JPS605265B2 - Soy sauce brewing method - Google Patents

Description

[Detailed Description of the Invention] This invention uses a sealed large-capacity tank to produce natural brewing of excellent quality in an extremely short period of time without loss of aroma components or deterioration of moromiho crab. This invention relates to a method for producing soy sauce in large quantities.

Naturally brewed soy sauce is produced by putting koji in a preparation device containing an appropriate amount of salt water and fermenting it. Since it contains components containing fats and the like and has a twilling action, it is difficult for the koji to absorb water, and a thick layer of koji floats on top of the salt water.

It is possible to make good contact between the koji and the salt water, but if a mechanical device is used to make good contact with the salt water, the number of times of punching and the strength of the moromi will become excessive, and the moromi will become viscous. . Therefore, it takes a very long time for koji to absorb water.
Conventional natural sake brewing methods required a very long production period of about one year. Shortening manufacturing time has been a major challenge in the industry. Moreover, since the moromi cannot be properly preserved, if a large-capacity tank is used, carbon dioxide remains in the middle to the bottom of the tank without being discharged outside the system, resulting in oxygen deficiency, which causes the moromi to rot. A phenomenon occurs. Therefore, with the current technology, it is impossible to brew high-quality Takaho crab soy sauce in large quantities using a large capacity tank of 200 to 3002'. Furthermore, because the conventional soy sauce brewing system uses a large amount of compressed air and is an open type, the oxidation of the moromi is intense, a large amount of oxidizing enzymes are generated, and alcohol, sugar, aroma components, etc. are volatilized. The disadvantages of the components being dispersed out of the system, resulting in quality deterioration and a decrease in yield, were unavoidable. The present invention has been made in order to finally solve these drawbacks, that is, a major problem that must be solved in the field of soy sauce brewing industry, and is truly an epoch-making invention. In other words, the purpose of this invention is to smoothly ferment the moromi, remove carbon dioxide gas, and use a closed system to prevent oxidation, prevent the dispersion of aromatic components and other useful components, and prevent the invasion of various bacteria. The purpose is to eliminate the deterioration of moromiho crab and to produce high-quality soy sauce in a short period of time and in large quantities. In order to achieve this objective, we conducted horizontal construction of the brewing tank, examined its form, chemically examined how to accelerate fermentation, physically examined, and
This invention was completed by considering all aspects of the fermentation system as a whole, and conducting further research.This invention incorporates many new and useful systems that have never been used before. Moreover, it is characterized by organically combining these systems.

In other words, the present invention has the following features: 1) Soy sauce moromi is placed in a closed large-capacity tank, and gas containing the necessary minimum amount of oxygen is aerated into the tank to promote circulation and fermentation of the soy sauce moromi. A soy sauce brewing method, and (2) charging soy sauce moromi into a brewing tank, adding an enzyme or an enzyme-containing substance thereto, and on the other hand, aerating a gas containing a minimum required amount of oxygen and overflowing as necessary, On the other hand, this fermentation system is degassed to reduce the pressure or vacuum at the top of the tank, remove carbon dioxide gas, promote the circulation and fermentation of soy sauce moromi, and remove volatile components such as alcohol, sugar, and aroma components. , without discharging it out of the system, it is reused together with the aeration body as an aeration body for soy sauce moromi, or it is collected and re-added to soy sauce moromi, and further fermentation is continued. This is a soy sauce brewing method.

As mentioned above, mixing koji and salt water well is a very delicate process, which is impossible with conventional methods.

However, in this invention, we devised the shape of the brewing tank, introduced new inventions to its internal structure, and at the same time adopted unique methods such as venting the overflowing gas to adjust the system pressure. After much research, they adopted a new biochemical method to reduce moromi viscosity and improve quality. Among these, the characteristic process of the present invention is the process of flooding the moromi with aeration gas. By adopting this humidification process, the fermentation of the moromi is greatly promoted, and the moromi at the bottom of the tank is This makes it easier for the moromi to move, improving the supply of oxygen, and at the same time, removing carbon dioxide gas smoothly and preventing the moromi from spoiling.

