Method for producing a sauce similar to soy sauce

Abstract

The present invention relates to a method for producing a cooking sauce from green table olive fermentation brine, preferably treated with an alkali. The brine used as the basis of the method must contain lactic acid bacteria and yeast, a salt content between 6.5-8.5%, a pH between 3.7-4.3, a free acidity of 1.0-1.3% and a combined acidity of 0.10-0.25 mEq. The method also consists of having fermented the olives for a long period of time, for example, between 3-18 months. Using this brine, the method comprises the following steps: filtering the fermentation brine to remove impurities; adding powdered yeast extracts to provide an umami flavour; adding plant extracts to obtain a colour and viscosity similar to soy sauce; adding a thickening agent to prevent the powdered yeast extract from separating from the rest of the brine; and packaging and pasteurising the resulting sauce.

Description

[0001] DESCRIPTION

[0002] Process for producing a culinary sauce similar to soy sauce from green olive fermentation brine

[0003] OBJECT OF THE INVENTION

[0004] The present invention belongs to the field of agri-food.

[0005] The object of the present invention is the development of a working process to obtain a new culinary sauce, similar to soy sauce, but obtained from green olive fermentation brine.

[0006] BACKGROUND OF THE INVENTION

[0007] Soy sauce, also known as soy sauce or shoyu in Japanese, is a condiment of Chinese origin produced by fermenting soybeans with fungi such as Aspergillus oryzae or Aspergillus sojae, along with halophilic bacteria and yeasts. Over the centuries, soy sauce has been a key ingredient in East Asian and Southeast Asian cuisine, prized for its unique flavor and culinary versatility. It is characterized as a salty, brown or black liquid that is a fundamental element in Eastern and Japanese cuisine, used in a wide variety of dishes.

[0008] The soy sauce fermentation process is a two-stage process that can last from several months to four years. The main steps in the soy sauce fermentation process are detailed below:

[0009] 1. Preparation of ingredients: The main ingredients of soy sauce are soybeans, cereals (wheat or barley), water and salt.

[0010] 2. Soybeans are soaked in water and steamed. They are then mixed with cereals and roasted.

[0011] 3. Koji production: The first phase of fermentation involves the production of koji, which is a solid mixture of soybeans and cereals inoculated with fungi such as Aspergillus oryzae or Aspergillus sojae.

[0012] 1

[0013] REPLACEMENT SHEET (RULE 26) 4. The koji is left to ferment aerobically for several days until a paste is formed.

[0014] 5. Moromi Production: The second stage of fermentation involves the production of moromi, a liquid mixture of koji, water, and salt. Moromi is left to ferment for several months to over four years in large wooden barrels. During this time, it is mixed and stirred regularly to ensure even fermentation, which is carried out by yeasts and lactic acid bacteria that are resistant to high salt concentrations.

[0015] 6. Filtering and Pasteurization: After several months, the moromi is filtered to separate the liquid soy sauce from the solids. The liquid soy sauce is pasteurized to stop fermentation and kill any bacteria or fungi present in the sauce.

[0016] Soy sauce has a high nutritional value as it is low in saturated fat and rich in fatty acids, excellent quality proteins, vitamins B and E, iron, calcium, phosphorus, potassium, and zinc. It also contains isoflavones, which act as antioxidants and help eliminate toxins from the body.

[0017] However, it's important to keep in mind that some varieties of soy sauce may contain high levels of sodium (13-20%), as well as high calories (50-100 kcal per 100 grams), so they should be consumed in moderation. Furthermore, in recent years, soybean cultivation has also faced significant environmental problems due to the deforestation it causes as cultivation areas increase and the use of genetically modified plants are used. It's also known that both wheat and soybeans contain an allergen component due to their gluten content.

[0018] Spanish patent ES2933106 describes a process for producing a fermented sauce similar to soy sauce, but with the advantages of a lower sodium content, lower calorie intake, gluten-free, and production with a lower environmental impact by reusing olive fermentation brines. Thus, in the first solid fermentation, microorganisms such as Aspergillus oryzae are used, releasing essential amino acids and carbohydrates from chickpeas and rice. Subsequently, in the second fermentation, microorganisms with high technological and probiotic potential (L. pentosus, S. cerevisiae, and W. anomalus) are used, and the brines from the 2

[0019] REPLACEMENT SHEET (RULE 26) Olive processing provides compounds such as polyphenols, present after contact with the olives. The process ends with aging in barrels and / or casks to round out its organoleptic profile. The result is a sauce rich in protein, amino acids, vitamins, mineral salts, and plant-based antioxidants (hydroxytyrosol) that has half the sodium content, fewer calories, and is also gluten-free.

