Process technology for controlling acidity balance and enhancing flavor when manufacturing gochujang sauce

Abstract

The present invention relates to a technology for effectively controlling acidity balance when manufacturing fermented gochujang by mixing highly acidic ingredients, such as tomato concentrate or fruit concentrate, with fermented gochujang, thereby simultaneously preserving the unique fermented flavor, sweet and sour taste, and functional nutritional components (lycopene, vitamins, etc.) characteristic of gochujang. The concentrate is concentrated for a short time at 60 to 70°C, and the pH is partially buffered by adding minerals and carbonate salts before being mixed into the gochujang. During fermentation, pH fluctuations are monitored using a pH sensor and a dynamic pH monitoring system (PLC, etc.), and if necessary, trace amounts of buffering substances (CaCO₃, plant minerals, etc.) are added in stages to stabilize the pH within the 4.5-5.0 range. Through this, fermentation inhibition or loss of flavor caused by excessive acidity drop is prevented, and the inherent functional components (lycopene, vitamins, etc.) of the tomato (or fruits such as apples and pineapples) are preserved to the maximum extent, thereby obtaining a fusion gochujang sauce that is sweet and sour while harmonizing spicy and umami flavors. In addition, since it can be integrated with automated equipment (PLC / SCADA), consistent quality is guaranteed even during mass production. As described above, unlike existing patents related to gochujang and fermented pastes, the present invention provides a groundbreaking technology capable of stably producing sweet and sour fusion gochujang required in overseas markets by specifically presenting a buffering system that precisely controls pH during fermentation. In particular, it has the advantage of minimizing inhibition of fermentation microbial activity even when various fruit concentrates are used, and increasing the preservation rate of functional components and sensory satisfaction.

Description

Technology Field

[0001] The present invention belongs to the field of food manufacturing technology, and in particular, relates to a method for stably controlling pH fluctuations during the production of fermented gochujang or fusion gochujang (with the addition of tomatoes, fruit concentrates, other functional materials, etc.) to preserve fermented aroma, umami, and functional nutrients in an optimal state, while simultaneously achieving a balanced sweet and sour taste. pH balance control technology It is about. Background Technology

[0002] 1. Globalization and Scalability of Gochujang Sauce

[0003] 1. Global spread of traditional gochujang

[0004] Gochujang is a unique Korean fermented sauce that has been widely used in Korean cuisine. Recently, as global market interest in spicy flavors and fermented tastes has grown, export volumes have increased, and there is a growing number of instances overseas where gochujang is being incorporated into various dishes.

[0005] 2. Fusion Gochujang (Tomato, Fruit, etc.) Market

[0006] Fusion-style gochujang sauces, which enhance the sweet and sour flavor compared to regular gochujang by adding tomato or various fruit concentrates, are gaining popularity. They are attracting the attention of domestic and international consumers due to their wide range of applications, such as pasta sauces, salad dressings, salsa sauces, and barbecue sauces.

[0007] 3. A balance of acidity and fermented flavor is needed.

[0008] A sharp drop in pH caused by strong acidity from sources such as tomatoes and fruit juices can inhibit the activity of fermentation microorganisms or disrupt the unique spiciness and umami flavors of gochujang. Therefore, maintaining a stable pH balance is a key challenge for the commercialization of such fusion sauces.

[0009] 2. Acidity-related issues during conventional gochujang production

[0010] 1. Inhibition of fermentation due to sudden pH changes

[0011] Typically, for gochujang fermentation to proceed properly, a pH level of 4.5 to 5.5 must be maintained. However, if acidity drops excessively (e.g., pH 4.0 or lower), microbial activity decreases drastically or the growth of certain beneficial microorganisms becomes unstable, leading to a decline in flavor.

[0012] 2. The problem of acidity-spiciness balance

[0013] When highly acidic ingredients such as tomato, apple, or pineapple concentrates are added, there are cases where an incongruous clash occurs with the spiciness of the gochujang, or the spiciness becomes relatively weaker, disrupting the balance of flavors.

[0014] 3. Nutrient loss

[0015] When stored for a long period at a low pH, there is a high possibility that functional ingredients such as vitamins and lycopene will rapidly decompose or lose stability. This weakens the health benefits of the sauce and poses a risk of quality deterioration during storage.

[0016] 3. Comparison with Existing Patent Documents

[0017] KR10-1399279B1 , KR10-1388137B1 , KR10-1106585B1 , WO2015 / 080514A1 , US10,080,381B2 These were found as representative examples. While these documents each possess technical characteristics such as the production of fusion sauces using tomatoes and fruits (or sterilization processes, utilization of special fermentation strains), Dynamic pH monitoring and buffering during the fermentation process as in the present invention so Stabilize pH fluctuations within ±0.2 It does not present an original system.

