US20150208702A1 - Processing of soybeans - Google Patents
Processing of soybeans Download PDFInfo
- Publication number
- US20150208702A1 US20150208702A1 US14/418,828 US201314418828A US2015208702A1 US 20150208702 A1 US20150208702 A1 US 20150208702A1 US 201314418828 A US201314418828 A US 201314418828A US 2015208702 A1 US2015208702 A1 US 2015208702A1
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- United States
- Prior art keywords
- soybeans
- arrangement
- stator
- soy sauce
- splitting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 235000010469 Glycine max Nutrition 0.000 title claims abstract description 40
- 244000068988 Glycine max Species 0.000 title claims abstract description 40
- 238000000034 method Methods 0.000 claims abstract description 46
- 235000013555 soy sauce Nutrition 0.000 claims abstract description 42
- 239000000203 mixture Substances 0.000 claims abstract description 34
- 108090000623 proteins and genes Proteins 0.000 claims description 21
- 102000004169 proteins and genes Human genes 0.000 claims description 21
- 238000000605 extraction Methods 0.000 claims description 16
- 239000012267 brine Substances 0.000 claims description 14
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 claims description 14
- 230000001105 regulatory effect Effects 0.000 claims description 3
- 239000000047 product Substances 0.000 description 23
- 235000018102 proteins Nutrition 0.000 description 19
- 239000000243 solution Substances 0.000 description 12
- 235000010627 Phaseolus vulgaris Nutrition 0.000 description 8
- 244000046052 Phaseolus vulgaris Species 0.000 description 8
- 239000000839 emulsion Substances 0.000 description 7
- 239000010903 husk Substances 0.000 description 5
- 239000012535 impurity Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 150000003839 salts Chemical class 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 239000007795 chemical reaction product Substances 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000003825 pressing Methods 0.000 description 3
- 235000015067 sauces Nutrition 0.000 description 3
- 241000251468 Actinopterygii Species 0.000 description 2
- 108010073771 Soybean Proteins Proteins 0.000 description 2
- 235000021307 Triticum Nutrition 0.000 description 2
- 241000209140 Triticum Species 0.000 description 2
- 238000010923 batch production Methods 0.000 description 2
- 238000010924 continuous production Methods 0.000 description 2
- 238000010411 cooking Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 239000003925 fat Substances 0.000 description 2
- 238000000855 fermentation Methods 0.000 description 2
- 230000004151 fermentation Effects 0.000 description 2
- 238000011081 inoculation Methods 0.000 description 2
- 238000000751 protein extraction Methods 0.000 description 2
- 238000007873 sieving Methods 0.000 description 2
- 241000228212 Aspergillus Species 0.000 description 1
- 241000193830 Bacillus <bacterium> Species 0.000 description 1
- 241000894006 Bacteria Species 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- 241000283956 Manis Species 0.000 description 1
- 230000003139 buffering effect Effects 0.000 description 1
- 235000013339 cereals Nutrition 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 235000021107 fermented food Nutrition 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- 235000021374 legumes Nutrition 0.000 description 1
- 235000013557 nattō Nutrition 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 235000021251 pulses Nutrition 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 239000013049 sediment Substances 0.000 description 1
- 235000013322 soy milk Nutrition 0.000 description 1
- 229940001941 soy protein Drugs 0.000 description 1
- 235000019710 soybean protein Nutrition 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 235000013548 tempeh Nutrition 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L11/00—Pulses, i.e. fruits of leguminous plants, for production of food; Products from legumes; Preparation or treatment thereof
- A23L11/05—Mashed or comminuted pulses or legumes; Products made therefrom
- A23L11/07—Soya beans, e.g. oil-extracted soya bean flakes
-
- A23L1/238—
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
- A23J1/00—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites
- A23J1/14—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites from leguminous or other vegetable seeds; from press-cake or oil-bearing seeds
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L27/00—Spices; Flavouring agents or condiments; Artificial sweetening agents; Table salts; Dietetic salt substitutes; Preparation or treatment thereof
- A23L27/20—Synthetic spices, flavouring agents or condiments
- A23L27/24—Synthetic spices, flavouring agents or condiments prepared by fermentation
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L27/00—Spices; Flavouring agents or condiments; Artificial sweetening agents; Table salts; Dietetic salt substitutes; Preparation or treatment thereof
- A23L27/50—Soya sauce
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
- A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs
Definitions
- This application relates to a process, a stator, a use and an arrangement for improved processing of fermented products, and in particular to a process, a stator, a use and an arrangement for improved handling of fermented soybeans to extract soysauce and the like.
- soybean is a species of legume native to East Asia, widely grown for its edible bean which has numerous uses.
