sensor to Measure Temperature of Fermentation Tank
TAH
A A
Dissolved Oxygen Level DO2
Air Flow
P
PH
T
Heating Stream
Air Flow
Alarm !!
Pressure Exceeds
Maximum Allowable
Level!
A A
Air Flow
P
PH
T
Heating Stream
Air Flow
Safety Relief Valve
AA
Dissolved Oxygen Level DO2
PHA
Heating Stream
Air Flow
Overall SIS Diagram
Inlet Air Flow
PA1
PA2
PY>
PC
PAH
TA1
TA2
TY>
TC
TAHSafety Relief Valve
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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Process Flow
Not enough salt in Brine solution
Fermentor Temperature too high
Koji Vat
Temperature too low
Incorrect temperatures
Heat ExchangerTemperature too low
Koji vat
Contaminated
Fermentor
pH level changes not accounted
Faulty sensorsIncorrect readings
Incorrect calibration
Control ErrorsContaminated fermentor
Contaminated Soy Sauce
Incorrect fungi concentration
Heating coil damaged
Aerator damaged
Soy bean cooking temperature too low
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Questions?