A soy sauce koji making method for reducing total number of koji molds through a synergistic process

Abstract

The present application relates to the field of soy sauce koji making, and particularly to a soy sauce koji making method for reducing total number of Aspergillus oryzae colonies through a synergistic process. The method comprises the following steps: equipment cleaning, feeding and early stage cultivation, first-time loose koji making, mid-stage temperature control, second-time loose koji making, and late stage temperature control. The present application uses a high-pressure water gun and micro-acid electrolytic water to deeply clean the equipment, controls the temperature in stages during the koji making process, and delays the loose koji making time, so that the three factors of cleaning, temperature control, and loose koji making timing synergistically work together to jointly inhibit the growth of miscellaneous bacteria, thereby stably controlling the total number of Aspergillus oryzae colonies at ≤10 7 CFU / g level.

Description

Technical Field

[0001] This invention relates to the field of soy sauce koji making, and in particular to a method for reducing the total number of koji colonies in soy sauce through a synergistic process. Background Technology

[0002] Traditional soy sauce koji-making methods suffer from incomplete cleaning and a lack of effective sterilization, resulting in a poor koji-cultivation environment. Furthermore, the absence of a reasonable integrated process for temperature and koji-releasing time control leads to issues such as excessively high temperatures and premature koji-releasing times. This results in a high total bacterial count in the finished koji, generally exceeding 10%. 8 Level, even 10 9 level.

[0003] Therefore, the traditional soy sauce koji-making process has the following main technical defects, which lead to a generally high total bacterial count in the finished koji (usually 10). 8 CFU / g, even reaching 10 9 CFU / g level), which in turn affects subsequent fermentation efficiency and soy sauce quality: (1) Incomplete cleaning and disinfection: Existing technologies mostly use low-pressure water (<10 kg) to rinse or simply clean the koji-making equipment (such as koji tanks, blowers, koji turning machines, etc.), which is difficult to completely remove the accumulated material and biofilm in the gaps and corners of the equipment. The lack of an effective disinfection process leads to a large number of bacteria remaining in the environment, which poses a risk of contamination to the koji seed at the beginning of koji making and creates hidden dangers for the subsequent growth of bacteria.

[0004] (2) Inappropriate temperature control strategy: Traditional processes have a relatively crude temperature control during the koji-making process. In particular, the temperature was not effectively maintained in the early stage of feeding (the first 10 hours), resulting in a low temperature in the early stage. This was not conducive to the rapid growth of beneficial bacteria such as Aspergillus oryzae into dominant bacteria, but instead created opportunities for the reproduction of miscellaneous bacteria. At the same time, in the middle and later stages, especially after the loosening of koji, the temperature was not controlled in a timely and precise manner within a suitable range, resulting in an excessively high temperature, which further aggravated the reproduction of miscellaneous bacteria and the increase in the total number of colonies.

[0005] (3) Inappropriate timing of loosening the koji: Traditional loosening time settings fail to effectively link with temperature control. The first loosening time is too early, when mycelial growth is insufficient and the koji material is only slightly compacted, so the loosening has limited effect on improving air permeability. Similarly, the second loosening time lacks coordination with the temperature curve, making it difficult to effectively control the temperature of the koji material after loosening. Instead, the disturbance promotes the spread and growth of miscellaneous bacteria. For example, the first loosening is carried out after 10-12 hours of cultivation, and the second loosening is carried out after 18-20 hours of cultivation. Moreover, these parameters are independent of the temperature control strategy and do not form a linkage. Summary of the Invention

[0006] To solve the above-mentioned technical problems, the purpose of this invention is to provide a method for making soy sauce koji by reducing the total number of koji colonies through a synergistic process.

[0007] The technical solution adopted by this invention to solve the problem is: a method for making soy sauce koji by reducing the total number of koji colonies through a synergistic process, comprising the following steps: S1. Equipment cleaning: Use high-pressure water with a pressure of 30-50 kg to clean the curvature tank, then disinfect it with disinfectant and drain it.

[0008] S2. Feeding and initial cultivation: The inoculated koji material is put into the tank, and the material temperature is controlled to 26-30℃ in the first 12 hours after feeding.

[0009] S3, First loosening: The first loosening is carried out 15-16 hours after the start of cultivation.