- the plant is classed as an oilseed rather than a pulse by the Food and Agricultural Organization (FAO).
- Soybeans produce significantly more protein per acre than most other uses of land.
- Traditional fermented foods include soy sauce, fermented bean paste, natto, and tempeh, among others.
- the traditional process for producing for example soy sauce is performed by sorting, rinsing and then cooking the soybeans to a desired level. After the cooking the soybeans are cooled to an optimum fermentation temperature and thereafter transferred to inoculation vats where the inoculation is done by adding a starter culture, for example a Bacillus or Aspergillus strain of bacteria. The mixture is then fermented for a time span of a few days to a couple of weeks in these large vats. The resulting culture is traditionally called Koji and is transferred to fermentation tanks where brine, or individual salt and water, is added to form a mixture traditionally called Moroni. The Moroni is fermented for a minimum of three months and sometimes up to a year. After this period the Moroni (which is a mash) is pressed or washed to extract the sauce. The pressing and washing is a batch process where sieving in several stages which are essential for the purity of the resulting soy sauce.
- a starter culture for example a Bacillus or Aspergill
- the quality of the resulting soy sauce is determined by the protein content and the purity of the soy sauce.
- the effectiveness of the soybean protein extraction and the purification of the resulting product is thus of importance.
- the batch process not being continuous is a disadvantage as it prevents the process from being fully automated and increases operation costs in that the batches need to be prepared, delivered and retrieved.
- the means for splitting the soybeans is comprised of a stator arranged to revolve at high speeds having a series of holes.
- Arrangements according to the teachings herein are beneficial in that they provide an end product of a high qualitative purity in a continuous manner. This is achieved by an insightful combination of the splitting means (the stator) and the decanter, which combination removes the need for a seperate buffering process of removing top floculation and bottom sediment.
- the arrangement further comprises a clarifier which increases the purity of the end product.
- a clarifier which increases the purity of the end product.
- stator for use as means for splitting soybeans, said stator comprising a circular member arranged with a series of holes.
- it t is an object of the teachings of this application to overcome the problems listed above by providing a use of a stator for splitting soybeans. According to one aspect, it t is an object of the teachings of this application to overcome the problems listed above by providing a process for extraction of soy sauce, said process comprising separating the soy sauce from a fermented mixture through decanting.
- it t is an object of the teachings of this application to overcome the problems listed above by providing a process for extracting protein from soybeans, said process comprising splitting the soybeans into discernible pieces.
- it t is an object of the teachings of this application to overcome the problems listed above by providing a process for processing soybeans, said process comprising separating the soy sauce from a fermented mixture through decanting and splitting the soybeans into discernible pieces.
- the inventors of the present invention have realized, after inventive and insightful reasoning that by decanting a fermented solution the solution can effectively be used to separate the desired product from husks or impurities and also other particles in a simple and elegant solution that allows for continuous operation. This has been confirmed by extensive experimentation.
- the inventors of the present invention have also realized, after inventive and insightful reasoning, that by splitting the beans an increased surface for protein extraction is achieved without risking that an emulsion is generated thereby providing a simple and elegant solution that allows for continuous operation.
- the inventors have further realized that to perform such splitting a stator designed according to herein may beneficially be used to provide a simple and elegant solution that allows for continuous operation.
- the teachings herein find use in, but is not limited to, extraction and production of soy sauce, fish sauce and other fermented products.
- the manner disclosed herein also find use in fermenting wheat products.
- FIG. 1 shows an arrangement for a traditional process for extraction of soy sauce
- FIG. 2 shows an improved arrangement for a process according to an embodiment herein for an improved extraction of soy sauce according to one embodiment of the teachings of this application;
- FIG. 3 shows an improved arrangement for a process according to an embodiment herein for an improved extraction of soy sauce according to the teachings of this application;
- FIG. 4 shows an improved arrangement for a process according to an embodiment herein for an improved extraction of soy sauce according to the teachings of this application;
- FIG. 5 illustrates a schematic flowchart for a process for extracting protein from and clarifying a mixture according to an embodiment of the teachings herein;
- FIGS. 6A and 6B each shows an illustration of a stator to be used in an arrangement according to one embodiment of the teachings of this application.
- FIG. 7 shows a schematic illustration of an arrangement according to an embodiment of the teachings herein.
- FIG. 1 shows an arrangement for a traditional process for extraction of soy sauce.
- the fermented Moroni referenced FERMENT in FIG. 1
- the soy sauce which is then sieved (referenced SIEVING in FIG. 1 ) repeatedly to produce the finished product, being soy sauce.
- FIG. 2 shows an improved arrangement 2 for a process according to an embodiment herein for an improved extraction of soy sauce.
