Do you want to know the soy sauce manufacturing process for commercial production? If yes, you are in the right place.
Soy sauce is one of the world’s oldest condiments and has been used in China for more than 2,500 years. Soya bean is a leguminous crop and is rich in proteins. Many value-added products are made from it like milk, paneer, cheese, and sauce. It is now one of the most profitable food processing businesses across the world at present.
Soya products are increasingly becoming popular especially amongst health-conscious people. Soy sauce is used as a taste enhancer as it has a typical bitter-sour and sweet taste as well as flavor.
The appealing and unique color, flavor, and fragrance of soy sauce are generated by the fusion of the soybeans, wheat, and salt that are the main raw materials.
The taste is mainly from soybean proteins, and the fragrance is mainly from wheat starch, created as the microorganisms work on each ingredient. The characteristic color comes from the combination of amino acids, obtained from proteins, and glucose, obtained from starch.
Here are the 7 steps for Commercial Soy Sauce Production
The manufacturing f soya sauce process is simple. De-fatted soya flour is processed by using the hydrolysis process. Flour and water along with other ingredients like salt, baking soda, vinegar, preservatives, etc. are mixed homogeneously to form a semi-liquid or paste-type mixture and it is passed through filter sieves to remove impurities. This mixture is then taken to SS neutralization tanks and kept for about 2 hours before packing.
Japan happens to be the biggest producer of soy sauce in the world. Below we will lid down the steps associated with the Japanese way of making soy sauce.
Lets us check the steps one by one:
1. Preparation process with Cooking Ingredients
The first step is to steam the Soybeans. On another vessel, the wheat is roasted and crushed. Then you need to mix the steamed soybeans and roasted wheat and create a malt mixture. Add salt and dissolve it in water.
Machinery Required to complete this part of the production process is a soybean cooking machine and wheat roasting machine.
2. Manufacture the Koji
The next step is to add Koji mold (Aspergillus oryzae or Aspergillus sojae) into the mixture already formed with soybeans and wheat. The mixture is then incubated for around three days to make koji.
The word “koji” in Japanese means the mixture of soybeans and wheat that is covered with koji mold. This is enzyme-riched and plays a critical role in the Moromi fermentation and maturation process.
For commercial production of Koji, you need a Koji making machine.
3. Develop Moromi
The third step in producing soy sauce is to form Moromi. The process is simple. One needs to add salt to the already formed mixture to create Moromi. The newly formed Moromi is then moved to fermentation tanks.
4. Fermentation and Maturation Process
The fourth step is ferment and mature the Moromi for a considerable period. It can be in the range of 6 months or more. The presence of yeast, Koji enzymes, yeast, and several other bacteria takes part in the maturation process and helps in creating wide varieties of flavors.
5. Filtration Process
After the process of fermentation and maturation is completed the filtration process starts. The Moromi is then encased part by part with cloths and kept in many layers. After this, the Moromi is filtered through the cloths by compressing slowly.
Finally, the raw soy sauce is produced from Moromi. In Japan, it is called Kiage.
6. Refining Process
The sixth stage is to sterilize the raw soy sauce and subsequently refined it. It is normally done by a heating mechanism. This part of the production process also acts as adding flavors, colors, and wide varieties of aromas. Now, you are ready for selling soy sauce commercially.
7. Packing Soy Sauce and Transportation to Buyers
This final stage involves bottling the soy sauce in bottles of different sizes as per requirements. A thorough quality inspection is a must in the final stage of the production process.
The market for soy-based products including soy sauce is in urban and semi-urban areas and while selecting the location of the plant, this aspect has to be kept in mind. Restaurants, clubs, caterers, star hotels are major consumers of soy sauce.