[0018] 1. KR10-1399279B1 : Method for preparing gochujang sauce for tteokbokki (mixing tomato, apple juice, etc.)

[0019] 2. KR10-1388137B1 Strong acid-strong base process for improving sterilization efficiency of fermented food products

[0020] 3. KR10-1106585B1 : Chogochujang-based sauce composition for raw fish bibimbap

[0021] 4. WO2015 / 080514A1 / US10,080,381B2: Improvement of Gochujang fermentation quality with a new strain (Aspergillus oryzae variant)

[0022] Unlike these, the present invention, (i) low-temperature, short-time concentration, (ii) preliminary pH adjustment using natural minerals and carbonate salts, (iii) real-time pH measurement during fermentation and addition of small amounts of buffering material. By combining, Suppressing excessive acidity drop and Preservation of functional ingredients (lycopene, vitamins, etc.) It has a differentiated technical configuration capable of achieving [this] simultaneously. The problem to be solved

[0023] 1. Preventing excessive acidity drop

[0024] Even when adding low-acidity concentrates such as tomatoes, apples, and pineapples, the pH is controlled so that it does not drop below 4.0, thereby maintaining the activity of fermentation microorganisms and preserving the unique flavor and umami of gochujang.

[0025] 2. Securing dynamic pH monitoring and buffering systems

[0026] By monitoring real-time pH changes using pH sensors (PLC, SCADA) inside the fermentation tank, If the pH deviates from the standard range (4.3–5.5) Establish a system for automatically and manually splitting and injecting small amounts of buffer material.

[0027] 3. Maximizing nutrition and flavor

[0028] It preserves functional components such as lycopene and vitamin C from tomato and fruit concentrates to the maximum extent, and creates a fusion gochujang sauce that harmonizes spicy, sweet, and acidic flavors. means of solving the problem

[0029] 1. Concentrate pretreatment process

[0030] · Low temperature short-time concentration (60~70℃, within 30 minutes) : Minimizes nutrient destruction while increasing sugar content (°Bx) to secure viscosity.

[0031] · Add 0.1~0.5 wt% of mineral / carbonate salts (calcium, magnesium, calcium carbonate, etc.). : It slightly raises the pH of the concentrate itself beforehand to alleviate excessive acidity and suppresses a sharp drop in pH when mixed with gochujang.

[0032] 2. Acidity neutralization / buffering system during fermentation

[0033] · Mixture of Gochujang concentrate & pre-treated concentrate: Adjust the initial pH to 4.5~4.8 in the preliminary mixture.

[0034] · Dynamic pH monitoring : Log data by measuring with a pH sensor throughout the fermentation period (e.g., 14–30 days).

[0035] · small divided doses : When the pH is 4.3 or lower or 5.5 or higher, a buffering agent such as calcium carbonate (CaCO₃) or a Ca / Mg complex is added in increments of 0.01 to 0.02% several times.

[0036] 3. Design of flavor enhancement factors

[0037] · Fermentation temperature (25~30℃) It is beneficial for the enzymatic activity of microorganisms and inhibits the oxidative degradation of lycopene and vitamins.

[0038] · Salinity and sugar content correction It balances salt and sugars (such as oligosaccharides) to harmoniously maintain the unique sweet and sour taste of the ingredients with the spiciness and umami of gochujang.

[0039] · Limited heat treatment (70~75℃, 1015 min) Finally, a short sterilization process is applied to ensure safety. Effects of the invention

[0040] 1. Harmony of acidity and fermented aroma

[0041] The natural blend of tangy fruit flavors and fermented gochujang flavor is expected to be well-received in overseas markets as well.

[0042] 2. Minimize nutrient loss

[0043] The content of functional substances such as lycopene and vitamins is maintained at a high level through low-temperature concentration, pH control during fermentation, and limited heat treatment.

[0044] 3. Expanding the scope of application

[0045] In addition to tomatoes, the same technology can be applied to various fruit concentrates such as apples, pineapples, mangoes, and black raspberries to easily produce fusion sauce products.