[0020] DESCRIPTION OF THE INVENTION

[0021] The inventors of the present application have developed a process for obtaining a new culinary sauce, similar to soy sauce, from the fermentation brine of green table olives. That is, the sauce of the present invention does not contain soy or wheat (like traditional soy sauce) nor chickpeas or rice (like the fermented sauce of Spanish patent ES2933106). Instead, it uses the fermentation brine of green olives as its sole raw material.

[0022] Currently, green olive fermentation brines are considered nothing more than a residue from table olive processing. It is estimated that, in Spain alone, approximately 300 million liters of brine are generated annually. Since they have no known use, they are typically evaporated in ponds. The present invention takes advantage of their high content of bioactive compounds from olive fermentation, such as polyphenols (mainly oleuropein, maslinic acid, hydroxytyrosol, and tyrosol), proteins, amino acids, vitamins, mineral salts, and antioxidants of plant origin, as well as their low carbohydrate content, to create a new culinary sauce with novel nutritional and organoleptic characteristics.

[0023] Thanks to its novel composition, the culinary sauce of the present invention not only offers, compared to traditional soy sauce, advantages associated with not containing soy and wheat (such as lower sodium content, lower allergenic potential, and less environmental impact). Furthermore, the fermented sauce of the invention offers advantages over the fermented sauce of Spanish patent ES2933106, associated with not containing chickpeas or rice, such as a lower carbohydrate content.

[0024] In this document, the term "olive fermentation brine" is understood to mean the solution of food-grade salt in potable water, used as a covering medium for table olives once they have been fermented. Therefore, fermentation brine is not the initial brine added to the olive, but the resulting brine.

[0025] REPLACEMENT SHEET (RULE 26) once the fermentation process has finished.

[0026] In this document, the term "food grade salt" is understood as the crystalline product consisting predominantly of sodium chloride, where the NaCl content must not be less than 97% by weight of the dry matter, excluding additives.

[0027] In this document, the term "olive" is understood to mean the fruit of the olive tree obtained at the appropriate state of ripeness and of such quality that, subjected to appropriate processing, it provides a product ready for human consumption and of good conservation. These fruits are treated with an alkaline sodium hydroxide solution ("cooked"), followed by washing with water, and subsequently placed in brine where they undergo lactic fermentation. The cooking process causes the hydrolysis of oleuropein, which is responsible for the bitterness of the olives. After washing with water to eliminate excess NaOH and thus reduce the combined acidity, a microbial population of lactic acid bacteria and yeasts develops in the brine within a few days, persisting until the end of fermentation and providing the highly valued and distinctive characteristics of Spanish-style green olives.

[0028] In this document, the term "combined acidity" refers to the residual lye (NaOH) released by fruits that have undergone a "cooking" process and released by the fruits into the fermentation brine. This acidity determines the brine's buffering capacity by combining with organic acids. It is determined by titration to a pH of 2.6 with hydrochloric acid solution and is expressed as normality (N).

[0029] A first aspect of the present invention is directed to a process for obtaining a new culinary sauce similar to soy sauce from green olive fermentation brine, preferably treated with alkali (NaOH), according to claim 1. The dependent claims describe optional features.

[0030] PREFERRED EMBODIMENT OF THE INVENTION

[0031] The process designed by the inventors of this application to produce the new culinary sauce from green olive fermentation brine is described in detail below.

[0032] The procedure starts with a fermentation brine that must have a series of

[0033] 4

[0034] REPLACEMENT SHEET (RULE 26) specific characteristics, without which it is not possible to obtain a new culinary sauce with similarities to soy sauce. In particular, the green olive fermentation brine from which the process of the invention starts must have fermented green olives for a long period of time, for example, more than 3 months, contain lactic bacteria (preferably at population levels greater than 10 3 -10 6cfu / mL) and have a salt content of between 6.5-8.5%, a pH of between 3.7-4.3 units, a free acidity of 1.0-1.3%, and a combined acidity of 0.10-0.25 N.

[0035] It is important that the fermentation brine comes from fermenting quality green olives, as the use of fermentation brine from other types of olives, for example, olives destined for the production process of oxidized black olives, is not acceptable. Specifically, the inventors of the present application have discovered that the fermentation brine from Sevillano-style green olives, preferably of the Hojiblanca or Manzanilla varieties, is particularly advantageous due to its high phenol content. A high phenol content is associated with greater nutritional value due to its antioxidant capacity. Very preferably, the brine comes from the fermentation of green olives treated with alkali (NaOH), also because these are the ones with the lowest bitterness.In any case, it would be possible to carry out the process of the invention starting from fermentation brines of green olives of other varieties, such as Aloreña, Cacereña, or others.

