Industrial Production Soy Sauce

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Industrial Production Soy Sauce

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

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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
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Popularity in the US
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Koikuchi Shoyu PFD
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Koji Fermentation
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Koikuchi Koji Overview

• Cooked soybeans and roasted wheat at 50/50 conc.
  (40 moisture content)
• Inoculated with Aspergillus Sojae/Oryzae
• Incubation within the perforated vats
• Salt solution is added

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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

• Maximize enzyme production
• Prevent denaturation of the enzymes
• Avoid the presence of undesirable micro-organisms
• Minimize the utilisation of nutrients by the Koji
  molds

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Koji Vats Perspective
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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
• Protein and starch hydrolysis
• Culture of lactic acid bacteria and pH reduction
• 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 C
• Anaerobic
• Initial pH value 6.5 7.0
• C6H12O6 CH3CHOHCOOH C2H5OH
  CO2
• Glucose Lactic acid
  Ethanol Carbon
  
• 
  
  dioxide
• Final pH value 5.0

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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

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Cost Estimation
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Cost Estimation Heat Exchanger

• Floating head, shell and tube c/s

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Woods Correlations (Ch. 5.5)
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Cost Estimation Heat Exchanger

• Inflation factor 4.756

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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 ºC)

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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!

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Dissolved Oxygen Level DO2
A A
Air Flow
Air Flow
T
P
Closed Tank
PH
Heating Stream
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Dissolved Oxygen Level DO2
A A
Inlet Air Flow
Outlet 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

PAH
PA1
PY
PA2
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A A
TAH

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

TA1
TY
TA2
TC
Heating Stream
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Dissolved Oxygen Level DO2
Alarm !! Pressure Exceeds Maximum
Allowable Level!
A A
Air Flow
Air Flow
T
P
PH
Heating Stream
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Air Flow
A A
Air Flow
Safety Relief Valve
T
P
PH
Heating Stream
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Overall SIS Diagram
Dissolved Oxygen Level DO2
Inlet Air Flow
Air Flow
AA
gt
Safety Relief Valve
TA1
TY
TAH
PC
TA2
TC
PAH
gt
PA1
PY
PA2
Heating Stream
PHA
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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
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Workplace Containment

• Plant Environment Protection
• Safety Tank that covers the fermentation
  tank

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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

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Troubleshooting
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Temperature too low
Heat Exchanger
Soy bean cooking temperature too low
Koji Vat
Incorrect fungi concentration
Process Flow
Incorrect temperatures
Aerator damaged
Temperature too high
Fermentor
Heating coil damaged
Temperature too low
Not enough salt in Brine solution
Contaminated Soy Sauce
Koji vat
Contaminated
Fermentor
Contaminated fermentor
Control Errors
pH level changes not accounted
Faulty sensors
Incorrect readings
Incorrect calibration
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