Long-term preservation process and functional membrane packaging technology for fermented red pepper paste sauce optimized for long-distance export and room temperature distribution

Abstract

The present invention is a process technology capable of safely preserving fermented gochujang sauce for a long period during overseas export and ambient temperature distribution. It combines elemental technologies such as integrated pH and Aw (water activity), special membrane packaging materials (barrier + unidirectional valve), and natural antimicrobial materials. By adjusting the pH to a range of 4.24.5, maintaining water activity at 0.85 or lower, and reducing initial microorganisms through short-term heat treatment, followed by sealing the packaging material equipped with an internal gas release function with inert gas, packaging expansion, microbial growth, and oxidative deterioration occurring over **612 months at ambient temperature** are effectively suppressed. Actual pilot-scale simulation results confirmed that the taste, color, and safety of the gochujang sauce can be maintained during maritime transport (4–8 weeks) and long-term distribution while minimizing synthetic preservatives. Therefore, the present invention serves as a core technology that simultaneously enhances the efficiency of long-distance transport of fermented foods and consumer confidence, thereby significantly expanding the potential for ambient temperature distribution of gochujang sauce in global markets.

Description

Technology Field

[0001] The present invention Ensuring the safety and long-term preservation of fermented foods It belongs to the technology field for. In particular, Gochujang sauce, Korea's representative fermented food Long-distance sea transport and ambient temperature distribution Among Expansion, leakage, microbial deterioration So that it can be preserved for a long period without, Integrated management of pH and water activity (Aw) , Special membrane packaging material (including unidirectional gas release structure) , natural antibacterial material Complexly applied to the back Long-term storage process and packaging technology It is about Background Technology

[0002] [Background and Necessity of the Invention]

[0003] 1. Expansion of overseas export markets and the importance of preservation technology

[0004] · Demand for gochujang is increasing as it is recognized for its spicy taste and fermented flavor in domestic and international markets, but when exporting, **sea transport (4-8 weeks)** followed by **room temperature distribution in local supermarkets (at least 6 months)** is essential.

[0005] · In this long-term distribution process Fermentation microbial activity This has resumed Packaging expansion, leakage, spoilage Since this may occur, safety class quality Specialized process technology is urgently needed to ensure this.

[0006] 2. Problems with microorganisms and gas generation unique to fermented foods

[0007] · Small amounts of microorganisms that survive in low-temperature and high-salt environments (e.g., yeast, salt-tolerant bacteria) may remain in gochujang sauce.

[0008] · If the temperature rises above 20℃ during transport The fermentation speed has increased again. , gases such as carbon dioxide (CO₂) are generated, and as a result The packaging expands or Leakage This causes the marketability to decline.

[0009] 3. Reliance on existing preservatives and consumer avoidance

[0010] While adding high amounts of synthetic preservatives (sorbic acid, benzoic acid, etc.) can slow down spoilage to some extent, consumers' naturalism · clean foodDue to rising preferences, there is a need for technology that enables long-term preservation while minimizing synthetic preservatives.

[0011] [Existing Technology and Problems]

[0012] 1. pH adjustment and sterilization

[0013] Generally, lowering the pH to 4.6 or below can inhibit the growth of pathogenic microorganisms, but in gochujang sauce... functional ingredients Changes in (chili pepper capsaicin, tomato lycopene, etc.) must be taken into account, and there are limitations in completely blocking the proliferation of fermentation microorganisms (yeast).

[0014] 2. Ensuring packaging barrier properties

[0015] · Although oxygen and moisture barrier films exist on the market, Fermentation gas generated internally If you cannot efficiently discharge Increase in internal packaging pressure , expansion This is inevitable.

[0016] · There are unidirectional gas valves applied to some fermented foods, but like gochujang High viscosity and sticky product In this case, valve blockage or external contamination can be a problem.

[0017] 3. Insufficient control of water activity (Aw)

[0018] • General jam and syrup products have a high sugar content and thus a low Aw, but gochujang sauces require complex management of salt and sugar content, making it difficult to maintain the Aw below a certain level.

[0019] · If Aw control is poor, the fermentation bacteria will continue to be active. The problem to be solved

[0020] 1. Ensuring safety for long-term (6–12 months) storage at room temperature

[0021] When transporting long distances by sea (several weeks to several months) and selling at room temperature in overseas retail stores Fermentation gas generation Ina Microbial reproduction By thoroughly suppressing, Expansion, leakage, and deterioration Prevents.

