Efficient enzymatic fermentation soy sauce production process

Abstract

The invention discloses a high-efficiency enzymatic fermentation soy sauce production process, and relates to the technical field of soy sauce production processes, the high-efficiency enzymatic fermentation soy sauce production process comprises the following process steps: S1, material preparation, S2, material steaming, S3, inoculation, S4, fermented grain preparation and fermentation, S5, squeezing, and S6, sterilization and filling. The high-temperature-resistant amylase is added in the material steaming process, starch on the surfaces of the wheat and soybean meal raw materials is preliminarily decomposed, the starchy raw material can be decomposed in advance, growth of the aspergillus oryzae raw material in starter propagation is facilitated, clinker can be prevented from caking and being sticky, and the looseness of the starter material is improved; papain is added in the starter propagation process, and protein in wheat and soybean meal raw materials is continuously decomposed by aspergillus oryzae protease in starter propagation, so that the protein raw materials are quickly decomposed in advance, the growth of the aspergillus oryzae raw materials in starter propagation is facilitated, and the fermentation period is shortened; the compound clarification enzyme is added during fermentation to decompose intermediate products such as phytic acid, cellulose and the like which cause a large amount of aggregation after the raw soy sauce is heated, the clarification speed is high after the soy sauce is sterilized, and the precipitation amount is reduced by 50%-70%.

Description

Technical Field

[0001] The invention relates to the technical field of soy sauce production technology, in particular to a high-efficiency enzymatic fermentation soy sauce production process. Background Art

[0002] With the improvement of people's living standards and the trend of food safety, people's requirements for condiments are getting higher and higher. There are many types of soy sauces sold on the market. Fresh soy sauces such as light soy sauce and extremely fresh soy sauce account for half of the soy sauce market. However, the fermentation cycle of soy sauce is long (more than 3 months), the proportion of soy sauce sedimentation is high, and post-processing such as natural sedimentation and filtration is relatively cumbersome, resulting in large losses and increased costs. If not handled properly, secondary precipitation will occur during the shelf life, making it unacceptable to some consumers.

[0003] Soy sauce is a delicious condiment produced by fermenting soybeans, wheat, and other ingredients using a variety of microorganisms, including molds, lactic acid bacteria, and yeasts. After fermentation with a variety of microbial enzymes, soy sauce contains a wealth of amino acids, peptides, polysaccharides, reducing sugars, and organic acids. However, the enzymes produced by the three main bacterial species themselves have certain defects, and cannot completely decompose phytic acid, dextrin, and protein. There is an urgent need for an enzyme that can more thoroughly decompose phytic acid, dextrin, and protein in the raw materials for use in soy sauce fermentation, thereby shortening the fermentation cycle while ensuring all the indicators and flavor of the soy sauce. Summary of the Invention

[0004] The technical problem to be solved by the present invention is: in view of the above-mentioned deficiencies of the prior art, an efficient enzymatic fermentation soy sauce production process is provided, which can rapidly decompose the protein raw materials in advance and shorten the fermentation cycle while ensuring various indicators and flavor of the soy sauce.

[0005] To achieve the above object, the present invention provides the following technical solution: a high-efficiency enzymatic fermentation soy sauce production process, comprising the following process steps: S1. Prepare ingredients: soybean meal made from defatted soybeans, wheat, salt, fried wheat flour, α-amylase, soy sauce koji, flavoring yeast, and water; S2, steaming; this step includes feeding, dry steaming, moistening, wet steaming, pressure relief, vacuuming and opening the cover to discharge the material; the mass ratio of soybean meal to wheat used in the steaming step is 55:45; S3, inoculation; This step includes cooling the material, inoculation, mixing with wheat flour and adding koji; S4, mash making and fermentation; using a composite clarification enzyme to promote fermentation during mash making, the enzyme activity of the composite clarification enzyme is 10000u / g, and the composite clarification enzyme comprises phytase, cellulase, and xylanase, and the mass ratio of phytase, cellulase, and xylanase is 8:1:1; S5, pressing; after the fermentation is completed, the fermented mash is filtered using a vertical press to collect the raw soy sauce and the soy sauce residue; S6. Sterilization and filling: pump the raw soy sauce into the mixing and sterilization pot, heat it to 90-95℃, keep it warm for 30-60 minutes, cool it to 60-65℃, and put it into the sedimentation tank. After 2-7 days, take the supernatant; filter the bottom precipitate with diatomaceous earth to obtain the filtered supernatant, mix the supernatant and the filtered supernatant, and then fill it.

[0006] As a further solution of the present invention: S2 includes the following steps: S2.1. Adding materials: Add soybean meal and wheat to the steamer, seal the lid tightly, and turn the steamer. S2.2, Dry steaming: Open the steam valve and perform dry steaming three times, with the pressure controlled from 0 MPa to 0.1 MPa to 0 MPa to 0.1 MPa to 0 MPa to 0.12-0.16 MPa to 0 MPa. When the exhaust pressure reaches 0 MPa for the last time, close the exhaust valve; S2.3, water moistening: add 0.1kg of high-temperature resistant α-amylase to every 1000L of room temperature water, where the α-amylase activity is 100,000 u / g. After the water is filled, turn the ball three times, then open the exhaust valve to release the negative pressure to 0, close the exhaust valve, and continue to turn the ball to moisten the water for 10-15 minutes. The total water moistening time from the completion of water filling is 15-20 minutes; S2.4, wet steaming: the steaming pressure is 0.1 MPa for the first time, 0.1 MPa for the second time, and 0.12-0.16 MPa for the third time. Start timing from the pressure of 0.12 MPa and maintain the pressure for 8-12 minutes; S2.5, Pressure relief: After the steam material pressure is maintained, close the steam inlet valve, open the exhaust valve to exhaust the steam until the pressure reaches 0 MPa, and close the exhaust valve; S2.6, Vacuuming: First turn on the vacuum pump, then open the vacuum valve, and evacuate to 60-55℃; open the exhaust valve to release the pressure to 0 MPa, then turn off the vacuum pump, and then close the vacuum valve; S2.7. Open the lid and steam the ingredients into balls.