[0046] 4. Industrial productivity and automation

[0047] Real-time pH monitoring and automatic correction during fermentation minimize quality variation and increase process efficiency, even during mass production. Brief explanation of the drawing

[0048] · Fig. 1 : Flowchart of the tomato concentrate pretreatment and buffer material blending process according to the present invention · Fig. 2 : Conceptual diagram of the dynamic pH monitoring system (PLC) · Fig. 3 : pH fluctuation graph for 1–14 days of fermentation (application of the present invention vs. control group) · Fig. 4 : Comparison graph of lycopene content during pretreatment process (low-temperature short-time concentration vs. general concentration) Specific details for implementing the invention

[0049] Preparation of Tomato Gochujang Using Tomato Concentrate and pH Control Test

[0050] 1. Ingredients and Formulation

[0051] · Gochujang concentrate : 70 parts by weight of already fermented traditional gochujang (salt content 10%, sugar content 28°Bx, pH 4.8)

[0052] Tomato concentrate : 60–65°Bx, pH 4.2, pretreatment: heat and concentrate at 60°C for 20 minutes

[0053] · mineral mixture (Calcium·Magnesium 1:1 ratio powder): 0.3 wt%

[0054] · Calcium carbonate powder (CaCO₃) : 0.1 wt%

[0055] · Sugars (oligosaccharides) : 5 wt%, Spices (paprika, etc.) : 0.5%

[0056] 2. Process sequence

[0057] · (a) Pretreatment of tomato concentrate :

[0058] · 1st Concentration: Fresh tomato juice is heated and concentrated at 60°C for about 20 minutes to reach a final sugar content of 60–65°Bx.

[0059] · After measuring the pH, dissolve and mix 0.3% of the mineral mixture and 0.1% of calcium carbonate to pre-adjust the pH to a range of approximately 4.2–4.3.

[0060] · Cool after filtration (100 mesh) to prevent microbial contamination.

[0061] · (b) Preliminary mixing :

[0062] · 70 parts by weight of gochujang concentrate, 30 parts by weight of pre-treated tomato concentrate, and sugars and spices are added and homogenized in a stirrer (300 rpm) for 10 minutes.

[0063] · When measuring the initial pH at this time, it was confirmed to be in the range of 4.5 to 4.6.

[0064] · (c) Dynamic pH monitoring fermentation :

[0065] · Transfer the mixture to a 50L capacity fermentation tank, then set the temperature to 28℃.

[0066] · Install a pH sensor (e.g., Mettler-Toledo pH probe) inside the fermentation tank and connect it to a PLC controller to log pH data at 1-hour intervals.

[0067] · The total fermentation period is 14 days. If the pH drops below 4.3, immediately administer 0.01–0.02% calcium carbonate to adjust the pH to approximately 4.5. (The maximum number of administrations per day is limited to 3 or fewer.)

[0068] · (d) Final sterilization / refill :

[0069] · After fermentation is complete, confirm that the pH is maintained at 4.6–4.7, sterilize briefly at 70°C for 10 minutes, and then aseptically fill or package in a hygienic container.

[0070] 3. Measurement items and methods

[0071] · pH: In-fermenter pH sensor + portable pH meter for calibration (offline sampling) in parallel

[0072] · Lycopene content : HPLC (High-Performance Liquid Chromatography) analysis. 2g of sample was extracted in an organic solvent (hexane / ethanol mixture) and quantified at a wavelength of 470nm.

[0073] · Vitamin C : Standard AOAC method (2,6-dichlorophenol-indophenol titration method).

[0074] · Sensory evaluation : 15 sensory panelists were asked to rate sourness, spiciness, umami, and overall preference (on a scale of 10).

[0075] 4. Results and Discussion

[0076] · pH stability :

[0077] On the 7th day of fermentation, when the pH dropped to about 4.4±0.05, 0.02% calcium carbonate was added, and within 24 hours, the pH rose to 4.6±0.03 and then stabilized.

[0078] · On the 14th day of fermentation, the final pH remained at 4.7.

[0079] · Nutrient retention rate :

[0080] · Lycopene content maintained at approximately 92% of the initial level (standard deviation ±2.3%).

[0081] · Vitamin C is preserved at approximately 85% of the initial level (standard deviation ±3.1%).

[0082] · Sensory evaluation :

[0083] · It received consistently high scores with sourness 8.1 / 10, spiciness 7.5 / 10, umami 8.2 / 10, and overall preference 8.3 / 10.

[0084] · Overall Conclusion :

[0085] · Due to low-temperature concentration and stepwise pH control, the unique flavor and nutrients of tomatoes were well preserved, and the microbial activity required for gochujang fermentation was stably maintained.

[0086] · Through this test Dynamic pH monitoring + split injection of buffer material It was verified that this is very effective in making fusion gochujang.