[0036] The brine must have fermented the green olives for a long period of time, for example, a minimum of 3 months, more preferably 3-18 months. Sufficiently long fermentation times ensure the transfer of substances originally present in the olives, such as proteins, amino acids, vitamins, mineral salts, and plant antioxidants, as well as other bioactive components, into the brine. This greatly contributes to improving the nutritional and organoleptic characteristics of the fermented sauce of the invention.

[0037] Furthermore, the fermentation brine must contain lactic acid bacteria, preferably of the Lactiplantibacillus / Lactobacillus genus, as well as yeasts. In the conventional fermentation process for table olives, inocula and / or starter cultures of lactic acid bacteria and yeasts with probiotic potential are frequently added. The lactic acid bacteria present in green olive brine play an essential role in the olive fermentation process and can provide several benefits aimed at both the preservation and quality improvement of the final product.

[0038] 5

[0039] REPLACEMENT SHEET (RULE 26) Below are some of the benefits of these lactic bacteria:

[0040] • Fermentation and preservation: Lactic acid bacteria help ferment olives, converting sugars into lactic acid, which is a key step in preserving these fruits. During fermentation, due to the production of lactic acid, the pH of the brine is reduced to a value below 4.3 units. This creates an acidic environment that inhibits the growth of pathogenic and spoilage microorganisms and contributes to the preservation of olives for long periods of time.

[0041] • Flavor and texture: Fermentation carried out by lactic acid bacteria and yeasts can improve the flavor and texture of green olives. These microorganisms contribute to the transformation of bitter and astringent compounds (e.g., oleuropein) into more palatable compounds due to their esterase and p-glucosidase activity.

[0042] • Aroma development: Lactic acid bacteria and yeasts can contribute to the production of aromatic compounds and pleasant flavors in olives. This can result in olives with more complex and appealing flavor profiles and preservation brines with high physicochemical and organoleptic properties.

[0043] • Nutritional composition: The fermentation of olives by lactic acid bacteria can increase the bioavailability of certain nutrients, such as minerals, due to their phytase activity. Furthermore, it may contribute to the production of bioactive compounds that have beneficial effects on health (e.g., hydroxytyrosol and maslinic acid, among others).

[0044] Furthermore, tests carried out by the inventors of the present application have shown that, in order to obtain the fermented sauce of the invention, it is necessary for the fermentation brine used as raw material to have particular characteristics, specifically a salt content of between 6.5-8.5%, a pH of between 3.7-4.3 units, a free acidity of 1.0-1.3%, and a combined acidity of 0.10-0.25 N.

[0045] Using olive brine with these characteristics is advantageous because it ensures the absence of spoilage microorganisms (Propionibacteria, Pseudomonas, etc.) or pathogens (Clostridium, Listeria, Staphylococcius, etc.), free of unpleasant odors and flavors, but at the same time, with a concentration of salt and free acidity high enough for use 6

[0046] REPLACEMENT SHEET (RULE 26) culinary in which it is intended to be used.

[0047] Starting from a brine that has these characteristics, the new culinary sauce of the present invention is obtained through the following steps:

[0048] 1. Filter the fermentation brine to remove impurities such as olive pieces, pits, and the like.

[0049] The filtering step may be carried out in any manner known in the art, the term “filtering” including any other means by which such impurities may be removed, such as decantation or others.

[0050] 2. Add yeast extract powder to provide an umami flavor.

[0051] Yeast extract contains compounds rich in glutamic acid, among others, which, when combined with sodium (present in the brine used to preserve olives), allows for the formation of monosodium glutamate, the sodium salt of glutamic acid, which contributes to the potential umami flavor. Adding yeast extract can intensify the overall flavor of foods and give them a richer, more complete flavor profile. In addition, yeast extract also provides other nutritionally interesting components, such as B vitamins, amino acids, and other growth factors.

[0052] Preferably, the yeast extract contains at least one of the following: glutamic acid, inosinate, or disodium guanylate. Indeed, powdered yeast extracts can have different characteristics, differing mainly in their sodium chloride content, % glutamic acid, inosinate, and disodium guanylate. These substances are the main umami substances, and it has also been scientifically proven that inosinate or guanylate drastically enhance the umami flavor of glutamate. This is known as umami synergy. In the product object of the invention, the objective is to use yeast extracts that provide the highest content of glutamic acid, inosinate, and disodium guanylate, given that these are the substances that enhance the flavor of a food and do not interfere with masking the original flavor of the olive brine.