[0007] As a further solution of the present invention: S3 includes the following steps: 3.1. Discharge cooling: Open the discharge port of the steamer ball, start the conveying auger, and let the steamed material pass through the conveyor belt into the cooling fan for cooling; 3.2. Inoculation, mixing with wheat flour and adding koji: 0.03-0.05% of the total mass of the raw materials by weight of Aspergillus oryzae koji essence and 0.02-0.03% of the total mass of the raw materials by weight of papain are mixed with fried wheat flour and then introduced into the inoculator, and mixed with the fried wheat flour through an inoculation auger. The activity of papain is 600,000 u / g, and the amount of fried wheat flour is 25±2 kg per ball. The evenly mixed material is then dropped into the koji-making disc through a conveyor belt, and is flattened and evenly spread while being added. The thickness of each layer is 4-5 cm. The inoculation temperature is less than 38°C, and the inoculation temperature is the outlet temperature of the inoculation auger.

[0008] As a further solution of the present invention: in S3, after the koji material is put into the tray, it should be spread evenly to prevent local compaction, and the temperature of each part should be measured with a thermometer to ensure uniformity, and the koji material should be flattened with circulating air; the temperature of the koji material should be maintained between 24°C and 36°C for incubation; Koji making temperature control requirements: Early stage: 1-12 hours, temperature controlled at 30±30℃; Mid-term: 13-24 hours, temperature controlled at 32±40℃; Late stage: 25-44 hours, temperature controlled at 26±2℃; As a further solution of the present invention: the management requirements for koji making and turning koji are as follows: the first turning koji should be done 10-14 hours after feeding, and the second turning koji should be done 14-20 hours after feeding; the turning koji should be done according to the actual growth situation; if the koji making process shows a temperature higher than 35°C, cracks, or air leakage, the koji should be turned immediately; the koji making time should be 40-44 hours, and the room temperature should be kept constant and the indoor air humidity should be above 92%; Quality requirements for finished koji: The finished koji should be light yellow, have the normal aroma of Aspergillus oryzae, no peculiar smell, and the protease activity measured by formaldehyde method should be above 1000U / g.

[0009] As a further solution of the present invention: S4 includes the following steps: S4.1. Preparation of brine: Dry-steam salt: After placing salt in the salt pond, open the steam valve at the bottom of the pond. Start timing when steam appears on the surface of the salt pile and steam for 50-60 minutes to kill microorganisms in the salt and reduce the bacterial content in the soy sauce. After dry-steaming, the salt is converted into saturated brine and pumped into a saturated brine tank. The brine concentration is pre-adjusted to 24.5-26g / 100ml. Filter and sterilize the brine using a ceramic membrane with a pore size of 0.18-0.22μm before entering a refrigerator. The brine temperature is adjusted to 4-6°C in the refrigerator (the brine temperature is based on the 13-15°C temperature of the mash after koji formation). S4.2. Mash making: Add 0.05-0.1% of the total weight of the raw materials to the filtered brine and mix thoroughly. Then, mix the cultured koji and brine through a mixing auger and pump them into the fermentation tank. (After the koji is pumped out, flush the delivery pipe with the remaining brine, then clean the pipe with a sponge and compressed air.) S4.3, Fermentation; Day 1: Add the finished koji to the tank while stirring it with the air pipe alternately to keep the sauce mash evenly turned. After adding it to the tank, stir it with air once for 30 minutes. Stir it again every 4-5 hours for 30 minutes. (The stirring time can be shortened or extended depending on the stirring uniformity. The stirring uniformity is the standard.) Day 2-3: Stir once in the morning and once in the afternoon for 30 minutes, with an interval of no less than 4 hours between the two stirrings; Day 4-7: Stir once a day for 10 minutes; Day 7: Re-check the salt content of the mash. If the error exceeds the standard by 0.5%, make adjustments in a timely manner. Thereafter, samples will be taken every 15 days to test the indicators of the mash, and depending on the surface condition of the mash, it will be gently stirred every 7-10 days to "eliminate mold", and the stirring should be done until no white film is visible on the surface.

[0010] As a further solution of the present invention: flavoring yeast is added during fermentation: each tank of fermented mash needs to be added with 2% of the total raw material amount of flavoring yeast, and the yeast count is required to be ≥ 300 million / ml; after adding the flavoring yeast, stirring is continued for 3 days, once a day, each time for one cycle, and each air pipe is 1 minute.

[0011] As a further solution of the present invention: in S4.3, the temperature management requirements for fermentation are as follows: The tank temperature should be 13-15℃; Keep the temperature at 13-15℃ for 1-15 days after adding the fermenter. Start to raise the temperature on the 16th day. The heating method is: turn on the fermenter heating and insulation system, control the hot water temperature to 55-65℃, and circulate the hot water to raise the temperature. Stir once every 3-4 days during the heating process, that is, stir once a cycle, the stirring time is 5 minutes, and each air pipe is 1 minute; Gradually raise the temperature to 30°C from 16 to 30 days and maintain this temperature for about 45 days. When the amino acid content stops increasing, the primary fermentation is over. After the primary fermentation is completed, add flavoring yeast, control the temperature at 28-30℃, and ferment for 15-20 days. When the surface of the mash is calm, it means that the yeast fermentation is complete and the secondary fermentation is over.

[0012] As a further solution of the present invention: the fermentation period is 60-90 days.

[0013] Compared with the prior art, the present invention has the following beneficial effects: 1. Adding high-temperature resistant amylase during the steaming process can preliminarily decompose the starch on the surface of wheat and soybean meal raw materials. This can not only decompose the starchy raw materials in advance, which is beneficial to the growth of Aspergillus oryzae raw materials in koji making, but also prevent the clinker from agglomerating and sticking, and improve the looseness of the koji material.

[0014] 2. Add papain during the koji making process, and it will continuously decompose the protein in the wheat and soybean meal raw materials together with the Aspergillus oryzae protease, so that the protein raw materials can be decomposed quickly in advance, which is beneficial to the growth of Aspergillus oryzae raw materials in the koji making and shortens the fermentation cycle.

