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1. Take bean cake or tempeh and bran as raw material.
2. Making koji using purely cultured Aspergillus (Aspergillus oryzae or Aspergillus sojae).
3. The use of low-salt solid state fermentation improves soy sauce flavor and improves quality.
4. The addition of diluted syrup during the fermentation is beneficial to the action of microorganisms such as yeast, thereby improving the flavor of the sauce.
Production Method
1. Raw material processing
(1) Soybean cake smashing: Soybean cake smashing is a heavy process that creates conditions for water and steaming. It is generally believed that the finer the raw material is crushed, the larger the surface area is, the greater the contact surface of Aspergillus fumigatus is, the better the decomposition effect is in the fermentation process, and the utilization rate of raw materials can be improved; however, when the fineness is too small, it is easy to agglomerate when it is water-dried. Fermentation, leaching, and dripping oil are all unfavorable, but affect the normal use of raw materials. Therefore, the degree of fineness must be properly controlled, as long as most of them reach the size of rice.
(2) Run water: Run water is to make the raw material contains a certain amount of moisture, in order to facilitate the appropriate protein denaturation and full gelatinization of starch, and provide certain water for the growth and reproduction of Aspergillus oryzae. Commonly used raw material ratio is soybean cake 100: bran 50-70; the amount of added water is usually controlled between 45 and 50% according to the moisture content of the clinker (assay value) (high line in summer, low line in winter, spring and autumn control Midline). If cold-pressed bean cakes are used, they must be steamed first to coagulate the protein and prevent agglomeration, and then add water to the material. When water is used, the water and the material must be distributed evenly so that the moisture can penetrate into the interior of the material.
(3) Steam: The steam is a state in which the protein in the raw material is moderately denatured and the starch is gelatinized, and it is easy to act on the enzyme. In addition, it is also possible to kill the microorganism attached to the surface of the raw material by heating and cooking to facilitate the growth of Aspergillus oryzae. Steam cooking with rotary cooking pot, should first discharge the condensate in the intake pipe; raw cold pressed soybean cake by dry steaming, water, open the exhaust valve to exclude air, so as to avoid false pressure in the pot, affect the effect of steam. When the exhaust pipe starts to spray steam, close the exhaust valve. When the pressure rises to 0.3 kg/cm2, discharge the cold air again. The pressure gauge is lowered to zero, and then pressurize as required. Steam pressure is generally controlled at about 0.8 to 1.5 kg/cm2, and maintained for 15 to 30 minutes (or 1.8 kg/cm2, 5 to 10 minutes). During cooking, the steamer should keep turning. After the steaming is complete, immediately exhaust, step down to zero, and then close the exhaust valve, start the water pump with a hydraulic ejector for decompression cooling. The product temperature in the pan is quickly cooled to the required level (about 50°C), and the pan can be discharged.
(4) Treatment of other raw materials: When using wheat, corn, ground rice, or sorghum as raw materials for koji-making, generally it should be roasted and roasted first to gelatinize and partially saccharify the starch to kill microorganisms on the surface of the raw materials and increase color and aroma. The above raw materials can also be ground directly and then liquefied and saccharified for fermentation.
The processing method using the other seed cake as a raw material is substantially the same as that of the bean cake. Rice cakes can be crushed as a substitute for bran.
2. Making music. Most of the current domestic use of thick air ventilation system. There are many advantages in thick-layer ventilation and koji-making. For example, the quality of the finished koji is stable, and the koji-making equipment has a small area; the management is centralized and the operation is convenient; the labor intensity is reduced; the mechanization is facilitated, and the labor productivity is improved. The raw material is steamed out of the pot, and the small lumps are broken during the conveying process, and then the seed music is inserted. The koji can be mixed well with the appropriate amount of fresh bran (preferably firstly dried and heat-treated) before use. The amount of the koji is about 0.3% of the total weight of the raw material, and the inoculation temperature is about 40°C (up to 35°C in summer and 40 in winter). ~ 45 °C) as well, and pay attention to doing a good job of health.