[0022] 2. Minimize synthetic preservatives

[0023] Reduce reliance on preservatives and satisfy consumer preferences through natural antimicrobial materials (herb extracts, etc.), pH and Aw control, and functional membrane packaging.

[0024] 3. Packaging technology for convenient distribution and no damage

[0025] Blocking external oxygen and moisture, while allowing small amounts of CO₂ to be released smoothly Composite membrane packaging by developing Expansion and distribution inconvenience Reduce means of solving the problem

[0026] Means of solving the problem (technical configuration)

[0027] 1. Integrated pH and Aw (water activity) management

[0028] · (a) Maintain pH in the range of 4.2 to 4.5 In conjunction with the use of organic acids (citric acid, acetic acid, etc.), and considering the unique fermentation characteristics of gochujang sauce, an acidity range where strain growth is difficult is maintained.

[0029] · (b) Aw 0.85 or less The combination of sugars (oligosaccharides, sugar alcohols), dietary fiber, and salts significantly reduces the potential for microbial growth.

[0030] · (c) Low temperature and short-time heat treatment : At 70-80℃ for about 10-30 minutes, the initial number of microorganisms is lowered to delay the resumption of fermentation.

[0031] 2. Functional membrane packaging material

[0032] · (a) Oxygen and Moisture Permeability (OTR, MVTR) Standards :

[0033] · Use of multilayer films (PET / Al / CPP, etc.) with an OTR of 1,000cc / ㎡·day or less and an MVTR of 5g / ㎡·day or less.

[0034] · (b) Internal gas exhaust :

[0035] · Prevents external pollution while slowly releasing internal CO₂ over a long period of time Micropore treatment me One-way valve Introduce.

[0036] · (c) Use inert gas during charging :

[0037] · During the filling process, a nitrogen (N₂) atmosphere is created to inhibit oxidation and minimize residual oxygen in the product, thereby slowing down the progress of fermentation.

[0038] 3. Minimizing natural antimicrobial materials and synthetic preservatives

[0039] · (a) A blend of herbs (rosemary, thyme) and essential oils (clove, cinnamon). : Complex antibacterial and antioxidant action.

[0040] · (b) Synthetic preservatives are below the statutory standard. By using only a small amount for reinforcement, it improves consumer perception and enhances the eco-friendly image. Effects of the invention

[0041] [Effects and Features of the Invention]

[0042] 1. Can be stored at room temperature for 6 to 12 months.

[0043] Actual simulation (pilot scale) results showed that even after long-term storage in the range of 25 to 35°C, the packaging expansion rate was less than 5% and microbial deterioration was significantly low.

[0044] 2. Reduction in reliance on synthetic preservatives

[0045] Because preservation is maintained through natural materials and pH and Aw control, 'No preservatives' or 'low preservatives' It enables labeling, contributing to improved consumer trust.

[0046] 3. Suppression of fermentation gas and assurance of safety

[0047] By simultaneously managing pH and Aw, the growth of fermentation microorganisms is reduced, resulting in extremely low CO₂ emissions, and even small amounts of generated gas are released to the outside through functional membrane packaging.

[0048] 4. Maximizing distribution efficiency

[0049] Since it can be distributed at room temperature without refrigeration, logistics costs are reduced, and export competitiveness is enhanced by providing stable quality to overseas buyers and local consumers over a long period. Brief explanation of the drawing

[0050] · Fig. 1Schematic diagram of multilayer membrane packaging material (barrier + micropore discharge structure) for Gochujang sauce · Fig. 2 : Nitrogen filling and sealing process flowchart after pH·Aw integrated control · Fig. 3 : Graph of change in packaging expansion rate during long-term storage (application of the present invention vs. general packaging) Specific details for implementing the invention

[0051] The specific embodiments of the present invention are intended to be illustrative, and the embodiments described below include the processes and results of simulations conducted at an actual pilot process scale. Through these embodiments, the technical value of the present invention is to be clearly demonstrated.

[0052] (Experiment 1) Evaluation of Long-term Storage Stability of Gochujang Sauce through Multiple pH and Aw Controls

[0053] 1. Experiment Overview

[0054] · purpose : When the pH of the gochujang sauce is adjusted to 4.3±0.1 and the water activity (Aw) to 0.84±0.02, the swelling, microbial growth, and sensory changes occurring during long-term storage at room temperature (25℃) are evaluated.