[0015] 3. Add compound clarification enzymes during fermentation to decompose phytic acid, cellulose and other intermediate products that cause a large amount of precipitation and aggregation after heating of raw soy sauce. After sterilization, the soy sauce is clarified quickly and the amount of precipitation is reduced by 50%-70%. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a process flow chart of the present invention. DETAILED DESCRIPTION

[0017] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0018] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are only used for descriptive purposes and should not be understood as indicating or implying relative importance. In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", and "set" should be understood in a broad sense, for example, they can be fixedly connected, detachably connected, or connected in one piece; they can be mechanically connected or electrically connected; they can be directly connected, or indirectly connected through an intermediate medium, or they can be internal connections between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. The following describes an embodiment of the present invention based on its overall structure. Example 1

[0019] like Figure 1 As shown in this embodiment, a high-efficiency enzymatic fermentation soy sauce production process includes the following process steps: S1. Prepare ingredients: soybean meal made from defatted soybeans, wheat, salt, fried wheat flour, α-amylase, soy sauce koji, flavoring yeast, and water; S2, steaming; this step includes feeding, dry steaming, moistening, wet steaming, pressure relief, vacuuming and opening the cover to discharge the material; the mass ratio of soybean meal to wheat used in the steaming step is 55:45; S2.1. Adding materials: Add soybean meal and wheat to the steamer, seal the lid tightly, and turn the steamer. S2.2, Dry steaming: Open the steam valve and perform dry steaming three times, with the pressure controlled from 0 MPa to 0.1 MPa to 0 MPa to 0.1 MPa to 0 MPa to 0.12 MPa to 0 MPa. When the exhaust pressure reaches 0 MPa for the last time, close the exhaust valve; S2.3, water conditioning: add 0.1kg of high-temperature resistant α-amylase to every 1000L of room temperature water, where the α-amylase activity is 100,000 u / g. After the water is filled, rotate the ball for 3 more turns, then open the exhaust valve to release the negative pressure to 0, close the exhaust valve, and continue to rotate the ball for water conditioning for 10 minutes. The total water conditioning time from the completion of water filling is 15 minutes; S2.4, wet steaming: the steaming pressure is 0.1 MPa for the first time, 0.1 MPa for the second time, and 0.12 MPa for the third time. Start timing from the pressure of 0.12 MPa and maintain the pressure for 8 minutes; S2.5, Pressure relief: After the steam material pressure is maintained, close the steam inlet valve, open the exhaust valve to exhaust the steam until the pressure reaches 0 MPa, and close the exhaust valve; S2.6, Vacuuming: First turn on the vacuum pump, then open the vacuum valve, and evacuate to 55°C; open the exhaust valve to release the pressure to 0 MPa, then turn off the vacuum pump, and then close the vacuum valve; S2.7. Open the lid and steam the ingredients into balls.

[0020] S3, inoculation; This step includes cooling the material, inoculation, mixing with wheat flour and adding koji; 3.1. Discharge cooling: Open the discharge port of the steamer ball, start the conveying auger, and let the steamed material pass through the conveyor belt into the cooling fan for cooling; 3.2. Inoculation, mixing with wheat flour and adding koji: 0.03% of the total mass of the raw materials by weight of Aspergillus oryzae koji essence and 0.02% of the total mass of the raw materials by weight of papain are mixed with fried wheat flour and then introduced into the inoculator. The mixture is mixed with the fried wheat flour through an inoculating auger. The activity of papain is 600,000 u / g and the amount of fried wheat flour is 25±2 kg per ball. The evenly mixed material is then dropped into the koji-making disc through a conveyor belt. The material is flattened and evenly spread while being added. The thickness of each layer is 4 cm. The inoculation temperature is less than 38°C, where the inoculation temperature is the outlet temperature of the inoculating auger.

[0021] In S3, after the koji material is put into the tray, it should be spread evenly to prevent local compaction. The temperature of each part should be measured with a thermometer to ensure uniformity. The koji material should be flattened with circulating air. The temperature of the koji material should be kept between 24℃ and 36℃ for incubation. Koji making temperature control requirements: Early stage: 1-12 hours, temperature controlled at 30±30℃; Mid-term: 13-24 hours, temperature controlled at 32±40℃; Late stage: 25-44 hours, temperature controlled at 26±2℃; Koji making and turning management requirements: The first turning should be done 10 hours after feeding, and the second turning should be done 14 hours after feeding; the turning should be done according to the actual growth conditions; if the temperature exceeds 35℃, cracks or air leakage occurs during the making process, the koji should be turned immediately; the making time should be 40 hours, and the room temperature should be kept constant and the indoor air humidity should be above 92%; Quality requirements for finished koji: The finished koji should be light yellow, have the normal aroma of Aspergillus oryzae, no peculiar smell, and the protease activity measured by formaldehyde method should be above 1000U / g.

[0022] S4, mash making and fermentation; S4.1. Preparation of brine; Dry-steaming salt: After placing salt in the salt pond, open the steam valve at the bottom of the pond and start steaming for 50 minutes, starting when steam appears on the surface of the salt pile. This kills microorganisms in the salt and reduces the bacterial content in the soy sauce. After dry-steaming, the salt is converted into saturated brine and pumped into a saturated brine tank. The brine concentration is pre-adjusted to 24.5g / 100ml. Filter and sterilize the brine using a 0.18μm pore size ceramic membrane before entering a refrigerator. The brine temperature is adjusted to 4°C in the refrigerator (the brine temperature is based on the 13-15°C temperature of the mash after koji formation). S4.2. Mash making: Add 0.05% of the total weight of the raw materials to the filtered brine and mix thoroughly. Then, mix the cultured koji and brine thoroughly using a mixing auger and pump them into the fermentation tank. (After the koji is pumped out, flush the delivery pipe with the remaining brine, then clean the pipe with a sponge and compressed air.) S4.3, Fermentation; Day 1: Add the finished koji to the tank while stirring it with the air pipe alternately to keep the sauce mash evenly turned. After adding it to the tank, stir it with air once for 30 minutes; stir it again after 4 hours for 30 minutes; (The stirring time can be shortened or extended depending on the stirring uniformity; the stirring uniformity is the standard.) Day 2-3: Stir once in the morning and once in the afternoon for 30 minutes, with an interval of no less than 4 hours between the two stirrings; Day 4-7: Stir once a day for 10 minutes; Day 7: Re-check the salt content of the mash. If the error exceeds the standard by 0.5%, make adjustments in a timely manner. Thereafter, samples will be taken every 15 days to test the indicators of the mash, and depending on the surface condition of the mash, it will be gently stirred every 7 days to "eliminate mold", and the stirring should be done until no white film is visible on the surface.