The moromi at the bottom of the tank not only has viscosity, but also because it is pressurized by the weight of the moromi coming from the top of the tank. Normally, the moromi temperature is relatively higher than room temperature, and the temperature of the aerated gas is lower than the moromi temperature). It wasn't enough. However, by ventilating the heated gas, the above-mentioned drawbacks were completely eliminated, and the circulation of moromi, especially the circulation of moromi in the lower part of the tank, became smooth. As a result, not only the soy sauce brewing period was further shortened, but the quality of the finished soy sauce did not deteriorate, and furthermore, it became possible to use a larger capacity brewing tank than when using cold gas. , something that was unimaginable in the soy sauce brewing industry has become possible. In carrying out the present invention, it is convenient to use the following apparatus.

The shape of the brewing tank is a cylinder with a bottom, and a hollow circulation inner cylinder is installed inside the tank, and a heating part is provided on the inner wall of the moromi circulation inner cylinder. When moromi is placed in such a tank, the moromi near the heating section of the circulation inner cylinder is flooded, its specific gravity becomes lighter, and it slowly rises along the inner wall of the inner cylinder. Also, this moromi contains carbon dioxide gas, which rises along the inner wall of the inner cylinder and reaches the top surface, where the liquid pressure is removed and the carbon dioxide gas in the moromi becomes bubbles in the tank. It will be dissipated into the upper space. Moromi, which has released carbon dioxide gas, increases in specific gravity and becomes heavier, and circulates downward, lowering the carbon dioxide pressure.
Fermentation is promoted accordingly, and as a result, the overall soy sauce brewing period can be shortened. In addition, the moromi that rises to the top due to the action of the circulation inner cylinder is cooled by the latent heat of vaporization as the tank is maintained at a reduced pressure to vacuum, and has the property of descending along the tank wall. This further facilitates the circulation of moromi due to the above-mentioned release of carbon dioxide gas. Therefore, it is preferable to create an appropriate temperature gradient between the inner wall of the tank and the circulation inner cylinder. Normally, the outer wall of the tank is surrounded by a jacket, and the tank is cooled by an appropriate means such as passing a cooling medium through it, and the heating section of the circulation inner cylinder is equipped with an electric heater or a spiral pipe through which the heating medium passes. If necessary, the outer wall of the inner cylinder may be cooled. The temperature gradient is suitably about 1 to 8°C, but preferably 2 to 4°C. In this moromi circulation system that utilizes the difference in the moromi specific gravity due to temperature gradients and carbon dioxide gas dissipation, it takes time for the koji to absorb water, especially at the beginning of the moromi preparation, so in this system, the moromi circulation and curdling are slow. It's not done enough.

Therefore, it is necessary to adopt physical methods, equipment improvements, and chemical methods to further facilitate the circulation and loss of moromi. First, as an improvement to the L device, a furnace plate for solid-liquid separation is installed at the bottom of the tank, the moromi liquid is taken out from the bottom, and the moromi liquid is ejected into the tank using a pump and a spout pipe.

Gas is vented from the bottom of the tank to further facilitate the circulation of the moromi and to ensure that it flows through the tank.

