JOWA

TOYO
SOY SAUCE

TOYO
BRIEF HISTORY
• Appeared during Western Han Dynasty (206 BC – 220 AD)
• Originally used to stretch salt
• During Zhou Dynasty fermented fish with salt was used as a condiment in which soybeans
were included during the fermentation process
• At the time of Han Dynasty replaced with the recipe for soy paste and its by-product soy
sauce by using soybeans as the principal ingredient with fermented fish-based sauces
developing separately into fish sauce
• The 19th century Sinologist Samuel Wells Williams wrote that in China, the best soy sauce is
"made by boiling beans soft, adding an equal quantity of wheat or barley, and leaving the mass
to ferment; a portion of salt and three times as much water are afterwards put in, and the whole
compound left for two or three months when the liquid is pressed and strained“.
SOY SAUCE
SOY SAUCE

• A liquid condiment of Chinese Origin

• Made from a fermented paste of soybeans, roasted wheat, brine and Aspergillus
oryzae or Aspergillus sojae mold
INGREDIENTS IN MAKING SOY SAUCE
• Soybeans – unique characteristics of soy sauce originate primarily from the proteins contained
in soybeans
• Wheat – carbohydrates contained in wheat are the components that give soy sauce its fine
aroma; wheat also adds sweetness to the soy sauce
• Salt and Water – salt is dissolved in water, and this brine is used to control the propagation of
bacteria during the fermentation process and act as a preservative
•  Aspergillus, a type of fungus, to propagate koji mold. Koji mold is one of the most important
elements in making soy sauce, and plays an essential role in fermenting the ingredients. This
activity is the key to the taste of soy sauce.
ASPERGILLUS ORYZAE
ASPERGILLUS SOJAE
PRODUCTION
TRADITIONAL
SOY SAUCE
TA K E S M O N T H S T O M A K E
TRADITIONAL

• Made by mixing soybeans and wheat with mold cultures and other related microorganism and
yeast
• Koji – the resulting mixture (mold)
• The mixture was fermented naturally in large urns and under the sun, which was believed to
contribute extra flavors.
SOAKING AND COOKING

soybeans are soaked in water and boiled until cooked, wheat is roasted and crushed
KOJI CULTURING
An equal amount of boiled soybeans and roasted wheat are mixed to form a grain mixture. A
culture of Aspergillus spore is added to the grain mixture and mixed or the mixture is allowed to
gather spores from the environment itself.
The cultures include:
• Aspergillus: a genus of fungus that is used for fermenting various ingredients (the cultures are
called koji in Japanese). Three species are used for brewing soy sauce:
– A. oryzae: Strains with high proteolytic capacity are used for brewing soy sauce.
– A. sojae: This fungus also has a high proteolytic capacity.
– A. tamarii: This fungus is used for brewing tamari, a variety of soy sauce.
• Saccharomyces cerevisiae: the yeasts in the culture convert some of the sugars to ethanol which
can undergo secondary reactions to make other flavor compounds
• Other microbes contained in the culture:
– Bacillus spp. (genus): This organism is likely to grow soy sauce ingredients, and to generate odors
and ammonia.
– Lactobacillus species: This organism makes a lactic acid that increases the acidity in the feed.
BREWING

The cultured grain mixture is mixed into a specific amount of salt brine for wet fermentation or
with coarse salt for dry fermentation and left to brew. Over time, the Aspergillus mold on the
soy and wheat break down the grain proteins into free amino acid and protein fragments and
starches into simple sugars. This amino-glycosidic reaction gives soy sauce its dark brown color.
Lactic acid bacteria ferments the sugars into lactic acid and yeast makes ethanol, which through
aging and secondary fermentation makes numerous flavor compounds typical of soy sauce
PRESSING

The fully fermented grain slurry is placed into cloth-lined containers and pressed to separate the
solids from the liquid soy sauce. The isolated solids are used as fertilizer or fed to animals while
the liquid soy sauce is processed further.
PASTEURIZATION

The raw soy sauce is heated to eliminate any active yeasts and molds remaining in the soy sauce
and can be filtered to remove any fine particulates
STORAGE

The soy sauce can be aged or directly bottled and sold.