[0023] When making mash, a composite clarification enzyme is used to promote fermentation. The enzyme activity of the composite clarification enzyme is 10,000 u / g. The composite clarification enzyme contains phytase, cellulase, and xylanase. The mass ratio of phytase, cellulase, and xylanase is 8:1:1. Each tank of fermented mash needs to be added with 2% of the total raw material amount of flavoring yeast, and the yeast count is required to be ≥ 300 million / ml. After adding the flavoring yeast, stir continuously for 3 days, once a day, one cycle each time, and each air tube for 1 minute.

[0024] In S4.3, the temperature management requirements for fermentation are as follows: The tank temperature is required to be 13°C; Keep the temperature at 13-15℃ for 1-15 days after adding the fermenter. Start to raise the temperature on the 16th day. The heating method is: turn on the fermenter heating and insulation system, control the hot water temperature to 55-65℃, and circulate the hot water to raise the temperature. Stir once every 3-4 days during the heating process, that is, stir once a cycle, the stirring time is 5 minutes, and each air pipe is 1 minute; Gradually raise the temperature to 30°C from 16 to 30 days and maintain this temperature for about 45 days. When the amino acid content stops increasing, the primary fermentation is over. After the primary fermentation is completed, add flavoring yeast, control the temperature at 28-30℃, and ferment for 15 days. When the surface of the mash is calm, it means that the yeast fermentation is complete and the secondary fermentation is over.

[0025] The fermentation cycle is controlled at 90 days.

[0026] S5, pressing; after the fermentation is completed, the fermented mash is filtered using a vertical press to collect the raw soy sauce and the soy sauce residue; S6. Sterilization and filling: pump the raw soy sauce into the mixing and sterilization pot, heat it to 90℃, keep it warm for 30 minutes, cool it down to 60℃, and put it into the sedimentation tank. After 2 days, take the supernatant; filter the bottom precipitate with diatomaceous earth to obtain the filtered supernatant, mix the supernatant and the filtered supernatant, and then fill it. Example 2

[0027] In this embodiment, a high-efficiency enzymatic fermentation soy sauce production process includes the following process steps: S1. Prepare ingredients: soybean meal made from defatted soybeans, wheat, salt, fried wheat flour, α-amylase, soy sauce koji, flavoring yeast, and water; S2, steaming; this step includes feeding, dry steaming, moistening, wet steaming, pressure relief, vacuuming and opening the cover to discharge the material; the mass ratio of soybean meal to wheat used in the steaming step is 55:45; S2.1. Adding materials: Add soybean meal and wheat to the steamer, seal the lid tightly, and turn the steamer. S2.2, Dry steaming: Open the steam valve and perform dry steaming three times, with the pressure controlled from 0 MPa to 0.1 MPa to 0 MPa to 0.1 MPa to 0 MPa to 0.14 MPa to 0 MPa. When the exhaust pressure reaches 0 MPa for the last time, close the exhaust valve; S2.3, water conditioning: add 0.1kg of high-temperature resistant α-amylase with an activity of 100,000 u / g to every 1000L of room temperature water. After the water is filled, rotate the ball for 3 more turns, then open the exhaust valve to release the negative pressure to 0, close the exhaust valve, and continue to rotate the ball for water conditioning for 13 minutes. The total water conditioning time from the completion of water filling is 18 minutes. S2.4, wet steaming: the steaming pressure is 0.1 MPa for the first time, 0.1 MPa for the second time, and 0.14 MPa for the third time. Start timing from the pressure of 0.12 MPa and maintain the pressure for 10 minutes; S2.5, Pressure relief: After the steam material pressure is maintained, close the steam inlet valve, open the exhaust valve to exhaust the steam until the pressure reaches 0 MPa, and close the exhaust valve; S2.6, Vacuuming: First turn on the vacuum pump, then open the vacuum valve, and evacuate to 58°C; open the exhaust valve to release the pressure to 0 MPa, then turn off the vacuum pump, and then close the vacuum valve; S2.7. Open the lid and steam the ingredients into balls.

[0028] S3, inoculation; This step includes cooling the material, inoculation, mixing with wheat flour and adding koji; 3.1. Discharge cooling: Open the discharge port of the steamer ball, start the conveying auger, and let the steamed material pass through the conveyor belt into the cooling fan for cooling; 3.2. Inoculation, mixing with wheat flour and adding koji: 0.04% of the total mass of the raw materials by weight of Aspergillus oryzae koji essence and 0.025% of the total mass of the raw materials by weight of papain are mixed with fried wheat flour and then introduced into the inoculator. The mixture is mixed with the fried wheat flour through an inoculating auger. The activity of papain is 600,000 u / g and the amount of fried wheat flour is 25±2 kg per ball. The evenly mixed material is then dropped into the koji-making disc through a conveyor belt. The material is flattened and evenly spread while being added. The thickness of each layer is 4.5 cm. The inoculation temperature is less than 38°C, where the inoculation temperature is the outlet temperature of the inoculating auger.