- the arrangement 2 comprises a decanter (referenced DECANT in FIG. 2 ) for extracting the soybeans and soybeans particles from the husk and other impurities, thereby efficiently defattening the mixture and increasing the protein yield of the finished product.
- the decanter is implemented as an Alfa Laval Foodtec® 500 or 510 decanter. These decanters have enough capacity to efficiently separate the husks and other particles and impurities from the beans or bean fragments.
- Decanters are known in other fields, but have not been used for the purpose of extracting soy sauce from the Moron mixtures. By realizing, after insightful reasoning, that decanters may also be used for separating the husks and impurities from the mixture, a simple and elegant, yet effective solution is provided to enable an efficient continuous process.
- decanters can also be used for separating soymilk from husks and impurities.
- FIG. 3 shows an improved arrangement 3 for a process according to an embodiment herein for an improved extraction of soy sauce.
- the arrangement 3 is arranged to split, chop or slice the soybeans in the mixture through the use of splitting means instead of pressing them. In one embodiment this slicing is achieved by the use of a revolving stator (referenced STATOR in FIG. 3 ).
- the stator is arranged to revolve at high speed, for example 2500 RPM.
- the revolving speed is in the range of 1000 to 4000 RPM and in one embodiment the revolving speed is 2000 to 3000 RPM.
- the stator is further arranged to have large holes.
- the holes should be large enough to at least partially receive a bean to be processed.
- the edges of the holes will interact with the soybeans by splitting them into smaller pieces.
- the resulting increased surface of the soybeans enables a higher yield of soy protein.
- the desired size of the resulting pieces depends on the finished product. The smaller the pieces, the higher the protein yield, but if the pieces are too small, the risk for generating an emulsion increases.
- the pieces should therefore be of a size where the pieces are still individually discernible and does not form a powder.
- By having rectangular cross sections of the stator holes a cleaner cut of the soybeans is achieved resulting in a cleaner product and less risk of an emulsion. It also provides a higher protein yield.
- the stator is arranged to split the soybeans into quarter-sized pieces.
- the holes may also have other cross sections such as circular.
- the size of the holes and the revolving speed of the stator interact in such a way that the higher the speed and the smaller the holes, the higher the risk of creating an emulsion. Smaller holes allows for less adjustment of the revolving speed.
- the holes should be at least the same substantial size as the particle to be split, in the case of the soysauce, the same size of the soybean.
- stator is implemented as a Tetra Almix in-line® mixer with a specially adapted stator. More details of the stator will be given with reference to FIG. 6 .
- stators are known in other fields, but stators have not been used for the purpose of extracting soy sauce from Moroni mixtures and like mixes.
- stators may also be used for slicing or chopping the soybeans to provide a resulting increased surface for extracting the protein, a simple and elegant, yet effective solution is provided to enable an efficient continuous process which provides a high protein yield.
- a prior art system produces soysauce having a protein yield of 2.1% per each produced litre.
- a system according to the teachings herein will produce a soysauce having a protein yield of more than 2.5% per each produced litre, thus providing an increase by over 20% for the protein yield.
- the process and arrangement includes a station or step where brine (or individual salt and water) is added to the mixture.
- brine affects the qualities of the resulting product, and also facilitates the run of the resulting mixture through the revolving stator and the subsequent decanter as the mixture is more fluid than the Moroni mixture on its own.
- the brine further affects the resulting yield of protein and the more brine that is added, the larger the total amount of extracted protein.
- FIG. 4 shows an improved arrangement 4 for a process according to an embodiment herein for an improved extraction of soy sauce.
- the arrangement 4 is arranged to add brine (referenced BRINE in FIG. 4 ) to the fermented mixture before or during the extraction.
- brine referenced BRINE in FIG. 4
- the process is arranged to keep the mixture at a temperature at a stable or low temperature, for example below 45 degrees Celsius. Increasing the temperature will affect the quality and cleanliness of the resulting product and it is therefore beneficial to maintain a low temperature all through the process.
- FIG. 5 illustrates a schematic flowchart for a process for extracting protein from and clarifying a mixture according to an embodiment of the teachings herein.
- brine or water and/or salt
- a succeeding or simultaneous step 520 the beans in the mixture are split, for example using a stator.
- the mixture is then run through a decanter in step 530 .
- step 550 a further step of running the mixture through a clarifier is performed in step 550 .
- the resulting mixture may also be run through a sieve in step 540 .
- These steps are optional and indicated as such in FIG. 5 by the dashed lines.
- FIG. 6A shows an illustration of a stator 10 to be used in an arrangement according to above.
- the stator 10 is comprised of a circular member 11 having an inner diameter of 200 mm and a thickness of material of 4 mm.