After the inoculation of the inoculated material, it will be more than 20 to 30 cm thick, and the thickness is generally 20 to 30 cm. The stacked vegetables and pines will be leveled and the ventilation will be checked in time. The product temperature will be adjusted to 28 to 30°C, and the static culture will be for 6 hours (the interval is 1 to 2 hours ventilation 1～ 2 minutes, to spore germination), product temperature can be raised to about 37 °C, began ventilation and cooling. Afterwards, if necessary, intermittent or continuous ventilation, and the use of circulating ventilation or ventilation to control the product temperature, so that the product temperature is not higher than 35 °C. About 11 to 12 hours into the pool, the product temperature rises quickly. At this time, due to agglomeration of mycelium, the ventilation resistance increases, the temperature of the material layer appears lower and higher, and there is a trend of exceeding 35°C. The first turn. After another 4 to 5 hours, the second turn is performed according to the increase in product temperature and the shrinkage of the material. Since then continue to maintain the product temperature at about 35 °C, such as the material and shrinkage cracks, product temperature difference between the great difference, but also to take 1 or 2 times the shoveling measures (or to turn generation shovel). 18 hours after entering the pool, the material began to sporulate, still should maintain product temperature 32 ~ 35 °C, to the spores gradually appear bright yellow-green, you can play music. If the koji temperature is slightly lower, the koji making time can be extended to 35-40 hours, which is good for improving the quality of soy sauce.
In the process of making music, it is necessary to strengthen the management of temperature, humidity, and ventilation, constantly observe the tour, and regularly check the product temperature, room temperature, humidity, and ventilation.
The komatsu operation is summed up in four points: "One Cook, Two Big, Three Low, Four Even".
A cooked: the raw material is required to be well cooked, and the raw material protein digestibility is between 80-90%;
The second largest: strong winds, large waters. The water content of the clinker in the clinker is required to be 45 to 50% (determined according to the season); the thickness of the tune layer is generally not more than 30 centimeters, and the ventilation volume per cubic meter of mixture is 70 to 803 cents per minute;
Three low: The temperature of the loading pool is low, the temperature of the manufactured food is low, and the inlet air temperature is low. The temperature of the loading pool is maintained at 28-30°C; the temperature of the manufactured food is controlled between 30-35°C; the inlet air temperature is generally 30°C. Four evenly: the raw materials are mixed and moistened evenly, the inoculation is even, the loading pool is loose and uniform, and the material layer is even and thick.
3. Fermentation. The main operations of solid low salt fermentation are as follows:
(1) Preparation of salt water: According to experience, about 1.5 kg of salt dissolved in 100 kg of water can be formulated as 1 B salt water. After the salt is dissolved in water, the concentration of salt water is measured by Baume's hydrometer.
(2) Preparation: Prepare 11 to 12 B of prepared salt water (according to actual needs to determine, generally a long fermentation period, a higher concentration of salt water), heated to 50 ~ 55 °C, and then mix thoroughly into the pool into the song and salt water. When mixing salt water, it is necessary to pay attention to the amount of water at any time. Usually, when the material is poured into the first 15 to 20 cm thick layer of pot, the amount of salt water should be controlled to be slightly less, and then gradually increase the amount of water until the remaining part of the salt water can be mixed. It is appropriate. Finally, the salt water was evenly poured on the surface of the lotus root until the salt water was completely absorbed into the material, and then the salt was sealed on the lotus root. The salt layer is about 3 to 5 cm thick and is covered on the surface of the pool.
The amount of brine mixed into the koji is required to be 65 to 100% of the total weight of the raw materials. Into the pool should be mixed with salt water in a timely manner to prevent the long heap caused by "burning music." Before the mixing of salt water, test the moisture of the koji, and then add the salt water to ensure that the moisture content of the soya sauce is stable. After entering the pool, the temperature of the soy sauce product is required to be 42-50° C. After about 8 days of fermentation, the sauce is basically mature. In order to increase the flavor, the fermentation period is usually extended to 12-15 days. If the fermentation temperature is controlled stepwise, the initial period is 40-48°C, the middle period is 44-46°C, and the later period is 36-40°C. Subsection control is conducive to the improvement of finished product flavor, but the finished product is light in color. During the fermentation, special personnel are responsible for management, and the temperature is checked on time. If abnormal phenomena are found, it is necessary to take necessary measures to promptly correct it.
The operation of solid-state low-salt fermentation should pay special attention to the concentration of brine and the temperature of the brine used to control the production of thorium. The amount of brine required for the production of thorium should be low, and the fermentation temperature should be properly controlled.