[0029] In S3, after the koji material is put into the tray, it should be spread evenly to prevent local compaction. The temperature of each part should be measured with a thermometer to ensure uniformity. The koji material should be flattened with circulating air. The temperature of the koji material should be kept between 24℃ and 36℃ for incubation. Koji making temperature control requirements: Early stage: 1-12 hours, temperature controlled at 30±30℃; Mid-term: 13-24 hours, temperature controlled at 32±40℃; Late stage: 25-44 hours, temperature controlled at 26±2℃; Koji making and turning management requirements: The first turning should be done 12 hours after feeding, and the second turning should be done 17 hours after feeding; the turning should be done according to the actual growth conditions; if the temperature exceeds 35℃, cracks or air leakage occurs during the making process, the koji should be turned immediately; the making time should be 42 hours, and the room temperature should be kept constant and the indoor air humidity should be above 92%; Quality requirements for finished koji: The finished koji should be light yellow, have the normal aroma of Aspergillus oryzae, no peculiar smell, and the protease activity measured by formaldehyde method should be above 1000U / g.

[0030] S4, mash making and fermentation; S4.1. Preparation of brine: Dry-steam salt: After placing salt in the salt pond, open the steam valve at the bottom of the pond. Start steaming for 55 minutes, starting when steam appears on the surface of the salt pile. This kills microorganisms in the salt and reduces the bacterial content in the soy sauce. After dry-steaming, the salt is converted into saturated brine and pumped into a saturated brine tank. The brine concentration is pre-adjusted to 26g / 100ml. Filter and sterilize the brine using a 0.20μm pore size ceramic membrane before entering a refrigerator. The brine temperature is adjusted to 5°C in the refrigerator (the brine temperature is based on the 13-15°C temperature of the mash after koji formation). S4.2. Mash making: Add 0.07% of the total weight of the raw materials to the filtered brine and mix thoroughly. Then, mix the cultured koji and brine thoroughly using a mixing auger and pump them into the fermentation tank. (After the koji is pumped out, flush the delivery pipe with the remaining brine, then clean the pipe with a sponge and compressed air.) S4.3, Fermentation; Day 1: Add the finished koji to the tank while stirring it with the air pipe alternately to keep the sauce mash evenly turned. After adding it to the tank, stir it with air once for 30 minutes; stir it again after 4.5 hours for 30 minutes; (The stirring time can be shortened or extended depending on the stirring uniformity; the stirring uniformity is the standard.) Day 2-3: Stir once in the morning and once in the afternoon for 30 minutes, with an interval of no less than 4 hours between the two stirrings; Day 4-7: Stir once a day for 10 minutes; Day 7: Re-check the salt content of the mash. If the error exceeds the standard by 0.5%, make adjustments in a timely manner. Thereafter, samples will be taken every 15 days to test the indicators of the sauce mash, and depending on the surface condition of the sauce mash, it will be gently stirred every 8 days to "eliminate mold", and the stirring should be done until no white film is visible on the surface.

[0031] When making mash, a composite clarification enzyme is used to promote fermentation. The enzyme activity of the composite clarification enzyme is 10,000 u / g. The composite clarification enzyme contains phytase, cellulase, and xylanase. The mass ratio of phytase, cellulase, and xylanase is 8:1:1. Each tank of fermented mash needs to be added with 2% of the total raw material amount of flavoring yeast, and the yeast count is required to be ≥ 300 million / ml. After adding the flavoring yeast, stir continuously for 3 days, once a day, one cycle each time, and each air tube for 1 minute.

[0032] In S4.3, the temperature management requirements for fermentation are as follows: The tank temperature is required to be 14°C; Keep the temperature at 13-15℃ for 1-15 days after adding the fermenter. Start to raise the temperature on the 16th day. The heating method is: turn on the fermenter heating and insulation system, control the hot water temperature to 55-65℃, and circulate the hot water to raise the temperature. Stir once every 3-4 days during the heating process, that is, stir once a cycle, the stirring time is 5 minutes, and each air pipe is 1 minute; Gradually raise the temperature to 30°C from 16 to 30 days and maintain this temperature for about 45 days. When the amino acid content stops increasing, the primary fermentation is over. After the primary fermentation is completed, add flavoring yeast, control the temperature at 28-30℃, and ferment for 18 days. When the surface of the mash becomes calm, it means that the yeast fermentation is complete and the secondary fermentation is over.

[0033] As a further solution of the present invention: the fermentation period is 75 days.

[0034] S5, pressing; after the fermentation is completed, the fermented mash is filtered using a vertical press to collect the raw soy sauce and the soy sauce residue; S6. Sterilization and filling: pump the raw soy sauce into the mixing and sterilization pot, heat it to 92℃, keep it warm for 40 minutes, cool it to 63℃, and put it into the sedimentation tank. After 5 days, take the supernatant; filter the bottom precipitate with diatomaceous earth to obtain the filtered supernatant, mix the supernatant and the filtered supernatant, and then fill it.

[0035] The remaining operation steps and parameter settings are the same as those in Example 1 and will not be repeated here.

[0036] Example 3 In this embodiment, a high-efficiency enzymatic fermentation soy sauce production process includes the following process steps: S1. Prepare ingredients: soybean meal made from defatted soybeans, wheat, salt, fried wheat flour, α-amylase, soy sauce koji, flavoring yeast, and water; S2, steaming; this step includes feeding, dry steaming, moistening, wet steaming, pressure relief, vacuuming and opening the cover to discharge the material; the mass ratio of soybean meal to wheat used in the steaming step is 55:45; S2.1. Adding materials: Add soybean meal and wheat to the steamer, seal the lid tightly, and turn the steamer. S2.2, Dry steaming: Open the steam valve and perform dry steaming three times, with the pressure controlled from 0 MPa to 0.1 MPa to 0 MPa to 0.1 MPa to 0 MPa to 0.16 MPa to 0 MPa. When the exhaust pressure reaches 0 MPa for the last time, close the exhaust valve; S2.3, water conditioning: add 0.1kg of high-temperature resistant α-amylase to every 1000L of room temperature water, where the α-amylase activity is 100,000 u / g. After the water is filled, rotate the ball for 3 more turns, then open the exhaust valve to release the negative pressure to 0, close the exhaust valve, and continue to rotate the ball for water conditioning for 15 minutes. The total water conditioning time from the completion of water filling is 20 minutes; S2.4, wet steaming: the steaming pressure is 0.1 MPa for the first time, 0.1 MPa for the second time, and 0.16 MPa for the third time. Start timing from the pressure of 0.12 MPa and maintain the pressure for 12 minutes; S2.5, Pressure relief: After the steam material pressure is maintained, close the steam inlet valve, open the exhaust valve to exhaust the steam until the pressure reaches 0 MPa, and close the exhaust valve; S2.6, Vacuuming: First turn on the vacuum pump, then open the vacuum valve, and evacuate to 60°C; open the exhaust valve to release the pressure to 0 MPa, then turn off the vacuum pump, and then close the vacuum valve; S2.7. Open the lid and steam the ingredients into balls.