[0010] S4. Mid-term temperature control: Control the temperature of the koji material between the first and second loosening processes to not exceed 38℃.

[0011] S5. Second loosening: The second loosening is carried out 22-24 hours after the start of cultivation.

[0012] S6. Post-fermentation temperature control: After the second loosening of the fermentation process, control the temperature at 25-30℃ until the fermentation is completed.

[0013] As a further improvement to the above technical solution, in step S1, the output flow rate of the high-pressure water is 50-70 L / min.

[0014] As a further improvement to the above technical solution, in step S1, the disinfectant is slightly acidic electrolyzed water, and the concentration of the slightly acidic electrolyzed water is 50-150 ppm.

[0015] As a further improvement to the above technical solution, in step S1, the concentration of the slightly acidic electrolyzed water is 80-100 ppm.

[0016] As a further improvement to the above technical solution, in step S2, the initial culture time is the first 10 hours after feeding.

[0017] As a further improvement to the above technical solution, in step S3, the first loosening time is 15-15.5 hours after the start of cultivation.

[0018] As a further improvement to the above technical solution, in step S5, the second loosening time is 22-23 hours after the start of cultivation.

[0019] As a further improvement to the above technical solution, in step S6, the fermentation time is 32 hours after the start of cultivation.

[0020] The beneficial effects of this invention are as follows: By using a high-pressure water gun and a slightly acidic electrolyzed water deep cleaning device, controlling the temperature in stages during the koji-making process, and delaying the loosening time, the invention achieves synergistic effects of cleaning, temperature control, and the timing of loosening, thereby inhibiting miscellaneous bacteria and stably controlling the total bacterial count of the koji to ≤10. 7 CFU / g level. Attached Figure Description

[0021] The present invention will be further explained and described below with reference to the accompanying drawings and specific embodiments.

[0022] Figure 1 This is a schematic diagram of the process of the present invention. Detailed Implementation

[0023] In all embodiments of the present invention, unless otherwise emphasized, temperature and pressure are at normal temperature and pressure. Unless otherwise specified, the equipment can be used according to conventional settings.

[0024] It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the invention.

[0025] like Figure 1 As shown, a method for reducing the total bacterial count in soy sauce koji production through a synergistic process includes the following steps: S1. Deep cleaning and disinfection of equipment: Before each batch of koji making begins, perform the following operations on the koji making equipment (including but not limited to koji tanks, incubators, koji turning machines, air ducts, floors, etc.): S11. High-Pressure Flushing: Use an ultra-high-pressure water gun to thoroughly flush the equipment surface, crevices, and dead corners. Key parameters are: water pressure 30-50 kg, water flow rate 50-70 liters / minute. The purpose of this step is to use the impact force of the high-pressure water flow to peel off and wash away residual substrate, mycelium, and biofilm.

[0026] S12. Electrolyzed Water Disinfection: After high-pressure rinsing, immediately spray or rinse the equipment thoroughly with slightly acidic electrolyzed water at a concentration of 50ppm-150ppm for disinfection. Electrolyzed water has broad-spectrum bactericidal properties, leaves no residue, and is harmless to humans and animals, effectively killing any remaining microorganisms. No further rinsing is required after disinfection; simply allow it to air dry naturally or blow dry.

[0027] S2. Feeding and Initial Culture: S21. Feeding: Mix the cooked and cooled raw materials with the starter culture evenly and send it into the cleaned and disinfected starter culture tank.

[0028] S22. Initial Temperature Control: Immediately after feeding, activate the temperature control system. Focus on controlling the temperature for the first 12 hours after feeding, ensuring it does not fall below 25℃ and remains stably within the suitable range of 26-30℃. The purpose of temperature control at this stage is to provide the optimal temperature for Aspergillus oryzae spore germination and initial mycelial growth, allowing it to quickly become the dominant microbial population and inhibiting the germination of other microorganisms.

[0029] S3, First Loosening and its Synergy: S31. Delayed loosening of koji: Changing the traditional practice of loosening koji too early, the first loosening of koji is delayed until 15-16 hours after the start of cultivation. At this time, the Aspergillus oryzae mycelium has grown to a certain extent, and the koji material begins to turn white and has a certain degree of compaction.

[0030] S32. Loosening operation: Start the turning machine to loosen the koji for the first time. The purpose is to break up the koji material, increase the air permeability between the material layers, and release the accumulated CO2 and heat.