- the stator 10 is arranged with a plurality of relatively large holes 12 .
- the stator 10 is arranged with fourteen holes 12 each having a diameter of 30 mm.
- the stator is a TetraPak stator having a product number CP3097735.
- the stator 10 is a TetraPak stator having a product number CA3026040 having an inner diameter of 200 mm, a thickness of material of 5.5 mm (in one embodiment 4 mm), and twenty holes 12 having a rectangular cross section measuring 30 mm (width) by 50 mm (height).
- the thickness of material is 4 to 6 mm.
- the holes 12 have different sizes. The size of the hole depends on design parameters for the stator 10 such as the thickness, the revolving speed, the material, the number of the holes and the thickness of the material to name a few.
- FIG. 7 shows a schematic illustration of an arrangement 7 according to an embodiment of the teachings herein.
- a fermenting station 71 is arranged to ferment a mixture.
- Brine or water and/or salt
- the brine is either added as a solution or by adding salts and water individually.
- the diluted solution is then run through a high speed revolving stator 73 and thereafter decanted in a decanter 74 .
- the solution may be sieved in a sieve 75 and also or alternatively clarified in a clarifier 76 .
- To regulate the temperature during the process temperature regulating means 77 are part of the arrangement.
- the temperature regulating means 77 may be implemented through a cooling system or other known manner of cooling a production line.
- One aspect of the disclosure here involves an arrangement ( 2 , 3 , 4 , 7 ) for extraction of soy sauce comprising a decanter ( 74 ) for separating the soy sauce from a fermented mixture through decanting.
- a stator ( 73 , 10 ) for use as means for splitting soybeans wherein the stator ( 10 ) comprises a circular member ( 11 ) arranged with a series of holes ( 12 ).
- a further aspect involves the use of a stator ( 73 , 10 ) for splitting soybeans.
- Further aspects of the disclosure include a process for extraction of soy sauce, wherein the process comprises separating the soy sauce from a fermented mixture through decanting, and a process for processing soybeans, wherein the process comprises separating the soy sauce from a fermented mixture through decanting and splitting the soybeans into discernible pieces.
- One benefit of the teachings herein is that the process and arrangement provides an end product of high quality.
- Another benefit of the teachings herein is that the process and arrangement provides a high yield of protein.
- the process and arrangement provides a lowered fat content.
- One more benefit of the teachings herein is that the process and arrangement enables continuous operation and is cheaper to operate.
- the process and arrangement also prevents an emulsion from being generated.
- the teachings herein relating to the use of the decanter and/or the stator find use in manufacturing and producing soy sauce, but also find use in producing other fermented products such as fish sauce, wheat-based products and other grain-based products.
Abstract
A process for processing soybeans, said process comprising separating the soy sauce from a fermented mixture through decanting and splitting the soybeans into discernible pieces.
Description
- This application relates to a process, a stator, a use and an arrangement for improved processing of fermented products, and in particular to a process, a stator, a use and an arrangement for improved handling of fermented soybeans to extract soysauce and the like.
- The soybean is a species of legume native to East Asia, widely grown for its edible bean which has numerous uses. The plant is classed as an oilseed rather than a pulse by the Food and Agricultural Organization (FAO). Soybeans produce significantly more protein per acre than most other uses of land. Traditional fermented foods include soy sauce, fermented bean paste, natto, and tempeh, among others.
- The traditional process for producing for example soy sauce is performed by sorting, rinsing and then cooking the soybeans to a desired level. After the cooking the soybeans are cooled to an optimum fermentation temperature and thereafter transferred to inoculation vats where the inoculation is done by adding a starter culture, for example a Bacillus or Aspergillus strain of bacteria. The mixture is then fermented for a time span of a few days to a couple of weeks in these large vats. The resulting culture is traditionally called Koji and is transferred to fermentation tanks where brine, or individual salt and water, is added to form a mixture traditionally called Moroni. The Moroni is fermented for a minimum of three months and sometimes up to a year. After this period the Moroni (which is a mash) is pressed or washed to extract the sauce. The pressing and washing is a batch process where sieving in several stages which are essential for the purity of the resulting soy sauce.
- The quality of the resulting soy sauce is determined by the protein content and the purity of the soy sauce. The effectiveness of the soybean protein extraction and the purification of the resulting product is thus of importance.
- The batch process, not being continuous is a disadvantage as it prevents the process from being fully automated and increases operation costs in that the batches need to be prepared, delivered and retrieved.
- There is thus a need for an improved manner of continuously extracting protein at a high yield. There is also a need for an improved manner of continuously purifying fermented products such as soy sauce.