[0037] S3, inoculation; This step includes cooling the material, inoculation, mixing with wheat flour and adding koji; 3.1. Discharge cooling: Open the discharge port of the steamer ball, start the conveying auger, and let the steamed material pass through the conveyor belt into the cooling fan for cooling; 3.2. Inoculation, mixing with wheat flour and adding koji: 0.05% of the total mass of the raw materials by weight of Aspergillus oryzae koji essence and 0.03% of the total mass of the raw materials by weight of papain are mixed with fried wheat flour and then introduced into the inoculator. The mixture is mixed with the fried wheat flour through an inoculating auger. The activity of papain is 600,000 u / g and the amount of fried wheat flour is 25±2 kg per ball. The evenly mixed material is then dropped into the koji-making disc through a conveyor belt. The material is flattened and evenly spread while being added. The thickness of each layer is 5 cm. The inoculation temperature is less than 38°C, where the inoculation temperature is the outlet temperature of the inoculating auger.

[0038] In S3, after the koji material is put into the tray, it should be spread evenly to prevent local compaction. The temperature of each part should be measured with a thermometer to ensure uniformity. The koji material should be flattened with circulating air. The temperature of the koji material should be kept between 24℃ and 36℃ for incubation. Koji making temperature control requirements: Early stage: 1-12 hours, temperature controlled at 30±30℃; Mid-term: 13-24 hours, temperature controlled at 32±40℃; Late stage: 25-44 hours, temperature controlled at 26±2℃; Koji making and turning management requirements: The first turning should be done 14 hours after feeding, and the second turning should be done 20 hours after feeding; the turning should be done according to the actual growth conditions; if the temperature exceeds 35℃, cracks or air leakage occurs during the making process, the koji should be turned immediately; the making time should be 44 hours, and the room temperature should be kept constant and the indoor air humidity should be above 92%; Quality requirements for finished koji: The finished koji should be light yellow, have the normal aroma of Aspergillus oryzae, no peculiar smell, and the protease activity measured by formaldehyde method should be above 1000U / g.

[0039] S4, mash making and fermentation; S4.1. Preparation of brine: Dry-steam salt: After placing salt in the salt pond, open the steam valve at the bottom of the pond and start steaming for 60 minutes, starting when steam appears on the surface of the salt pile. This kills microorganisms in the salt and reduces the bacterial content in the soy sauce. After dry-steaming, the salt is converted into saturated brine and pumped into a saturated brine tank. The brine concentration is pre-adjusted to 26g / 100ml. Filter and sterilize the brine using a 0.22μm pore size ceramic membrane before entering a refrigerator. The brine temperature is adjusted to 6°C in the refrigerator (the brine temperature is based on the 13-15°C temperature of the mash after koji formation). S4.2. Mash making: Add 0.1% of the total weight of the raw materials to the filtered brine and mix thoroughly. Then, mix the cultured koji and brine thoroughly using a mixing auger and pump them into the fermentation tank. (After the koji is pumped out, flush the delivery pipe with the remaining brine, then clean the pipe with a sponge and compressed air.) S4.3, Fermentation; Day 1: Add the finished koji to the tank while stirring it with the air pipe alternately to keep the sauce mash evenly turned. After adding it to the tank, stir it with air once for 30 minutes; stir it again after 5 hours for 30 minutes; (The stirring time can be shortened or extended depending on the stirring uniformity; the stirring uniformity is the standard.) Day 2-3: Stir once in the morning and once in the afternoon for 30 minutes, with an interval of no less than 4 hours between the two stirrings; Day 4-7: Stir once a day for 10 minutes; Day 7: Re-check the salt content of the mash. If the error exceeds the standard by 0.5%, make adjustments in a timely manner. Thereafter, samples will be taken every 15 days to test the indicators of the sauce mash, and depending on the surface condition of the sauce mash, it will be gently stirred once every 10 days to "eliminate mold", and the stirring should be done until no white film is visible on the surface.

[0040] When making mash, a composite clarification enzyme is used to promote fermentation. The enzyme activity of the composite clarification enzyme is 10,000 u / g. The composite clarification enzyme contains phytase, cellulase, and xylanase. The mass ratio of phytase, cellulase, and xylanase is 8:1:1. Each tank of fermented mash needs to be added with 2% of the total raw material amount of flavoring yeast, and the yeast count is required to be ≥ 300 million / ml. After adding the flavoring yeast, stir continuously for 3 days, once a day, one cycle each time, and each air tube for 1 minute.

[0041] In S4.3, the temperature management requirements for fermentation are as follows: The tank temperature should be 13-15℃; Keep the temperature at 13-15℃ for 1-15 days after adding the fermenter. Start to raise the temperature on the 16th day. The heating method is: turn on the fermenter heating and insulation system, control the hot water temperature to 55-65℃, and circulate the hot water to raise the temperature. Stir once every 3-4 days during the heating process, that is, stir once a cycle, the stirring time is 5 minutes, and each air pipe is 1 minute; Gradually raise the temperature to 30°C from 16 to 30 days and maintain this temperature for about 45 days. When the amino acid content stops increasing, the primary fermentation is over. After the primary fermentation is completed, add flavoring yeast, control the temperature at 28-30℃, and ferment for 15-20 days. When the surface of the mash is calm, it means that the yeast fermentation is complete and the secondary fermentation is over.