In this case, if the temperature of the gas to be vented is kept at room temperature (that is, lower than the moromi temperature in the tank), this will not only prevent the fermentation of the moromi portion that comes into contact with these gases, but also increase the viscosity of the moromi. As a result of extensive research, we have discovered that aerating excess gas can produce a much better effect than using cold gas. This is the method of the present invention because it has been realized. The present invention particularly focuses on this step,
That is, it is particularly distinctive in that it employs a step of venting the overflowing gas, and this step is an essential component. The temperature of the aerator depends on the composition of the moromi used, the fermentation temperature,
It varies depending on the capacity of the tank, but about 20
~55o0. In normal cases, about 25 to 3
Although a temperature of 5o0 is preferred, particularly good results are obtained in a temperature range of 28 to 32C. The location and number of ventilation points for this heated gas may be determined as appropriate and necessary, but it is preferable to provide one to several ventilators at the lower part of the inner cylinder (or outer cylinder) for moromi circulation. When the overflowing gas is vented in this way, useful dissipative components such as soy sauce aroma, alcohol, and sugar, and carbon dioxide gas are discharged together with the vent. Regarding carbon dioxide gas, it is convenient to remove it from the moromi as quickly as possible in order to shorten the soy sauce brewing period and improve the quality of the soy sauce, so it is removed outside the system. Other useful luminescent components are not removed from the system, but are recycled or collected and added to the moromi again. Therefore, in this invention, all systems must be closed, which is completely different from conventional open systems. As the aeration medium, oxygen, which tends to be insufficient in moromi, may be used, or air, which is an oxygen-containing gas, may be used.
It is sufficient to aerate for 3 to 5 minutes several times a day. However, if too much oxygen exists, the moromi will be oxidized and the quality of the soy sauce will deteriorate, so it is more convenient to use a gas containing the minimum amount of oxygen necessary for fermentation of the moromi. As this gas, any gas can be used as long as it does not act on the moromi raw material, such as nitrogen, carbon dioxide, helium, neon, argon, krypton, and xenon, but nitrogen is particularly useful. is convenient. The gas containing the minimum required amount of oxygen (an equivalent amount of air may be used) should be sterilized and the temperature adjusted, and the aeration rate of this gas mixture can be adjusted as appropriate depending on the moromi raw materials, fermentation temperature, etc. Although it can be changed, it is usually about 700 to 1500 som/hour per 1000 som tank.
A gas containing the minimum required amount of oxygen, and one suitable example of a gas that is enriched with this gas is one that burns air to remove the unnecessary amount of oxygen and then cools it to an appropriate temperature. I can list some things that I did. The recovery of useful dissipated components in closed tanks is carried out using the following system.

A ventilator discharge pipe is provided above the closed large-capacity tank, and the ventilator discharge pipe is connected to the ventilator introduction pipe via a circulation pump, and the ventilator inlet pipe is connected to the closed large-capacity tank as it is. (preferably the inner cylinder part for circulation), and provide a waste gas discharge port and a fresh mixed gas inlet in the ventilator discharge pipe or ventilator inlet pipe, or provide a collection tank. A system may also be used. This latter system has a collection tank attached to the closed large capacity tank that allows internal soy sauce moromi to circulate, and there is no ventilation between the bottom of the tank and the upper part of the closed large capacity tank. A body discharge pipe is provided, and an aeration body introduction pipe is provided between the upper part of the collection tank and the bottom of the closed large-capacity tank (the inner cylinder part for circulation is preferable), and the aeration body introduction pipe is provided with an aeration body introduction pipe. It is equipped with a circulation pump, a waste gas exhaust port, and a fresh gas inlet.
By using such a closed system and fermenting the moromi with an overflow of inert gas, the fermentation and circulation of the moromi occurs smoothly, unnecessary carbon dioxide gas is removed, and oxygen is supplied in the required amount. By introducing this method, fermentation of moromi will proceed smoothly, and as a result, the soy sauce brewing period will be shortened. In addition, the amount of oxygen used is the minimum required, the light components can be dissipated to the outside world, and compared to conventional open systems, there is no loss of aroma components, sugar, alcohol, etc. Since there is little decrease in yield and the moromi is not excessively oxidized, the quality of the soy sauce product is improved. One of the most important problems in the fermentation industry is the problem of contamination by bacteria. This problem is always present in open systems, but with such a closed system and heated inert gas, you only need to be careful about contamination when introducing the vent. , it can be said that the contamin problem has been almost completely solved. One of the features of the present invention is the introduction of a physical system that degass the fermentation system to create a vacuum or vacuum above the closed large capacity tank, and The company adopted a method of ventilating heated gas.