INDUSTRIAL
PRODUCTION
FERMENTATION
KOJI PRODUCTION

• Koji is a source of proteolytic enzymes for converting soy bean proteins into peptides and
amino acids, and amylase for hydrolyzing gelatinized starch into simple sugars
• The substances converted by the enzymes in Koji become the nutrients for yeasts and lactic
bacteria in the subsequent brine fermentation.
• Koji manufacturing process has been changed from a manual process to an automatic
equipment process
• This includes a continuous cooker for the soy beans, a continuous wheat roaster, mixer, cooler,
automatic inoculator, mechanical mixer, temperature controllers, conveyors, and mechanical
devices for turning the substrates during incubation.
• The automatic Koji-making system increases the protease activity of Koji and protects it from
infection by undesirable microorganisms.
• This new device reduces the labor cost by 85-90% compared with the conventional manual
method.
KOJI PRODUCTION PROCESS

• defatted soybean flakes or soy beans are soaked in water to increase the moisture content and
then cooked under pressure in a retort
• Formerly, the soaked soy beans containing 60% moisture were cooked with saturated steam at
0.8-1.0 kg cm -2 gauge pressure for 40-45 rain in a batch type pressure cooker.
• Currently, the soaked beans containing 30-45% moisture are cooked at 6-7 kg cm -2 gauge
pressure (about 170°C for 20-30 s in a continuous cooker which allows high pressure and
short time cooking
• The wheat contains 8% moisture and is heated in a continuous roaster with hot air at 150°C
for 30-45 s at atmospheric pressure.
• It is then cracked in a machine into 4 or 5 pieces per kernel accompanied by smaller particles
of wheat flour.
• In making regular soy sauce, defatted soy flakes are mixed with an equal amount of roasted
wheat and then inoculated with 0.1-0.2% of starter mold (Aspergillus oryzae or Aspergillus
sojae) in wooden trays, each loaded with a 3-5 cm thickness of the fermenting Koji.
• The ratio of wheat to cooked soybean may vary, depending on the type of soy sauce m be
prepared
• After incubation at 25°C for 72 h, the Koji becomes a greenish yellow mass as a result of mold
growth and sporulation
• It is necessary to stir the contents, to remove the metabolic heat formed, and to stir further to
control the temperature at 25-28°C
• The important factors are selection of the best strains of A. oryzae and A. sojae and controlling
the product temperature in that range during the Koji fermentation process.
• The inoculated mixture is put into large shallow perforated vats in closed chambers and forced
air is circulated through the mass.
• After 3 days, A. oryzae or A. sojae grows and the culture mixture becomes green-yellow in
color as a result of mold growth and sporulation.
BRINE FERMENTATION

• Brine utilizes the lactic bacterium, Pediococcus halophiIus and the yeasts Zygosaccharomyces
rouxii and Candida species both of which tolerate a salt concentration of 20 g per 100 ml
• effectively prevents growth of undesirable microorganisms
• It is important to control the microorganisms in the brine fermentation.
BRINE FERMENTATION PROCESS

• harvested Koji is mixed with 20% salt brine, and transferred by means of a spiral pump into
deep fermentation steel tanks coated with epoxy resins on the interior
• resultant mixture is called moromi mash
• The specially selected P. halophilus is cultured and added to the mash
• To control its growth rate it is necessary to keep the fermenting mixture at 15°C for the first
month, allowing the pH of the mash to decrease slowly from 6.5 to 5.0.
• cultures of Z rouxii and Candida species are then added as a starter
• temperature of the moromi is allowed to rise slowly to nearly 28°C until vigorous alcoholic
fermentation starts
• temperature in the tank can be controlled by coil type heat exchangers with mixing devices,
thermocouples, and control systems.
• After the alcohol fermentation is finished, the temperature is kept at 25°C
• Aeration stimulates microbial growth and mixes the contents
• During the fermentation period, proteolytic enzymes from Koji hydrolyze the proteins in soy
bean and wheat to form amino acids and low molecular weight peptides
• Starch is converted to simple sugars which are fermented primarily to lactic acid, ethanol and
carbon dioxide
• During the brine fermentation, the pH of the mixture drops from 6.5 to 5.0 in the first month at
15°C
• This is followed by fermentation at 28°C for four months
• Sometimes it is necessary to add more pure cultures of P. halophilus and Z. rouxii and Candida
species to the moromi mash during the fermentation
REFINING