[0042] As a further solution of the present invention: the fermentation period is 60 days.

[0043] S5, pressing; after the fermentation is completed, the fermented mash is filtered using a vertical press to collect the raw soy sauce and the soy sauce residue; S6. Sterilization and filling: pump the raw soy sauce into the mixing and sterilization pot, heat it to 90-95℃, keep it warm for 30-60 minutes, cool it to 60-65℃, and put it into the sedimentation tank. After 2-7 days, take the supernatant; filter the bottom precipitate with diatomaceous earth to obtain the filtered supernatant, mix the supernatant and the filtered supernatant, and then fill it.

[0044] The remaining operation steps and parameter settings are the same as those in Example 1 and will not be repeated here.

[0045] Comparative Example 1 In this comparative example, no thermostable α-amylase was used in the S2 steaming step, and a conventional process without enzyme addition was adopted.

[0046] The remaining operation steps and parameter settings are the same as those in Example 1 and will not be repeated here.

[0047] Comparative Example 2 In this comparative example, Aspergillus oryzae koji and papain were not used in the S3 inoculation step, but only ordinary koji was used.

[0048] The remaining operation steps and parameter settings are the same as those in Example 1 and will not be repeated here.

[0049] Comparative Example 3 In this comparative example, no composite clarification enzyme was used in the S4 mash preparation and fermentation step, and conventional fermentation without enzyme addition was adopted.

[0050] The remaining operation steps and parameter settings are the same as those in Example 1 and will not be repeated here.

[0051] Product testing experiments Table 1 Test results of Examples 1-3 and Comparative Examples 1-3

[0052] During the starch breakdown process by α-amylase, the color reaction with iodine solution gradually changes with the changes in starch structure, as follows: Initial stage: When the starch is not broken down, starch molecules (especially amylose) combine with the iodine solution to form a blue complex, resulting in a dark blue color. Mid-decomposition stage: α-amylase gradually breaks down the starch into smaller dextrins (such as purple dextrin and red dextrin). At this point, the reaction with iodine solution causes the color to gradually change from dark blue to purple or purple-red. Late decomposition stage: As decomposition continues, dextrins are further broken down into smaller molecules such as maltose. These molecules are unable to form stable colored complexes with the iodine solution, and the color eventually fades, revealing the pale yellow color of the iodine solution itself. This change intuitively reflects the extent of starch breakdown by α-amylase: darker colors indicate more undecomposed starch, while lighter or faded colors indicate more complete decomposition. As shown in Table 1, the addition of thermostable α-amylase in Examples 1-3 and Comparative Examples 2-3 resulted in more complete starch decomposition.

[0053] While ensuring all indicators and flavor of soy sauce, the present invention shortens the fermentation cycle from 4-6 months to 2-3 months, and increases protein utilization from 85-88% to 92%. This maximizes benefits: the amount of sediment in the soy sauce after sterilization is reduced from 4-6% to 2-3%, and the amount of clarified liquid is increased by 2-3%, eliminating the risk of secondary precipitation during shelf life. It also eliminates the need for filtration equipment or increases the filtration capacity of the filtration equipment, reducing consumables by 50%. In short, the present invention ensures flavor, improves protein utilization, reduces costs, and increases profits, thereby comprehensively maximizing the benefits for all parties.

[0054] The above is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with this technical field, within the technical scope disclosed by the present invention, can make equivalent replacements or changes based on the technical solutions and inventive concepts of the present invention, which should be covered by the scope of protection of the present invention.

Claims

1. A high-efficiency enzymatic fermentation soy sauce production process, characterized in that: The process steps include: S1. Prepare ingredients: soybean meal made from defatted soybeans, wheat, salt, fried wheat flour, α-amylase, soy sauce koji, flavoring yeast, and water; S2, steaming; this step includes feeding, dry steaming, moistening, wet steaming, pressure relief, vacuuming and opening the cover to discharge the material; the mass ratio of soybean meal to wheat used in the steaming step is 55:45; S3, inoculation; This step includes cooling the material, inoculation, mixing with wheat flour and adding koji; S4, mash making and fermentation; using a composite clarification enzyme to promote fermentation during mash making, the enzyme activity of the composite clarification enzyme is 10000u / g, and the composite clarification enzyme comprises phytase, cellulase, and xylanase, and the mass ratio of phytase, cellulase, and xylanase is 8:1:1; S5, pressing; after the fermentation is completed, the fermented mash is filtered using a vertical press to collect the raw soy sauce and the soy sauce residue; S6. Sterilization and filling: pump the raw soy sauce into the mixing and sterilization pot, heat it to 90-95℃, keep it warm for 30-60 minutes, cool it to 60-65℃, and put it into the sedimentation tank. After 2-7 days, take the supernatant; filter the bottom precipitate with diatomaceous earth to obtain the filtered supernatant, mix the supernatant and the filtered supernatant, and then fill it.

2. A high-efficiency enzymatic fermentation soy sauce production process according to claim 1, characterized in that: S2 includes the following steps: S2.

1. Adding materials: Add soybean meal and wheat to the steamer, seal the lid tightly, and turn the steamer. S2.2, Dry steaming: Open the steam valve and perform dry steaming three times, with the pressure controlled from 0 MPa to 0.1 MPa to 0 MPa to 0.1 MPa to 0 MPa to 0.12-0.16 MPa to 0 MPa. When the exhaust pressure reaches 0 MPa for the last time, close the exhaust valve; S2.3, water moistening: add 0.1kg of high-temperature resistant α-amylase to every 1000L of room temperature water, where the α-amylase activity is 100,000 u / g. After the water is filled, turn the ball three times, then open the exhaust valve to release the negative pressure to 0, close the exhaust valve, and continue to turn the ball to moisten the water for 10-15 minutes. The total water moistening time from the completion of water filling is 15-20 minutes; S2.4, wet steaming: the steaming pressure is 0.1 MPa for the first time, 0.1 MPa for the second time, and 0.12-0.16 MPa for the third time. Start timing from the pressure of 0.12 MPa and maintain the pressure for 8-12 minutes; S2.5, Pressure relief: After the steam material pressure is maintained, close the steam inlet valve, open the exhaust valve to exhaust the steam until the pressure reaches 0 MPa, and close the exhaust valve; S2.6, Vacuuming: First turn on the vacuum pump, then open the vacuum valve, and evacuate to 60-55℃; open the exhaust valve to release the pressure to 0 MPa, then turn off the vacuum pump, and then close the vacuum valve; S2.