- According to one aspect, it is an object of the teachings of this application to overcome the problems listed above by providing an arrangement for extraction of soy sauce comprising a decanter for separating the soy sauce from a fermented mixture through decanting.
- According to one aspect, it is an object of the teachings of this application to overcome the problems listed above by providing an arrangement for extracting protein from soybeans comprising a means for splitting the soybeans into discernible pieces.
- According to one aspect, it is an object of the teachings of this application to overcome the problems listed above by providing an arrangement for processing soybeans comprising a decanter for extraction of soy sauce by separating the soy sauce from a fermented mixture through decanting and a means for splitting the soybeans into discernible pieces.
- Such arrangements provide simple solutions allowing continuous operation and that result in end products having high quality.
- In one embodiment the means for splitting the soybeans is comprised of a stator arranged to revolve at high speeds having a series of holes.
- Arrangements according to the teachings herein are beneficial in that they provide an end product of a high qualitative purity in a continuous manner. This is achieved by an insightful combination of the splitting means (the stator) and the decanter, which combination removes the need for a seperate buffering process of removing top floculation and bottom sediment.
- In one embodiment the arrangement further comprises a clarifier which increases the purity of the end product. In fact, after the clarifier the resulting product is ready to be sold. The arrangement as disclosed herein is thus highly efficient and cost efficient to operate providing an end result of high quality.
- According to one aspect, it t is an object of the teachings of this application to overcome the problems listed above by providing a stator for use as means for splitting soybeans, said stator comprising a circular member arranged with a series of holes.
- According to one aspect, it t is an object of the teachings of this application to overcome the problems listed above by providing a use of a stator for splitting soybeans. According to one aspect, it t is an object of the teachings of this application to overcome the problems listed above by providing a process for extraction of soy sauce, said process comprising separating the soy sauce from a fermented mixture through decanting.
- According to one aspect, it t is an object of the teachings of this application to overcome the problems listed above by providing a process for extracting protein from soybeans, said process comprising splitting the soybeans into discernible pieces.
- According to one aspect, it t is an object of the teachings of this application to overcome the problems listed above by providing a process for processing soybeans, said process comprising separating the soy sauce from a fermented mixture through decanting and splitting the soybeans into discernible pieces.
- It is an object of the teachings of this application to overcome the problems listed above by providing a soysauce produced according to a process according to above.
- The inventors of the present invention have realized, after inventive and insightful reasoning that by decanting a fermented solution the solution can effectively be used to separate the desired product from husks or impurities and also other particles in a simple and elegant solution that allows for continuous operation. This has been confirmed by extensive experimentation.
- The inventors of the present invention have also realized, after inventive and insightful reasoning, that by splitting the beans an increased surface for protein extraction is achieved without risking that an emulsion is generated thereby providing a simple and elegant solution that allows for continuous operation. The inventors have further realized that to perform such splitting a stator designed according to herein may beneficially be used to provide a simple and elegant solution that allows for continuous operation.
- The teachings herein find use in, but is not limited to, extraction and production of soy sauce, fish sauce and other fermented products. The manner disclosed herein also find use in fermenting wheat products.
- An arrangement and a process according to the teachings herein can beneficially be used in and integrated into the production Ketjap Manis and like products, the teachings herein being combined with other processes and arrangements enabling such production.
- Other features and advantages of the disclosed embodiments will appear from the following detailed disclosure, from the attached dependent claims as well as from the drawings.
- Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to “a/an/the [element, device, component, means, step, etc]” are to be interpreted openly as referring to at least one instance of the element, device, component, means, step, etc., unless explicitly stated otherwise. The steps of any method disclosed herein do not have to be performed in the exact order disclosed, unless explicitly stated.