By reducing the pressure in the fermentation system, carbon dioxide, which is a fermentation inhibiting substance for moromi, is removed from the system, and at the same time, carbon dioxide generated from inside to the bottom of the moromi tank is quickly discharged to the outside of moromi. As a result, Moromi, which is already difficult to use due to its high viscosity, becomes easily consumed because the movement of circulating gas becomes smooth due to the movement of carbon dioxide gas. The moromi at the bottom of the large-capacity tank is under enormous pressure due to the moromi's own weight, so the carbon dioxide generated during fermentation cannot radiate out from the moromi, and generally the moromi at the bottom is transferred to the moromi at the top of the tank. In comparison, there were drawbacks such as delayed fermentation and spoilage, but by deaerating the upper part of the tank and utilizing the pressure difference between the inside and outside of the moromi, as in the present invention, these drawbacks can be solved and the production period can be shortened. Benefits such as shortening or improved quality will be obtained. What is also noteworthy is that in combination with this carbon dioxide emission mechanism, the overflowing gas blown into the moromi column from the bottom of the tank also increases its mobility, allowing the moromi to be rapidly circulated and discarded. It is. Moromi, which exists especially at the bottom of a large-capacity tank, is extremely difficult to mix and destroy, so it takes a very long time to control the temperature and transfer heat, and it also causes undesirable problems such as spoilage and quality deterioration of moromi. This phenomenon was likely to occur. These drawbacks were solved to some extent by ventilating a large amount of cold, high-pressure air into the tank, but the oxidation caused by the large amount of air, the scattering of volatile active ingredients such as alcohol, and the rapid cooling of moromi due to the latent heat of vaporization. There were many shortcomings such as. However, by aerating and sealing the overflowing gas according to the present invention, these drawbacks were solved at once, and it was possible to produce soy sauce without spoilage or quality deterioration in a shorter period of time. . Further, if necessary, even better results can be obtained by freely controlling the degree of fermentation, the timing of soy sauce brewing, and the temperature of the gas in each step. Generally, aeration of the overflowing mixed gas is carried out almost continuously for 2 to 3 months immediately after preparation, and after entering the latter stage of ripening, the mixture is aged with occasional aeration or without aeration. The soy sauce brewing process will be completed in 3 to 5 months.

Degassing is the process of reducing the pressure or creating a vacuum in the system, and any device capable of such operations can be used, but it is advantageous to use a vacuum pump or the like. The degree of pressure reduction varies depending on the type, amount, and carbon dioxide content of the moromi, and can be varied widely within the range of 75 m Hg to vacuum, but excessive reduction in pressure for a long time may have an adverse effect on the moromi due to the reduced pressure. This should be avoided as it will cause harm to you. Although the vacuum pump may be attached to any part of the closed system, it is usually preferable to attach it to an appropriate part of the pipe connecting the upper and lower parts of the tank. However, when deaeration is performed using a vacuum pump, in addition to carbon dioxide gas, which is a fermentation inhibitor, useful volatile components such as soy sauce aroma components and alcohol are also degassed, so a separation device is used to separate carbon dioxide gas and useful volatile components. need to be separated. A further feature of this invention is that it employs a biochemical system.

Moromi generally has a very high viscosity, and this phenomenon hinders the circulation of moromi, but when enzymes were used to break down moromi, the circulation of moromi was improved. , condensation was carried out smoothly, and at the same time the quality of the product improved, and no other copyright use was allowed.
As the enzyme to be added, since the components of moromi are mainly starch, protein, and fat, an enzyme that decomposes these is used. In other words, as the starch degrading enzyme, Q-amylase,
8-amylase, glucoamylase, phosphorylase,
Proteolytic enzymes include protease, phycin, bromelain, papain, trypsin, chymotrypsin, polypeptidase, etc., and lipolytic enzymes include lipase and the like. In addition to pure enzyme products, substances containing them, such as malt or malt extracts or cultures of these enzyme-producing microorganisms, can also be used. The amount of enzyme used varies depending on the type of moromi raw material, composition, pH, temperature, etc., but is 0.01 to 20%.
It can be changed as appropriate within the range. The enzyme may be added from the start of fermentation or during fermentation, and may be added in the required amount all at once, or may be added in portions. In addition to the above-mentioned advantages, the advantage of using enzymes is that by changing the type and amount of enzymes used, you can change the fermentation rate and add subtle tastes and aromas to the soy sauce product. It is possible.
The closed moromi tank 1 of Example 2002' is used.