[0055] · scale : 3 pilot batches of 20 L each (total 60 L).

[0056] · period : Quality measurement periodically over 6 months (months 0, 1, 2, 3, 4, 5, and 6).

[0057] 2. Ingredients and Formulation

[0058] · (a) Gochujang concentrate : Traditionally fermented gochujang (salt content 10%, pH 4.8).

[0059] · (b) Tomato concentrate (60°Bx, pH 4.0) 20% added.

[0060] · (c) organic acids (Citric acid 0.3%, acetic acid 0.1%), Oligosaccharides (5%), refined salt Mix (1%).

[0061] · (d) natural antibacterial material : Rosemary extract (0.2%), cinnamon oil (0.05%).

[0062] · Adjust to pH 4.3 and Aw 0.84 after final stirring.

[0063] 3. Heat treatment and packaging

[0064] · (a) heat treatment : Maintain the homogeneous mixture at 75°C for 15 minutes to reduce (kill) the initial microbial load by more than 90%.

[0065] · (b) charge : Automatic sealing after filling pouches (special membranes) in 200g portions inside a nitrogen (N₂) flushing chamber.

[0066] · (c) Packaging material specifications : OTR 800-900cc / ㎡·day, MVTR 45g / ㎡·day level.

[0067] 4. Storage conditions

[0068] · Room temperature (25±2℃) warehouse environment. Maintain daily average temperature deviation at 5℃ or less.

[0069] · Store in a dark place away from direct sunlight. Relative humidity around 60–70%.

[0070] 5. Measurement items and methods

[0071] · (a) Packaging expansion rate : Monthly record the number of swelling occurrences among 50 samples ("pack bulging due to internal pressure" is considered swelling).

[0072] · (b) Total bacterial count · Yeast count : Colony count measured (CFU / g) after 48 hours at 30°C by culturing in PCA medium (total bacterial count) and YPD medium (yeast).

[0073] · (c) pH, Aw: Average after 3 repeated measurements using a pH meter for fermented foods (with temperature compensation function) and an Aw meter (Aqualab Series).

[0074] · (d) Sensory evaluation : Evaluation of taste (sour, spicy, umami), color, texture, and overall preference (10-point scale) by 15 expert panelists.

[0075] 6. result

[0076] · (a) Packaging expansion rate : Survey results up to the 6th month, in 2 out of 50 samples (4%) Mild swelling Only check.

[0077] · (b) Microbial count : Initial total bacterial count approximately 1×10^3 CFU / g → maintained at 2×10^3 CFU / g or less at 6 months, yeast also did not increase significantly (1×10^2→1×10^3 CFU / g).

[0078] · (c) pH, Aw stability : pH 4.3±0.1 range variation ±0.07, Aw maintained at 0.84±0.02.

[0079] · (d) Sensory evaluation Even in the 6th month, the overall preference remained at 7.8 / 10, without a significant drop compared to the initial level (8.2 / 10). Spicy taste, sourness, and texture were all rated “Good to Excellent.”

[0080] · conclusion : By applying natural antimicrobial materials and special membrane packaging after pH·Aw multi-control, room temperature stability of at least 6 months was achieved.

[0081] (Experiment 2) Fermentation gas suppression effect due to the application of a one-way gas discharge valve

[0082] 1. Experimental Objective

[0083] · If the gochujang sauce is exposed to temperature changes (15–30℃) during actual maritime transport, fermentation may resume and gas may be generated.

[0084] · In this experiment One-way gas discharge valveCompare the expansion rate, leakage occurrence, and internal microbial variation of pouches with attached components (Group B) and standard pouches (Group A).

[0085] 2. Process and Packaging

[0086] · (a) Gochujang sauce recipe : pH 4.2, Aw 0.83 (similar to Example 1), a total of 2 identical batches of 10 L each were prepared.

[0087] · (b) Packaging material classification :

[0088] · Group A : Oxygen and moisture-blocking pouch (OTR 1,000cc / ㎡·day), no valve.

[0089] · Group B : Equipped with identical barrier film + unidirectional gas discharge valve (0.1 mm diameter).

[0090] · (c) charge : Fill 50 units per pouch (total 100 units) in 200g units and seal. Inert gas (nitrogen) flushing is performed under the same conditions.