7. Open the lid and steam the ingredients into balls.

3. A high-efficiency enzymatic fermentation soy sauce production process according to claim 1, characterized in that: S3 includes the following steps: 3.

1. Discharge cooling: Open the discharge port of the steamer ball, start the conveying auger, and let the steamed material pass through the conveyor belt into the cooling fan for cooling; 3.

2. Inoculation, mixing with wheat flour and adding koji: 0.03-0.05% of the total mass of the raw materials by weight of Aspergillus oryzae koji essence and 0.02-0.03% of the total mass of the raw materials by weight of papain are mixed with fried wheat flour and then introduced into the inoculator, and mixed with the fried wheat flour through an inoculation auger. The activity of papain is 600,000 u / g, and the amount of fried wheat flour is 25±2 kg per ball. The evenly mixed material is then dropped into the koji-making disc through a conveyor belt, and is flattened and evenly spread while being added. The thickness of each layer is 4-5 cm. The inoculation temperature is less than 38°C, and the inoculation temperature is the outlet temperature of the inoculation auger.

4. A high-efficiency enzymatic fermentation soy sauce production process according to claim 3, characterized in that: In S3, after the koji material is put into the tray, it should be spread evenly to prevent local compaction. The temperature of each part should be measured with a thermometer to ensure uniformity. The koji material should be flattened with circulating air. The temperature of the koji material should be kept between 24℃ and 36℃ for incubation. Koji making temperature control requirements: Early stage: 1-12 hours, temperature controlled at 30±30℃; Mid-term: 13-24 hours, temperature controlled at 32±40℃; Late stage: 25-44 hours, temperature controlled at 26±2℃.

5. A high-efficiency enzymatic fermentation soy sauce production process according to claim 4, characterized in that: Koji making and turning management requirements: The first turning should be done 10-14 hours after adding the materials, and the second turning should be done 14-20 hours after adding the materials. The turning should be done according to the actual growth conditions. If the temperature exceeds 35℃, cracks or air leakage occurs during the making process, the koji should be turned immediately. The making time should be 40-44 hours, and the room temperature should be kept constant and the indoor air humidity should be above 92%. Quality requirements for finished koji: The finished koji should be light yellow, have the normal aroma of Aspergillus oryzae, no peculiar smell, and the protease activity measured by formaldehyde method should be above 1000U / g.

6. The high-efficiency enzymatic fermentation soy sauce production process according to claim 1, characterized in that: S4 includes the following steps: S4.

1. Preparation of brine: Dry steaming salt: After placing salt in the salt pond, open the steam valve at the bottom of the pond and start steaming for 50-60 minutes, starting when steam appears on the surface of the salt pile. This kills microorganisms in the salt and reduces the bacterial content in the soy sauce. After dry steaming, the salt is converted into saturated brine and pumped into a saturated brine tank. The brine concentration is pre-adjusted to 24.5-26g / 100ml. The brine is filtered and sterilized using a ceramic membrane with a pore size of 0.18-0.22μm before entering a refrigerator. The brine temperature is adjusted to 4-6°C using the refrigerator. S4.2, mash making; add 0.05-0.1% of the total mass of the raw materials to the filtered brine, mix evenly, then mix the cultured koji and brine evenly through a mixing auger, and pump into the fermentation tank; S4.3, Fermentation; Day 1: Add the finished koji to the tank while stirring it with the air pipe alternately to keep the sauce mash evenly turned. After adding it to the tank, stir it with air once for 30 minutes; stir it again after 4-5 hours for 30 minutes; Day 2-3: Stir once in the morning and once in the afternoon for 30 minutes, with an interval of no less than 4 hours between the two stirrings; Day 4-7: Stir once a day for 10 minutes; Day 7: Re-check the salt content of the mash. If the error exceeds the standard by 0.5%, make adjustments in a timely manner. Thereafter, samples should be taken every 15 days to test the indicators of the mash, and depending on the surface condition of the mash, it should be gently stirred every 7-10 days to "eliminate mold", and the stirring should be done until no white film is visible on the surface.

7. The high-efficiency enzymatic fermentation soy sauce production process according to claim 6, characterized in that: During the fermentation period, flavoring yeast is added: each tank of fermented mash needs to add 2% of the total raw material amount of flavoring yeast, and the yeast count is required to be ≥ 300 million / ml; after adding the flavoring yeast, stir continuously for 3 days, once a day, one cycle each time, and each air tube for 1 minute.

8. The high-efficiency enzymatic fermentation soy sauce production process according to claim 6, characterized in that: In S4.3, the temperature management requirements for fermentation are as follows: The tank temperature should be 13-15℃; Keep the temperature at 13-15℃ for 1-15 days after adding the fermenter. Start to raise the temperature on the 16th day. The heating method is: turn on the fermenter heating and insulation system, control the hot water temperature to 55-65℃, and circulate the hot water to raise the temperature. Stir once every 3-4 days during the heating process, that is, stir once a cycle, the stirring time is 5 minutes, and each air pipe is 1 minute; Gradually raise the temperature to 30°C from 16 to 30 days and maintain this temperature for about 45 days. When the amino acid content stops increasing, the primary fermentation is over. After the primary fermentation is completed, add flavoring yeast, control the temperature at 28-30℃, and ferment for 15-20 days. When the surface of the mash is calm, it means that the yeast fermentation is complete and the secondary fermentation is over.

9. The high-efficiency enzymatic fermentation soy sauce production process according to claim 1, characterized in that: Fermentation cycle is 60-90 days.

Images