This tank is surrounded by a snake pipe or jacket and is 2y0
Let it cool down to a certain degree. This tank 1 has a lid 1
1 and an inner cylinder 2 for circulation of moromi are provided. The inner wall of the inner cylinder 2 is flooded to about 2800 ml with a flexible pipe 2a or an electric heater, etc.
Its outer wall is slightly cooled like the outer wall of tank 1.
A temperature regulating medium for heating or cooling may be circulated inside the corrugated pipes la, 2a by circulation pumps lb, 2b and heat exchangers lc, 2c, respectively. In this moromi tank 1, put 12 tons of koji, 147 tons of 22% salt solution, and 250 k9 of malt.

The pressure pump 19 is operated, and the nitrogen gas from the valve 10 is heated to 28° C. by the temperature controller 10' at a ratio of 250° C., and the pressure tank 15, the pipe 17,
Vent from the bottom of the tank through 18. After 5 to 1 step after the start of ventilation, the heated air tank is filled with air, and a part of it goes out to the discharge pipe 7 and is slowly circulated. This cycle is performed several times a day for approximately 3-5 minutes. When the oxygen concentration of this circulating gas becomes about 3 to 5% or less, the air intake port 20,
Air is taken in via the sterilization device 21 and the valve 22
The soy sauce fermenting bacteria are supplied in small amounts at a time, and the temperature is controlled by 10' so as not to reduce the activity of the soy sauce fermenting bacteria. In this case, if air is combusted and the resulting gas is used, it is not necessary to employ a separate supply system for nitrogen and air, and only the temperature control device 10' is sufficient. At the same time, run the vacuum pump 9 twice a day.
Operated three times at a gauge pressure of 50 Hg.

Then, in addition to the movement of carbon dioxide gas by the vent, due to the pressure difference between the inside and outside of the moromi due to the reduced pressure, the carbon dioxide gas that is present and moving in the tank to the bottom is also forcibly moved and discharged. Useful gaseous components are sucked into the vacuum pump together with carbon dioxide gas, so this is led to the circulating liquid reservoir 3, and the moromi (solid and liquid is separated by the screen IJ 3) is introduced from the bottom of the tank. ) and dissolve it in moromi,
By the action of the circulation pump 31, this mixed liquid is injected from the liquid injection port 32 disposed inside the annular part of the tank and guided to the gas-liquid separation tower 33, where excess carbon dioxide is discharged to the outside and the moromi is liquid. The tip of the injection pipe 34 is the tank 1
The moromi liquid on the tank wall is sprayed downward from the liquid injection nozzle 35 onto the liquid surface of the moromi liquid, which is particularly close to the wall of the tank. to help circulate the moromi throughout the tank.
Here, the useful volatile components are completely dissolved in the moromi in the tank 1, and the moromi becomes rich in useful volatile components.
In addition, if the spouting pipe 34 above the moromi liquid level is not limited to one pipe, but is provided around the same as a textbook, it is possible to spray the moromi on the floating koji and make it settle at once, and at the same time, the moromi is cooled at the bottom. can be dispersed to ensure smooth circulation of moromi. Ejection pipe 32 provided in the inner weaving part for circulation
The number may also be increased as necessary. Further, moromi is decomposed by the action of amylase, protease, and other enzymes contained in malt, and its viscosity decreases, making it easier to mix with gas.