[0031] S4. Mid-term cultivation and temperature control before the second loosening of the bending process: S41. Cultivation after loosening: After the first loosening, Aspergillus oryzae enters a rapid growth period with vigorous metabolism and high heat production.

[0032] S42. Strict Temperature Control: The key at this stage (before the second loosening of the koji) is to prevent the product temperature from becoming too high. It is essential to ensure that the koji temperature does not exceed 38℃ by adjusting the ventilation volume and temperature. Exceeding this limit will greatly promote the growth of heat-resistant bacteria.

[0033] S5, Second Songqu and its Synergies: S51, Delayed loosening: The second loosening should be carried out 22-24 hours after the start of cultivation.

[0034] S52. Loosening the koji: Perform a second loosening operation to further break up the koji material and ensure that the material layer is loose and the air is evenly ventilated throughout the koji-making process.

[0035] S6. Late-stage culture and temperature control: S61. Temperature control after loosening the mold: After the second loosening of the mold, the bacterial growth tends to mature and the heat production gradually decreases.

[0036] S62. Precise Cooling: At this stage, the material temperature needs to be controlled within the range of 25-30℃, and not higher than 30℃. This temperature range is conducive to the accumulation and maturation of various enzymes in Aspergillus oryzae, while inhibiting the secondary growth of miscellaneous bacteria in the later stages of koji making. Maintain this temperature until the end of koji making (usually around 30 hours).

[0037] S7. Producing the starter culture: Complete the entire starter culture production cycle and obtain starter culture with a significantly reduced total bacterial count.

[0038] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0039] Example 1: S1. Equipment cleaning: Thoroughly clean the flute using an ultra-high pressure water gun with a water pressure of 35 kg and a water flow rate of 60 L / min, then spray it with 100 ppm slightly acidic electrolyzed water for comprehensive disinfection, and let it drain naturally.

[0040] S2. Feeding and initial cultivation: The inoculated koji material is fed into the tank, and the material temperature is controlled at 28℃ for the first 10 hours.

[0041] S3, First loosening: The first loosening is carried out 15.5 hours after the start of cultivation.

[0042] S4. Mid-term temperature control: After the first loosening of the koji, adjust the ventilation to ensure that the temperature of the koji does not exceed 37℃.

[0043] S5. Second loosening: The second loosening is carried out 23 hours after the start of cultivation.

[0044] S6. Temperature control in the later stage: After the second loosening of the koji, the temperature is controlled at 28℃ until the koji is produced after 32 hours, thus obtaining Example 1.

[0045] Example 2: S1. Equipment cleaning: Thoroughly clean the flute using an ultra-high pressure water gun with a water pressure of 35 kg and a water flow rate of 60 L / min, then spray it with 80 ppm slightly acidic electrolyzed water for comprehensive disinfection, and let it drain naturally.

[0046] S2. Feeding and initial cultivation: The inoculated koji material is fed into the tank, and the material temperature is controlled at 28℃ for the first 10 hours.

[0047] S3, First loosening: The first loosening is carried out 16 hours after the start of cultivation.

[0048] S4. Mid-term temperature control: After the first loosening of the koji, adjust the ventilation to ensure that the temperature of the koji does not exceed 37℃.

[0049] S5. Second loosening: The second loosening is carried out 24 hours after the start of cultivation.

[0050] S6. Temperature control in the later stage: After the second loosening of the koji, the temperature is controlled at 28°C until the koji is produced after 32 hours, thus obtaining Example 2.

[0051] Comparative Example 1 (Traditional Process): A1. Equipment cleaning: Rinse the flute with low-pressure water, do not disinfect, and let it drain naturally.

[0052] A2. Feeding: The inoculated koji material is fed into the tank, and the temperature is controlled at a constant 30℃ throughout the process.

[0053] A3. First loosening: The first loosening is carried out 11 hours after the start of cultivation.

[0054] A4. Second loosening: The second loosening is carried out 19 hours after the start of cultivation, until the koji is produced after 32 hours, to obtain Comparative Example 1.

[0055] Comparative Example 2 (Lack of Synergy): A1. Equipment cleaning: Thoroughly clean the flute using an ultra-high pressure water gun with a water pressure of 35 kg and a water flow rate of 60 L / min, then spray it with 100 ppm slightly acidic electrolyzed water for comprehensive disinfection, and let it drain naturally.