- The invention will be described in further detail under reference to the accompanying drawings in which:
-
FIG. 1 shows an arrangement for a traditional process for extraction of soy sauce; -
FIG. 2 shows an improved arrangement for a process according to an embodiment herein for an improved extraction of soy sauce according to one embodiment of the teachings of this application; -
FIG. 3 shows an improved arrangement for a process according to an embodiment herein for an improved extraction of soy sauce according to the teachings of this application; -
FIG. 4 shows an improved arrangement for a process according to an embodiment herein for an improved extraction of soy sauce according to the teachings of this application; -
FIG. 5 illustrates a schematic flowchart for a process for extracting protein from and clarifying a mixture according to an embodiment of the teachings herein; -
FIGS. 6A and 6B each shows an illustration of a stator to be used in an arrangement according to one embodiment of the teachings of this application; and -
FIG. 7 shows a schematic illustration of an arrangement according to an embodiment of the teachings herein. - The disclosed embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which certain embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
-
FIG. 1 shows an arrangement for a traditional process for extraction of soy sauce. The fermented Moroni (referenced FERMENT inFIG. 1 ) is pressed or otherwise treated to extract (referenced EXTRACT inFIG. 1 ) the soy sauce which is then sieved (referenced SIEVING inFIG. 1 ) repeatedly to produce the finished product, being soy sauce. -
FIG. 2 shows an improvedarrangement 2 for a process according to an embodiment herein for an improved extraction of soy sauce. Thearrangement 2 comprises a decanter (referenced DECANT inFIG. 2 ) for extracting the soybeans and soybeans particles from the husk and other impurities, thereby efficiently defattening the mixture and increasing the protein yield of the finished product. In one embodiment the decanter is implemented as an AlfaLaval Foodtec® 500 or 510 decanter. These decanters have enough capacity to efficiently separate the husks and other particles and impurities from the beans or bean fragments. - Decanters are known in other fields, but have not been used for the purpose of extracting soy sauce from the Moron mixtures. By realizing, after insightful reasoning, that decanters may also be used for separating the husks and impurities from the mixture, a simple and elegant, yet effective solution is provided to enable an efficient continuous process.
- The use of decanters can also be used for separating soymilk from husks and impurities.
- A problem that arises when pressing the Moroni mixture is that the resulting mash is prone to generate an emulsion of the fats and the proteins. It is nearly impossible to mechanically separate the fats from the proteins in such an emulsion.
-
FIG. 3 shows animproved arrangement 3 for a process according to an embodiment herein for an improved extraction of soy sauce. Thearrangement 3 is arranged to split, chop or slice the soybeans in the mixture through the use of splitting means instead of pressing them. In one embodiment this slicing is achieved by the use of a revolving stator (referenced STATOR inFIG. 3 ). The stator is arranged to revolve at high speed, for example 2500 RPM. In one embodiment the revolving speed is in the range of 1000 to 4000 RPM and in one embodiment the revolving speed is 2000 to 3000 RPM. - The stator is further arranged to have large holes. The holes should be large enough to at least partially receive a bean to be processed. The edges of the holes will interact with the soybeans by splitting them into smaller pieces. The resulting increased surface of the soybeans enables a higher yield of soy protein. The desired size of the resulting pieces depends on the finished product. The smaller the pieces, the higher the protein yield, but if the pieces are too small, the risk for generating an emulsion increases. The pieces should therefore be of a size where the pieces are still individually discernible and does not form a powder. By having rectangular cross sections of the stator holes a cleaner cut of the soybeans is achieved resulting in a cleaner product and less risk of an emulsion. It also provides a higher protein yield. In one embodiment the stator is arranged to split the soybeans into quarter-sized pieces. As will be described later on, the holes may also have other cross sections such as circular.
- The size of the holes and the revolving speed of the stator interact in such a way that the higher the speed and the smaller the holes, the higher the risk of creating an emulsion. Smaller holes allows for less adjustment of the revolving speed. The holes should be at least the same substantial size as the particle to be split, in the case of the soysauce, the same size of the soybean.
- In one embodiment the stator is implemented as a Tetra Almix in-line® mixer with a specially adapted stator. More details of the stator will be given with reference to
FIG. 6 . - The use of stators is known in other fields, but stators have not been used for the purpose of extracting soy sauce from Moroni mixtures and like mixes. By realizing, after insightful reasoning and careful and extensive experimentation, that stators may also be used for slicing or chopping the soybeans to provide a resulting increased surface for extracting the protein, a simple and elegant, yet effective solution is provided to enable an efficient continuous process which provides a high protein yield. For example, a prior art system produces soysauce having a protein yield of 2.1% per each produced litre. A system according to the teachings herein will produce a soysauce having a protein yield of more than 2.5% per each produced litre, thus providing an increase by over 20% for the protein yield.
- To facilitate the handling of the Moroni mixture, the process and arrangement includes a station or step where brine (or individual salt and water) is added to the mixture. The brine affects the qualities of the resulting product, and also facilitates the run of the resulting mixture through the revolving stator and the subsequent decanter as the mixture is more fluid than the Moroni mixture on its own. The brine further affects the resulting yield of protein and the more brine that is added, the larger the total amount of extracted protein.
-
FIG. 4 shows animproved arrangement 4 for a process according to an embodiment herein for an improved extraction of soy sauce. Thearrangement 4 is arranged to add brine (referenced BRINE inFIG. 4 ) to the fermented mixture before or during the extraction. - In one embodiment the process is arranged to keep the mixture at a temperature at a stable or low temperature, for example below 45 degrees Celsius. Increasing the temperature will affect the quality and cleanliness of the resulting product and it is therefore beneficial to maintain a low temperature all through the process.