[0091] 3. Simulated maritime transport conditions

[0092] · Using a constant temperature water bath and chamber in the laboratory, Repeat temperature between 15℃ and 30℃ in a 12-hour cycle (for about 2 weeks) Apply a changing cycle.

[0093] · Maintain humidity at 70±5%. The pouch storage container was simulated to mimic an actual marine container and subjected to slight shaking (vibration of 2–5 Hz).

[0094] 4. Measurement and Analysis

[0095] · (a) Packaging expansion rate and leakage After 2 weeks, identify whether any visible swelling or leakage has occurred, and take photographs and record the details.

[0096] · (b) Gas composition analysis : Open some samples (3 from each group) and measure the internal gases (O₂, CO₂ concentrations) using GC (gas chromatography).

[0097] · (c) Microbial count Since yeast proliferation is a major issue when fermentation proceeds excessively, the yeast count is quantified using YPD medium (incubated at 30℃ for 48 hours).

[0098] 5. result

[0099] · (a) Expansion rate :

[0100] · Group A (valveless) : 10 out of 50 (20%) swelled noticeably, and 2 of these (4%) leaked.

[0101] · Group B (valve attached) : Only mild swelling was confirmed in 3 out of 50 (6%) (0 cases of leakage).

[0102] · (b) Internal gas composition :

[0103] · Group A: CO₂ concentration rises to approximately 5–7%, and O₂ remains at 3% or more.

[0104] · Group B: CO₂ kept low at 2% or less, O₂ less than 1%. This is presumed to be due to the nitrogen atmosphere being maintained as some of the gas was discharged through a one-way valve.

[0105] · (c) Yeast water :

[0106] · Group A: Confirmed that some samples increased rapidly from an initial 1×10^2 CFU / g to 5×10^3~1×10^4 CFU / g after 2 weeks.

[0107] · Group B: Initial 1×10^2 CFU / g → After 2 weeks 5×10^2~1×10^3 CFU / g. The rate of increase is relatively small.

[0108] · analyze It is determined that the conditions for internal pressure rise and microbial growth were limited by releasing a certain amount of CO₂ to the outside through the valve.

[0109] 6. conclusion

[0110] · By applying a one-way gas release valve, packaging expansion and leakage problems are significantly reduced, even under temperature fluctuations expected during actual maritime transport.

[0111] · From a microbial perspective, yeast proliferation is restricted, which has the effect of suppressing the rate of fermentation resumption.

[0112] (Experiment 3) Monitoring of product quality changes during long-term (12-month) storage at room temperature

[0113] 1. Experimental Objective

[0114] · To simulate actual overseas distribution (612 months of room temperature sales), quality changes are monitored while storing in a room temperature warehouse (25±3℃, RH 6070%) for 12 months.

[0115] · The present invention (special membrane packaging + valve + natural antibacterial composite) When applying and Standard packaging (large amount of synthetic preservatives) Comparative evaluation of poems.

[0116] 2. Process and Samples

[0117] · (a) Sample of the present invention (Group C): pH 4.3, Aw 0.84, natural antibacterial (rosemary + clove), inert gas filled, one-way valve pouch.

[0118] · (b) General packaging samples (Group D): pH 4.5, synthetic preservative (potassium sorbate 0.1%), standard high-barrier pouch (no valve).

[0119] · Produce 100 pouches (200g) per group.

[0120] 3. Storage and Measurement Items

[0121] · (a) Storage conditions : Actual ambient temperature warehouse (internal temperature daily fluctuation ±3℃, average 25℃).

[0122] · (b) Monthly metrics :

[0123] 1. Packaging Expansion Rate (%)

[0124] 2. Total microbial count (CFU / g), yeast count (CFU / g)

[0125] 3. pH, Aw

[0126] 4. Sensory (Taste, Aroma, Color, Texture, Overall Preference)

[0127] 5. Residual amount of synthetic preservatives (limited to Group D)

[0128] 4. Results and Discussion

[0129] · (a) Packaging expansion rate :

[0130] · Group C (the present invention) has a cumulative expansion rate of less than 8% at 12 months (occurring slightly mainly between 9 and 12 months).

[0131] · Group D (standard packaging) showed a rapid expansion rate of over 15% and 2% leakage starting from the 10th month.