[0087] (Experiment 2) Comparison of Fermentation Quality According to Type of Acidity Buffering Substance

[0088] 1. purpose

[0089] The efficacy of various buffering substances (CaCO₃, MgCO₃, Ca / Mg complex, plant mineral complex, etc.) for controlling pH fluctuations during fermentation is compared and evaluated to determine the optimal formulation and input conditions.

[0090] 2. Experimental design

[0091] · Experimental group composition (Groups A~D)

[0092] · Group A : Calcium carbonate (CaCO₃) alone (based on 0.2%)

[0093] · Group B : Magnesium carbonate (MgCO₃) alone (based on 0.2%)

[0094] · Group C : Ca / Mg complex (1:1 ratio, total 0.2%)

[0095] · Group D : Plant-based mineral complex (natural mineral powder from Manufacturer X) 0.2%

[0096] · Basic formulation : 25 parts by weight of tomato concentrate : 75 parts by weight of gochujang (fully fermented), initial pH set to 4.5.

[0097] · Fermentation conditions : 4 x 25L stainless steel fermentation tanks, temperature 28℃, fermentation period 14 days.

[0098] · Measurement items : pH fluctuation, lycopene content, number of lactic acid bacteria, sensory evaluation (taste, color, aroma, etc.).

[0099] 3. Detailed method

[0100] · Each group is pre-mixed in the same manner and then added to the fermentation tank, and

[0101] · Measure the pH every 2 days, and if it drops to 4.3 or lower, add an additional 0.01% of the corresponding buffer substance formulated for each group in divided doses (the limit for administration is less than 3 times per day).

[0102] · At the end of fermentation (Day 14), the final pH, lycopene retention rate, and microbial count (medium: PCA or MRS agar) were evaluated.

[0103] 4. Results and Interpretation

[0104] · (a) pH fluctuation range

[0105] · Group C (Ca / Mg complex): Most stable with pH fluctuations within ±0.2 during fermentation. Maintains an average range of 4.5–4.7.

[0106] · Group D (Plant-based mineral complex): Condition was good from day 1 to day 10, but pH dropped sharply to 4.2 after day 11; returned to 4.5 after additional divided administration.

[0107] · Group A , Group B (Using a single carbonate): Increased frequency of pH dropping below 4.3 during the later stages of fermentation (days 12–14).

[0108] · (b) Lycopene content

[0109] · Group C: Maintained over 90% of initial level (±2.0%), Groups A, B, and D: 80–88% level.

[0110] · It is presumed that the stable pH of group C acted favorably in inhibiting lycopene degradation.

[0111] · (c) Sensory evaluation

[0112] · Group C received the highest scores in taste (harmony of acidity and umami), color (vividness), and aroma (8.5 / 10 level).

[0113] · Group D had a decent taste, but a browning phenomenon was observed where the color became slightly darker.

[0114] · conclusion The Ca / Mg complex (1:1 mixture) is the most ideal and is highly effective in maintaining a stable pH even in the later stages of fermentation. It also demonstrates excellent performance in terms of color and flavor. Dynamic pH control process of the present invention It is considered to be a buffering material optimized for.

[0115] (Experiment 3) Acidity control when applying various fruit concentrates (apple, pineapple, etc.)

[0116] 1. purpose

[0117] In addition to tomatoes, the present invention Apples, pineapples, etc. Verify whether it is equally applicable to various types of fruit concentrates, and verify fermentation stability and sensory quality.

[0118] 2. Ingredients and Formulation

[0119] · Apple concentrate : 67°Bx, pH 3.8, Cold concentrate after juicing domestic apples

[0120] · Pineapple concentrate : 60°Bx, pH 3.5, processed using imported raw materials from the Philippines

[0121] · Gochujang concentrate : pH 4.9, salinity 9.5%, sugar content 30°Bx

[0122] · Ca / Mg complex buffer material : 0.2~0.3% blend

[0123] · Basic mixing ratio: Gochujang (70) : Concentrate (30)

[0124] 3. Process and Measurement

[0125] · (a) Preliminary Mixing & Fermentation :

[0126] · Mix apple concentrate and pineapple concentrate with gochujang in a 7:3 ratio, and apply a fermentation temperature of 28℃ and a fermentation period of 14 days.

[0127] · After measuring the initial pH (apple group 4.3, pineapple group 4.1), adjust to around 4.5 using a Ca / Mg compound.