-
FIG. 5 illustrates a schematic flowchart for a process for extracting protein from and clarifying a mixture according to an embodiment of the teachings herein. In afirst step 510 brine (or water and/or salt) is added to the mixture. In a succeeding orsimultaneous step 520 the beans in the mixture are split, for example using a stator. The mixture is then run through a decanter instep 530. - To further clarify and clean the resulting product a further step of running the mixture through a clarifier is performed in
step 550. Depending on the desired finished product and the quality of the product the resulting mixture may also be run through a sieve instep 540. These steps are optional and indicated as such inFIG. 5 by the dashed lines. -
FIG. 6A shows an illustration of astator 10 to be used in an arrangement according to above. Thestator 10 is comprised of acircular member 11 having an inner diameter of 200 mm and a thickness of material of 4 mm. Thestator 10 is arranged with a plurality of relativelylarge holes 12. In the example embodiment ofFIG. 6 thestator 10 is arranged with fourteenholes 12 each having a diameter of 30 mm. In this embodiment the stator is a TetraPak stator having a product number CP3097735. In an alternative embodiment, seeFIG. 6B which shows an illustration of a cross section of astator 10 to be used in an arrangement according to above, thestator 10 is a TetraPak stator having a product number CA3026040 having an inner diameter of 200 mm, a thickness of material of 5.5 mm (in oneembodiment 4 mm), and twentyholes 12 having a rectangular cross section measuring 30 mm (width) by 50 mm (height). In an embodiment the thickness of material is 4 to 6 mm. Experiments have shown that such a stator is more beneficial in that it provides cleaner cuts. In one embodiment theholes 12 have different sizes. The size of the hole depends on design parameters for thestator 10 such as the thickness, the revolving speed, the material, the number of the holes and the thickness of the material to name a few. -
FIG. 7 shows a schematic illustration of an arrangement 7 according to an embodiment of the teachings herein. A fermenting station 71 is arranged to ferment a mixture. Brine (or water and/or salt) is effectively added to the mixture by means for adding brine in abrine station 72. The brine is either added as a solution or by adding salts and water individually. The diluted solution is then run through a highspeed revolving stator 73 and thereafter decanted in adecanter 74. To further improve the quality of the product the solution may be sieved in asieve 75 and also or alternatively clarified in aclarifier 76. To regulate the temperature during the process temperature regulating means 77 are part of the arrangement. The temperature regulating means 77 may be implemented through a cooling system or other known manner of cooling a production line. - Experiments have shown that using a process as described above, soy sauce with a fat content of less than 0.5% can be achieved.
- The addition of the brine which allows for the beans to be split with a stator also makes the solution suitable for decanting with a decanter.
- The use of a decanter and a stator is thus technically linked to provide an improved process and arrangement for such a process for processing soybeans.
- One aspect of the disclosure here involves an arrangement (2, 3, 4, 7) for extraction of soy sauce comprising a decanter (74) for separating the soy sauce from a fermented mixture through decanting. Another aspect of the disclosure involves a stator (73, 10) for use as means for splitting soybeans, wherein the stator (10) comprises a circular member (11) arranged with a series of holes (12). A further aspect involves the use of a stator (73, 10) for splitting soybeans. Further aspects of the disclosure include a process for extraction of soy sauce, wherein the process comprises separating the soy sauce from a fermented mixture through decanting, and a process for processing soybeans, wherein the process comprises separating the soy sauce from a fermented mixture through decanting and splitting the soybeans into discernible pieces.
- One benefit of the teachings herein is that the process and arrangement provides an end product of high quality.
- Another benefit of the teachings herein is that the process and arrangement provides a high yield of protein. The process and arrangement provides a lowered fat content.
- One more benefit of the teachings herein is that the process and arrangement enables continuous operation and is cheaper to operate. The process and arrangement also prevents an emulsion from being generated.
- The teachings herein relating to the use of the decanter and/or the stator find use in manufacturing and producing soy sauce, but also find use in producing other fermented products such as fish sauce, wheat-based products and other grain-based products.
- The invention has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended patent claims.
Claims (15)
1. (canceled)
2. An arrangement for extracting protein from soybeans comprising a means for splitting the soybeans into discernible pieces.
3. An arrangement for processing soybeans comprising a decanter for extraction of soy sauce by separating the soy sauce from a fermented mixture through decanting and a means for splitting the soybeans into discernible pieces.
4. The arrangement of claim 2 , wherein the means for splitting the soybeans is comprised of a stator arranged to revolve at high speeds having a series of holes.
5. The arrangement of claim 1 , wherein the holes have a rectangular cross section.
6. The arrangement according to claim 2 further comprising means for adding brine to the fermented mixture.
7. The arrangement according to claim 2 further comprising a clarifier.
8. The arrangement according to claim 2 further comprising means for regulating the temperature of the arrangement to be maintained below 45 degrees Celsius.