• The final process in soy sauce fermentation is refining which includes pressing, filtration,
pasteurization and packaging.
REFINING PROCESS
• aged moromi is pressed in a vertical automatic press to separate the soy sauce from the
residue
• After pressing, the filtered raw soy sauce is pasteurized in a heat-exchanger at 70-80°C for a
few minutes to ensure clarity, to inactivate residual enzymes, and to inactivate any undesirable
microorganisms
• It may be necessary to clarify the soy sauce additionally by centrifugation or sedimentation
• The sauce is treated with caramel as a coloring agent, and then packaged either in clean glass
bottles, enameled gallon cans or in plastic containers
ACID-
HYDROLYSIS
PROCESS
• Instead of fermenting, many modern manufacturers artificially break down soy protein by a
chemical process known as hydrolysis because it is much faster (Hydrolysis takes few days)
• the acid-hydrolyzed soy sauce is less attractive in aroma and flavor because of lack of aromatic
substances such as esters, alcohols and carbonyl compounds which are derived from the
fermentation process
soybeans are boiled with food grade hydrochloric acid for 15-20 hours to remove the amino
acids.
• Defatted soya beans are boiled with food grade hydrochloric acid (acts as a catalyst for acid
hydrolysis) for 15-20 hours in a pressure cooker
• The amino acid liquid (hydrolysate) is neutralized with sodium hydroxide or sodium carbonate
under careful supervision so that excessive alkali does not come into contact with the neutralized
product
• The acid-hydrolyzed soy sauce is refined by sedimentation, treatment with active carbon,
filtration through a filter press to remove undesirable substances, and high vacuum to remove
undesirable volatile compounds
• Caramel color, corn syrup, and salt are added to this protein mixture to obtain the appropriate
color and flavor. The mixture is then refined and packaged.
QUALITY
• Sauces produced by the chemical method are harsher and do not have as desirable a taste
profile as those produced in the traditional brewed manner.
• The difference in taste occurs because the acid hydrolysis used in the non-brewed method tends
to be more complete than its fermentation counterpart
• . This means that almost all the proteins in the non-brewed soy sauce are converted into amino
acids, while in the brewed product more of the amino acids stay together as peptides, providing
a different flavor.
• The brewed product also has alcohols, esters, and other compounds which contribute a
different aroma and feel in the mouth.
• In addition to the brewed method and the non-brewed method, there is also a semi-brewed
method, in which hydrolyzed soy proteins are partially fermented with a wheat mixture. This
method is said to produce higher quality sauces than can be produced from straight hydrolysis
• In some countries, a combination of fermentation and acid-hydrolysis procedures are used for
making less expensive soy sauce.
• High quality soya sauce is made exclusively by the fermentation process.
GRADES OF SOY SAUCE

• In Japan, 'Special grade' soy sauce or 'Koikuchi' is made exclusively by the fermentation
process, and is marketed under the Japanese Agricultural Standard (JAS) for this grade.
• All-purpose seasoning characterized by a pleasant aroma, complex flavor, and a deep reddish
brown color
• comprises more than 56% of the annual soy sauce production in Japan
• 'Upper grade' or 'Usukuchi shoyu' which is characterized by a lighter reddish brown color and
milder aroma and flavor, and comprises about 24% of the total production.
• The product is used mainly for cooking when one wishes to preserve the original flavor and
color of the foodstuff itself
• 'Standard grade' or 'Tamari shoyu' which is characterized by a slightly higher amino acid
content, but lacks in aroma.
• The distinguishing feature of 'Standard grade' is that soy bean is the main raw material and
wheat is not used or is used only in small amounts.
• This grade comprises 8% of the total production. The remainder belongs to the 'Non-JAS'
grade.
FOUR DIFFERENT TYPES OF SOY
SAUCE
• Sweet, salty, light and brown are stored at 4°C until use
• sweet and salty soy sauce were obtained from Jalen Sdn.Bhd, Malaysia, PT.Heinz AB,
Indonesia and Syarikat Salmi Hj. Tamin Sdn Bhd, Malaysia
• light and dark soy sauce, both types were obtained from Nguan Chiang Food Industry Co., Ltd,
Thailand, Syarikat Salmi Hj. Tamin Sdn Bhd, Malaysia and Pinakamasarap Corperation,
Phillipines.
BYPRODUCT
• Fermentation process produces many “byproducts” that are actually useful flavor compounds
• various sugars are derived from the vegetable starches by action of the moromi enzymes which
help subdue the saltiness of the finished product
• alcohols are formed by yeast acting on sugars
• ethanol is the most common of these alcohols, and it imparts both flavor and odor
• Acids are generated from the alcohols and sugars, which round out the flavor and provide
tartness
• aromatic esters (chemicals that contribute flavor and aroma) are formed when ethanol
combines with organic acids
• Chemical hydrolyzation also leads to byproducts, but these are generally considered
undesirable
• byproducts are a result of secondary reactions that create objectionable flavoring components
such as furfural, dimethyl sulfide, hydrogen sulfide, levulinic acid, and formic acids
• Some of these chemicals contribute off odors and flavors to the finished product.*****