Since the effective number component lost from the moromi tank along with the mixed gas is returned to the moromi tank, there is almost no loss of the rope component.

Moreover, since the amount of oxygen is the minimum amount required for fermentation, oxidation of the moromi ingredients is suppressed to the utmost. If this intermittent circulation aeration is carried out for about a month, the early and middle stages of fermentation will be completed, so after that, aeration will be carried out for a long period of time and the latter stage of maturing fermentation will be carried out for about a month and a half. Finish fermentation. When the moromi after fermentation is roasted, a soy sauce with rich sugar and alcohol content, light color, and aroma is obtained, resulting in a soy sauce of excellent quality that cannot be found in soy sauce produced by conventional methods. , obtained in an extremely short period of time.

As detailed above, the design of the inner cylinder for moromi circulation, the sealing of the entire system, the adoption of reduced pressure treatment, the removal of carbon dioxide gas, the reuse of useful volatile components, the overfilling, and the use of oxygen to contain the minimum amount necessary. By adopting new and useful processing steps such as gas aeration, circulation of moromi liquid, spraying treatment, and decomposition treatment of moromi using enzymes, and further organically combining these steps, extremely excellent effects have been achieved. is obtained.

In other words, the moromi is circulated smoothly, carbon dioxide is removed, oxygen is supplied, and the temperature is accurately controlled, so fermentation occurs quickly.
As a result, it has become possible to surprisingly shorten the brewing period, which was previously thought to be excessively long. In addition, since it is possible to process a large amount of moromi, it is now possible to use outdoor large-capacity tanks, which were previously considered impossible. It became possible to brew soy sauce using large-capacity tanks, and mass production became possible. Regarding the quality of soy sauce, by adopting a closed system, the useful enzyme components that were traditionally dissipated are retained and enriched in the moromi, improving the quality, and depending on the selection of enzymes, the quality can be improved. It can impart aroma and flavor. Further, the method of the present invention is not limited to one brewing tank, but can be carried out by connecting a plurality of tanks. Furthermore, if there is a shortage of alcohol and aroma components in the maturing moromi that has already completed aerated fermentation, it is also possible to aerate the moromi with a mixed gas containing volatile components to dissolve and replenish these useful components. It is. An important feature of the method of the invention is the flooding step with gas venting from the bottom of the tank.

By adopting this process, it becomes possible to control the temperature of moromi to the desired temperature at the necessary time and for the necessary time, and it is now possible to easily control the temperature of moromi at the bottom of the tank, which was particularly difficult to control in the past. It became possible to adjust the temperature, freely change the soy sauce brewing period, and manufacture soy sauce under the most appropriate conditions according to the soy sauce raw materials, outside air temperature, etc. be.

[Brief explanation of the drawing]

The drawing is a longitudinal sectional view of the apparatus used to carry out the invention. 1... Brewing tank, 2... Inner cylinder for moromi circulation, 7... Gas pipe, 9... Vacuum pump, 10... Inert Gas supply valve, 10'
...Temperature regulator, 16... Pressure tank, 22.
... Oxygen supply valve, 18 ... Inert gas pipe, 30 ... Circulating liquid reservoir, 32 ... Liquid injection port, 33 ... Gas-liquid separation tower , 34...
liquid injection pipe.

Claims (1)

[Claims] 1. A closed large-capacity tank with a hollow internal cylinder for circulation of moromi is used in a cylindrical brewing tank, soy sauce moromi is charged into this tank, and heated to contain the minimum required amount of oxygen as necessary. On the other hand, the fermentation system is degassed to create a reduced pressure or vacuum in the upper part of the tank to remove carbon dioxide gas, promote circulation and fermentation of soy sauce moromi, and remove alcohol, sugar, and aroma. Regarding volatile components such as ingredients, they are not discharged outside the system and are reused together with the aeration gas as an aeration agent for soy sauce moromi, or they are collected and re-added to soy sauce moromi, A soy sauce brewing method characterized by further fermentation.