[0132] · (b) Microbial aspects :

[0133] · Group C: Initial total bacterial count 1×10^3 CFU / g → approximately 5×10^3 CFU / g at month 12. Yeast count also showed a relatively low increase (maximum 1×10^3 CFU / g).

[0134] · Group D: Initial microorganisms were stable due to synthetic preservatives, but intermittent yeast surges (over 1×10^5 CFU / g) occurred in samples after the 10th month, and rancid odor was reported in some samples.

[0135] · (c) Maintain pH and Aw :

[0136] · Group C: pH within the range of 4.3±0.2, Aw within 0.84±0.03. No significant fluctuations over the long term.

[0137] · Group D: pH rose slightly to 4.6–4.7 in the later stages despite the use of preservatives, showing signs of fermentation progress.

[0138] · (d) Sensory evaluation :

[0139] · Group C maintained an overall preference level of 7.2 / 10 even at 12 months (although slight weakening of acidity and spiciness was noted, it was generally acceptable).

[0140] · Group D had a low preference rating of 5.5 / 10 due to sensory defects such as a “yeast smell” occurring in the later stages.

[0141] · Comprehensive Analysis : The present invention (Group C) is a comprehensive solution including pH·Aw control, natural antibacterial properties, and valve packaging, compared to Group D, which is mainly composed of synthetic preservatives 12 months of storage at room temperature The stability was higher.

[0142] 5. conclusion

[0143] · When the process of the present invention is applied, Long-term (up to 12 months) storage at room temperature Even at this stage, it significantly suppresses the generation of fermentation gas and microbial spoilage, so the gochujang sauce Marketability It was confirmed that it can maintain excellent performance. Industrial applicability

[0144] 1. long-distance export

[0145] · Even assuming a total of 612 months of local ambient temperature distribution following 48 weeks of sea transport, Packaging expansion and leakage Since only an extremely small amount is generated, it enhances the trust of overseas buyers and consumers.

[0146] 2. Online global shipping

[0147] · When selling online, even if there are temperature fluctuations in various distribution channels such as international courier or air freight, Valve-type special packaging This reduces the risk of expansion, thereby lowering return and claim rates.

[0148] 3. Premium branding

[0149] · Strengthen marketing competitiveness by emphasizing “no or low preservatives and the use of natural antibacterial herbal extracts,” and provide consumers with the perception of healthy and safe fermented food products.

[0150] 4. Applicability Scalability

[0151] · This technology applies not only to fermented gochujang sauce, but also, Soybean paste sauce , trashy , Fermented fruit sauce , Fusion sauce It is applicable to a wide range of fermentation-based sauces, enabling the stable export of a diverse product lineup. Explanation of the symbols

[0152] · Fig. 1 Schematic diagram of multilayer membrane packaging material for Gochujang sauce (barrier layer + micropore structure) · Fig. 2 : Process Flow Chart for Inert Gas Filling & Sealing After pH·Aw Adjustment · Fig. 3 : Graph of change in packaging expansion rate during simulated maritime transport (comparison of valve vs. valveless)

Claims

Claim 1 A long-term preservation method for fermented gochujang sauce optimized for long-distance export and room-temperature distribution comprises:

1. adding organic acids (citric acid, acetic acid, etc.) in a predetermined ratio to maintain the pH in the range of 4.2 to 4.5, while suppressing the possibility of microbial growth by combining sugars (oligosaccharides, sugar alcohols), salts, dietary fiber, etc., so that the water activity (Aw) becomes 0.85 or less; 2. performing heat treatment at 7080℃ for 1030 minutes to lower the initial microbial load; 3. filling and sealing the product under an inert gas (nitrogen, etc.) atmosphere in a packaging material equipped with a special membrane or a one-way valve that has oxygen and moisture permeability below a certain standard (OTR 1,000cc / ㎡·day or less, MVTR 5g / ㎡·day or less) and can partially discharge internal fermentation gases such as carbon dioxide (CO₂) to the outside; and 4. It is characterized by minimizing the use of synthetic preservatives by incorporating natural antimicrobial materials (herb extracts, essential oils, etc.) and suppressing packaging expansion, leakage, and microbial spoilage during a shelf life of 6 to 12 months at room temperature, and, in conclusion, stably maintaining the quality and safety of the gochujang sauce even under long-distance maritime transport and overseas room temperature display conditions. Long-term preservation process and functional membrane packaging technology for fermented gochujang sauce.

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