9. The arrangement according to claim 2 further comprising a sieve.
10. (canceled)
11. (canceled)
12. (canceled)
13. A process for extracting protein from soybeans, said process comprising splitting the soybeans into discernible pieces.
14. (canceled)
15. A soysauce produced according to a process according to claim 13 .
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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SE1250904 | 2012-08-01 | ||
SE1250904-8 | 2012-08-01 | ||
PCT/EP2013/065909 WO2014019984A1 (en) | 2012-08-01 | 2013-07-29 | Improved processing of soybeans |
Related Parent Applications (1)
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PCT/EP2013/065909 A-371-Of-International WO2014019984A1 (en) | 2012-08-01 | 2013-07-29 | Improved processing of soybeans |
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US15/671,893 Division US10779559B2 (en) | 2012-08-01 | 2017-08-08 | Processing of soybeans |
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US15/671,893 Active 2034-05-05 US10779559B2 (en) | 2012-08-01 | 2017-08-08 | Processing of soybeans |
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JP (1) | JP6387347B2 (en) |
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WO (1) | WO2014019984A1 (en) |
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---|---|---|---|---|
JPS603464B2 (en) * | 1976-05-12 | 1985-01-28 | ダイセル化学工業株式会社 | soy sauce manufacturing method |
JPS606187B2 (en) * | 1982-04-08 | 1985-02-16 | 日産化学工業株式会社 | Soy sauce clarification method |
JPS63146762A (en) * | 1986-12-09 | 1988-06-18 | Izumi Food Mach:Kk | Grinder for unsoaked soybean for preparation of bean curd |
JPH05285697A (en) * | 1992-04-13 | 1993-11-02 | Arai Tekkosho:Kk | Device for separation of solid from liquid |
JP2743247B2 (en) * | 1993-11-29 | 1998-04-22 | カゴメ株式会社 | Lycopene oil production method |
JP4284437B2 (en) * | 2003-01-30 | 2009-06-24 | 明治乳業株式会社 | Method for producing coffee bean extract |
JP2006204265A (en) * | 2005-01-31 | 2006-08-10 | Japan Research & Development Association For New Functional Foods | Method for producing soybean oil and soy sauce |
CN1718098A (en) * | 2005-07-19 | 2006-01-11 | 王宝贵 | Process for producing fresh sauce |
JP2008167660A (en) * | 2007-01-05 | 2008-07-24 | Kikkoman Corp | Liquid seasoning |
JP4093320B2 (en) * | 2007-03-20 | 2008-06-04 | ヤマモリ株式会社 | Production method of black soybean soy sauce |
KR20080097531A (en) * | 2007-05-02 | 2008-11-06 | 문경화 | Manufacturing system of raw soybean fine powder and thereof, manufacturing system of soy milk/tofu using the powder and method thereof |
CN101909465B (en) * | 2007-12-26 | 2014-01-29 | 龟甲万株式会社 | Process for producing soy sauce using gelatinized brown rice as starch material |
CN201139041Y (en) * | 2008-01-09 | 2008-10-29 | 中山装备制造工业研究院 | Sauce slag processing system |
KR20080097962A (en) * | 2008-06-27 | 2008-11-06 | 문경화 | Manufacturing system of raw soybean fine powder |
US9441257B2 (en) * | 2008-08-29 | 2016-09-13 | Pharvis R&D Korea Co., Ltd. | Method for producing fermented edible plants or edible animal/plants, fermented edible plants or edible animal/plants produced by same, and foods containing same |
DE102009016489A1 (en) * | 2009-04-06 | 2010-10-14 | Krones Ag | Method for preparing soya bean sauce, comprises providing and mixing raw materials, converting valuable components of the raw materials by fermentation and/or by hydrolysis, separating solid contents and obtaining fluid by a whirlpool |
-
2013
- 2013-07-29 US US14/418,828 patent/US20150208702A1/en not_active Abandoned
- 2013-07-29 JP JP2015524753A patent/JP6387347B2/en active Active
- 2013-07-29 WO PCT/EP2013/065909 patent/WO2014019984A1/en active Application Filing
- 2013-07-29 CN CN201380041102.1A patent/CN104507332B/en active Active
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2017
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US10779559B2 (en) | 2020-09-22 |
CN104507332B (en) | 2018-02-13 |
US20170332680A1 (en) | 2017-11-23 |
WO2014019984A1 (en) | 2014-02-06 |
CN104507332A (en) | 2015-04-08 |
JP2015523092A (en) | 2015-08-13 |
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