[0128] · (b) pH Monitoring & Buffer Injection :

[0129] · Real-time monitoring using a pH sensor (automatic measurement at 30-minute intervals). If it drops below 4.3, administer in divided doses of 0.01% to restore the pH to 4.5–4.7.

[0130] · (c) Sensory analysis :

[0131] · After fermentation is complete, evaluate sourness, color (golden, brown, etc.), fruit aroma, spiciness, overall preference, etc. (total panel of 15 people).

[0132] 4. Results and Discussion

[0133] · Apple concentrate mixture :

[0134] · Initial pH 4.3 → Final 4.7±0.1 on day 14 of fermentation. Stabilized by two additions of Ca / Mg during fermentation.

[0135] · The subtle, distinctive aroma of apples blends harmoniously with the spiciness of gochujang. Sensory score for sweet and sour flavor: 8.1 / 10.

[0136] · Pineapple concentrate mixture :

[0137] · The initial pH was somewhat low at 4.1, but the final pH was 4.5±0.1 after adding Ca / Mg 3 times during the 14 days of fermentation.

[0138] · The characteristic tartness of tropical fruits remains intact, and the intense sweetness slightly softens the spiciness of the gochujang. Sensory score 7.8 / 10.

[0139] · Nutrition / Flavor Evaluation :

[0140] It is determined that the apple group contains polyphenols and the pineapple group contains bromelain (a proteolytic enzyme), resulting in unique flavors and textures during the fermentation process.

[0141] · If no buffering agent is added, the pH drops sharply to 4.0 or lower, which is expected to lead to poor growth of fermentation microorganisms and cessation of fermentation, but by maintaining the pH appropriately according to the present invention, fusion gochujang of uniform quality could be obtained.

[0142] 5. Expansion potential

[0143] · Based on the above results, the same method can be applied to highly acidic fruits (Korean black raspberry, cherry, plum, etc.) Low-temperature concentration + buffering material + dynamic pH control It suggests that it can be applied, enabling the development of diverse fusion gochujang products. Industrial applicability

[0144] 1. Development of domestic and international fusion sauces

[0145] Through the present invention, it is possible to stably produce fusion gochujang sauce using various concentrates such as not only tomatoes but also apples, pineapples, mangoes, and black raspberries, and to introduce the harmony of spicy and sweet and sour flavors to the global market.

[0146] 2. Expansion of exports

[0147] It is possible to supply gochujang sauce with added acidity and sweetness preferred in overseas markets in large quantities and stably, and to enhance export competitiveness by resolving quality issues caused by excessive acidity even during long-term distribution.

[0148] 3. Enhancing the added value of agricultural products

[0149] By combining local specialty agricultural products such as domestic tomatoes (including those from Buyeo), apples, and black raspberries with gochujang, high value-added products can be produced, contributing to mutual growth with farmers and the revitalization of the local economy.

[0150] 4. Process automation and quality standardization

[0151] By monitoring and automatically correcting pH in real time during fermentation using a dynamic pH monitoring system (PLC / SCADA), dependency on operators and defect rates are significantly reduced, allowing for the maintenance of homogeneous quality even in mass production. Explanation of the symbols

[0152] It becomes smaller and process efficiency increases.

Claims

Claim 1 In a technology for controlling acidity balance during the manufacture of gochujang sauce, 1. a pretreatment process is performed to minimize nutrient loss by concentrating highly acidic ingredients (tomato concentrate, fruit concentrate, etc.) at a temperature of 60–70°C for a short period (within 30 minutes), while simultaneously pre-adjusting the pH by adding a predetermined amount of natural minerals or carbonate salts (calcium, magnesium, calcium carbonate, magnesium carbonate, etc.) in the range of 0.1–0.5 wt%; 2. the pretreatment concentrate is mixed with fermented gochujang stock in a weight ratio of 20–40% to ensure that the initial pH is approximately 4.5–4.8; 3. a dynamic pH control process is performed by monitoring real-time pH fluctuations using a pH sensor during fermentation, and if the pH drops below 4.3 or rises above 5.5, a trace amount (0.05–0.3 wt%) of a buffering substance (e.g., CaCO₃, plant mineral complex) is added stepwise to maintain the pH in the 4.5–5.0 range; and 4. Characterized by setting the fermentation temperature to a range of 25~30℃ to minimize the loss of lycopene, vitamins, etc. derived from tomato concentrate, while simultaneously providing an environment favorable for the activity of fermentation microorganisms, and 5. suppressing quality degradation and microbial risks during long-term storage through final sterilization (70~75℃, 1015 min) or aseptic filling if necessary. Method for adjusting acidity balance in gochujang sauce.

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