[0056] A2. Feeding: The inoculated koji material is fed into the tank, and the temperature is controlled at a constant 30℃ throughout the process.

[0057] A3. First loosening: The first loosening is carried out 11 hours after the start of cultivation.

[0058] A4. Second loosening: The second loosening is carried out 19 hours after the start of cultivation, until the koji is produced after 32 hours, to obtain Comparative Example 2.

[0059] The total bacterial count of Example 1, Example 2, Comparative Example 1, and Comparative Example 2 obtained by the above method was determined, and the test results are as follows:

[0060] The data in the table shows that the total number of colonies in Comparative Example 2 obtained using only the cleaning method of this invention was 7.6 x 10⁻⁶. 7 While superior to Comparative Example 1 (traditional process), it is still significantly higher than the levels of Examples 1 and 2, which employ the complete process of this invention. This indicates that optimal results can only be achieved when cleaning and disinfection, segmented precise temperature control, and delayed loosening work synergistically, reducing the total bacterial count to 10. 6 CFU / g. The results of Comparative Example 2 demonstrate the limitations of a single cleaning method, while Examples 1 and 2 demonstrate the significant technological advancements brought about by the synergistic process claimed in this invention.

[0061] Furthermore, by comparing Example 1 and Example 2, it can be seen that the concentration of slightly acidic electrolyzed water and the specific loosening time will further affect the total number of Daqu colonies. Therefore, the applicant has also conducted a preliminary study on the effect of the specific concentration of slightly acidic electrolyzed water and the specific loosening time on the total number of Daqu colonies, but detailed and complete experimental data have not yet been formed. According to the existing data, when the concentration of slightly acidic electrolyzed water is controlled at 100-110 ppm, the first loosening time is controlled at 15-15.5 h, and the second loosening time is controlled at 22-23 h, the total number of Daqu colonies can be further reduced.

[0062] The above are merely preferred embodiments of the present invention and do not limit the patent scope of the present invention. All equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct or indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A method for reducing the total bacterial count in soy sauce koji production through a synergistic process, characterized in that, Includes the following steps: S1. Equipment cleaning: Clean the curvature tank with high-pressure water at a pressure of 30-50 kg, then disinfect it with disinfectant and drain it. S2. Feeding and initial cultivation: The inoculated koji material is put into the tank, and the material temperature is controlled to 26-30℃ in the first 12 hours after feeding. S3, First loosening: The first loosening is carried out 15-16 hours after the start of cultivation; S4. Mid-term temperature control: Control the temperature of the koji material between the first and second loosening processes to not exceed 38℃; S5. Second loosening: The second loosening is carried out 22-24 hours after the start of cultivation; S6. Post-fermentation temperature control: After the second loosening of the fermentation process, control the temperature at 25-30℃ until the fermentation is completed.

2. The soy sauce koji-making method for reducing the total bacterial count of koji through a synergistic process as described in claim 1, characterized in that: In step S1, the output flow rate of the high-pressure water is 50-70 L / min.

3. The soy sauce koji-making method for reducing the total bacterial count of koji through a synergistic process as described in claim 1, characterized in that: In step S1, the disinfectant is slightly acidic electrolyzed water with a concentration of 50-150 ppm.

4. The soy sauce koji-making method for reducing the total bacterial count of koji through a synergistic process as described in claim 3, characterized in that: The concentration of the slightly acidic electrolyzed water is 80-100 ppm.

5. The soy sauce koji-making method for reducing the total bacterial count of koji through a synergistic process as described in claim 1, characterized in that: In step S2, the initial culture time is the first 10 hours after feeding.

6. The soy sauce koji-making method for reducing the total bacterial count of koji through a synergistic process as described in claim 1, characterized in that: In step S3, the first loosening time is 15-15.5 hours after the start of cultivation.

7. The soy sauce koji-making method for reducing the total bacterial count of koji through a synergistic process as described in claim 1, characterized in that: In step S5, the second loosening time is 22-23 hours after the start of cultivation.

8. The soy sauce koji-making method for reducing the total bacterial count of koji through a synergistic process as described in claim 1, characterized in that: In step S6, the fermentation time is 32 hours after the start of cultivation.

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