[0053] In order to ensure the homogenization of the mixture (brine + extract

[0054] 7

[0055] REPLACEMENT SHEET (RULE 26) yeast) and prevent the formation of lumps, the process of the invention preferably also comprises a first stirring after the addition of the powdered yeast extracts. To improve the result of the first stirring, this step may also include heating to a temperature of between 45-65 e C. These steps are vitally important to prevent product separation and stratification in the package, which would be unacceptable to the consumer. The dissolution temperature of the yeast extract depends on several factors, such as the extract concentration and the product's needs. Applying heat accelerates the product's dissolution process, reduces unwanted microbial load, and improves the extract's stability. Adding plant extracts can achieve a color and viscosity similar to soy sauce.

[0056] The addition of plant extracts can also contribute to providing antioxidants, improving nutritional quality, and enhancing flavor. The result is that the inventive sauce acquires a color / viscosity very similar to that of traditional soy sauce.

[0057] To ensure homogenization of the mixture, after adding the plant extracts, the process of the invention preferably includes a second stirring for 5-20 minutes to achieve a homogeneous color. A thickener is added to prevent the yeast extract powder from separating from the rest of the brine.

[0058] In principle, any suitable thickener can be used, although guar gum or xanthan gum are preferred. This thickener will also give the sauce of the invention a texture / creaminess similar to that of traditional soy sauce.

[0059] Again, to ensure homogeneous mixing, after adding the thickener, a third agitation of the fermentation brine is preferably carried out to facilitate its dispersion or dissolution. This third agitation can be combined with heating to a temperature of between 55 and 65 °C. e C, which makes it easier for the thickener to dissolve. Package the resulting fermented sauce.

[0060] 8

[0061] REPLACEMENT SHEET (RULE 26) The packaging process may be carried out in any manner known in the art. For example, packaging may be carried out at a temperature of between 55°C and 100°C. e C and 65 e C.

[0062] Packaging may also include a final pasteurization step. Pasteurization is typically the best option for eliminating potential spoilage and pathogenic species that the product may contain, as well as extending its shelf life. For example, pasteurization can be carried out at a temperature of between 75 and 85°C. e C for 10-20 minutes.

[0063] The process described allows to obtain a gluten-free culinary sauce that has the following composition per 100 grams:

[0064] - 6000-9000 milligrams of sodium chloride

[0065] 1-10 grams of carbohydrates

[0066] - 10-20 kcal

[0067] - bioactive compounds such as oleuropein, maslinic acid, tyrosol and / or hydroxytyrosol (250-1000 ppm),

[0068] 9

[0069] REPLACEMENT SHEET (RULE 26)

Claims

CLAIMS 1. Process for producing a culinary sauce similar to soy sauce from green olive fermentation brine, characterized in that the fermentation brine used contains lactic acid bacteria and yeasts, a salt content of between 6.5-8.5%, a pH of between 3.7-4.3, a free acidity of 1.0-1.3%, and a combined acidity of 0.10-0.25 N, and in that it comprises at least the following steps: - filter the fermentation brine to remove impurities; - add yeast extract powder to provide an umami flavor; - add plant extracts to obtain a color and smoothness similar to soy sauce; - add a thickener to prevent the yeast extract powder from separating from the rest of the brine; and - package the resulting fermented sauce.

2. Method according to claim 1, wherein the fermentation brine comes from the fermentation of green olives treated with alkali.

3. Method according to any of the preceding claims, wherein the olive brine has been fermented for a period of between 3-18 months.

4. Method according to any of the preceding claims, wherein the powdered yeast extract contains at least one of the following components: glutamic acid, inosinate, or disodium guanylate.

5. Method according to any of the preceding claims, further comprising a first stirring after the addition of the powdered yeast extracts to ensure homogenization and prevent the formation of lumps.

6. Method according to claim 5, further comprising a heating step to a temperature of between 45-65 eC during the first stirring.

7. Method according to any of the preceding claims, further comprising a second stirring for 5-20 minutes after the addition of the plant extracts to achieve a homogeneous color.

8. Method according to any of the preceding claims, wherein the 10 REPLACEMENT SHEET (RULE 26) thickener is chosen from guar gum or xanthan gum.

9. Method according to any of the preceding claims, further comprising a third stirring of the fermentation brine after the addition of the thickener.

10. Method according to claim 9, further comprising a heating step to a temperature of between 55-65 eC during the third agitation.

11. Method according to any of the preceding claims, wherein the packaging step is carried out at a temperature between 55 e C and 65 e C.

12. Method according to any of the preceding claims, further comprising a final pasteurization step.

13. Method according to claim 12, wherein pasteurization is carried out at a temperature between 75-85 e C for 10-20 minutes. 11 REPLACEMENT SHEET (RULE 26)