4. Leaching. Leaching refers to the solubilization of soluble substances by soaking and filtering after ripening. Leaching includes soaking and filtering.
(1) Soaking: According to the requirements for producing various grades of soy sauce, after the soy sauce is mature, it can be firstly added into the second soaking oil (preheating to 70-80°C). When adding the second benzine, the surface should be covered with a layer of bamboo mats. , as a "buffer." The amount of secondary oil should usually be increased by 25-30% according to the planned production. After adding the second oil, the container is still tightly closed to prevent heat dissipation. After 2 hours, the sauce floats up (if the block is floating or there is a sticky block at the bottom, both are poor fermentation, affecting the oil). Soaking time generally requires about 20 hours, product temperature above 60 °C. Prolonging the soaking time and increasing the soaking temperature are beneficial for improving the yield and deepening the color of the finished product. If the leaching is carried out, the sauce must be kept loose. If necessary, some grains can be added and mixed to facilitate leaching.
(2) Filtration: In large production, depending on the specific conditions of the equipment capacity, two types of intermittent filtration and continuous filtration may be adopted. After soaking in soy sauce, the raw oil can be released from the false bottom of the container. Add salt, wait for the head oil to finish (note that the noodles do not expose the liquid surface), close the valve; then add preheat to 80 ~ 85 °C Sanlin oil, soak for 8 to 10 hours, filter out the second shower oil (preparation for the next dipping use); then add hot water (can also use tap water), soak for about 2 hours, filter out the three shower oil reserve. In short, the head of the oil is the product, the second coating of oil spilling out of the head, the third coating of oil to the second shower oil, and finally set out with the water of the three shower oil, this method of cyclic set of shower, known as the intermittent filter method. However, in some factories, due to insufficient equipment, there is also a continuous filtration method, that is, when the head of oil will be filtered, the surface has not exposed the liquid surface, the timely addition of hot three oil; soaked for 1 hour, release the second shower oil; In the same way, filter out Sanshang oil. In this way, it takes only about 8 hours from Sanitary Oil to Samson Oil. Drain the slag immediately after filtration and clean the false bottom and container. If Sanlin oil is not used in time, salt must be added immediately to prevent corruption.
In the filtration process, factors such as stickiness of the mash, thick material layer, too much salt in the buckling solution, too low immersion temperature, and high quality of soaking oil will directly affect the speed of oil leaching and the rate of production, and must be taken seriously.
5. Preparation and processing
(1) Heating: Heating raw soy sauce can achieve the purpose of sterilization, blending flavor, increasing color, and removing suspended solids to further improve the quality of the finished product. The heating temperature is generally controlled above 80°C (higher soy sauce can be slightly lower, and lower soy sauce can be slightly higher). Heating methods are customary with direct fire heating, double boiler or serpentine heating, and heat exchanger heating. During the heating process, the raw soy sauce must be kept fluid so as not to burn. After each heating, clean the heating equipment.
(2) Preparation: In order to strictly implement the relevant provisions of the product quality standards, for each batch of brewed soy sauce produced must also be properly formulated. Preparation is a meticulous task. To do this well, not only should a strict technical management system be in place, but also a detailed record of the quantity, quality, and storage conditions of production. After the preparation, it must adhere to the re-inspection in order to leave the factory.
(3) Mildew: In order to prevent mildew in soy sauce, a certain amount of preservative may be added to the finished product. With the consent of the health authorities, the commonly used soy sauce preservatives are benzoic acid, sodium benzoate and other varieties, especially sodium benzoate. Others, such as sodium sorbate, have not been widely adopted for a variety of reasons.
(4) Clarification and packaging: After the raw soy sauce is heated, the condensate is produced so that the soy sauce becomes turbid. It must be allowed to stand in the container for more than 3 days (more than one grade of high-quality soy sauce should extend the settling time) before it can make the condensate together with other Impurities gradually accumulate at the bottom of the vessel to achieve clarity and transparency. If raw sauce is not cooked properly and is not completely decomposed, not only the amount of produced soy sauce increases but also it is not easy to settle. The sauce can be collected again with a cloth bag to collect soy sauce.
Soy sauce packaging sub-washing, loading, stamping, labeling, inspection, packing and other processes, and finally as a product.
Production features