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Q: Manufacturing soya sauce ( Answered 4 out of 5 stars,   2 Comments )
Subject: Manufacturing soya sauce
Category: Science
Asked by: silvercouch-ga
List Price: $10.00
Posted: 09 May 2002 21:54 PDT
Expires: 16 May 2002 21:54 PDT
Question ID: 14148
Need commercial detailed manufacturing process for soya sauce.  Please
also include any suggestions on manufacturing machinery required (to
bottle), suggested ingredients etc.
Subject: Re: Manufacturing soya sauce
Answered By: musashidam-ga on 10 May 2002 12:59 PDT
Rated:4 out of 5 stars
Thanks for your inquiry!

The manufacturiung of soy sauce is quite involved, and most of the
online resources I've found tend to discourage those who wish to
embark on home-brewing their own soy sauce. Aside from the
difficulties of making your own soy sauce, there are also a number of
varieties of soy sauce. Foodnotes breaks down the various types of soy
sauce as follows:

While true tamari or shoyu is an aged product, most of the commercial
soy sauce sold in the United States is a nonfermented synthetic
product made from defatted soybean meal and grains mixed with
chemicals. Real aged tamari or shoyu has a different flavor than
commercial, synthetic soy sauce. In Japan, synthetic soy sauce is not
recognized by the government, which allows five different types of soy
sauce to be labeled as shoyu. Among the synthetic brands,
reduced-sodium soy sauce is available."

Foodnotes - Soy Sauce:

However, I did locate detailed step-by-step instructions for brewing
soy sauce (or Toyo as it is called by Filipinos) at the following

How to make Toyo or Soy Sauce:

Please bear in mind that this recipe is for a smaller quantity of soy
sauce than I imagine you would be attempting, as your question implies
you are interested in making soy sauce in commercially viable
quantities. However, this should give you a good idea of the process
involved on a smaller scale. The process, paraphrased from the above
site, is as follows:

You willl need to produce two base materials for the process, a mold
starter and a yeast starter. The Mold Starter is made from rice
kernels and "pure culture Aspergillus oryzae or Apergillus sojae"
(these last two ingredients are fermentation products). You wash and
steam the rice kernels, spreading them over a tray (make sure the tray
has holes to pass air) and subsequently 'innoculating' the rice with
the fungal cultures (sounds dangerous, eh?). After innoculating the
molds, cover them with paper and let dry for 15-20 hours. Once the
molds are dry, you grind them up and put them in a clean bottle. Store
them until you are ready to prepare your soy sauce.

To make the yeast starter you need pure cultures of Pediococcus
halophius, Saccharomyces rouxii, and Torulopsis versatilis and Potato
dextrose broth mixed with 10% sodium chloride. (The exact quantities
are a bit vague) Mix these ingredients together and you have your
yeast starter.

Once you have these two base materials created you are ready to
prepare your soy sauce.

The website referenced above lists the following materials and
ingredients for this recipe:

a. whole soybean meal or residue
b. wheat flour 
c. salt
d. starter culture
e. bamboo tray
f. perforated tray
g. fermentation vessel
i. stirrers
j. pressure cooker or autoclave
k.containers for soaking
l. stainless steel presser
m. casseroles
n. aging tank
o. funnels
p. siphons
q. bottles with caps 

You can see that this is probably not the sort of thing you're going
to whip up in your home kitchen.

Soak the soybeans for 16 hours, changing the water twice to prevent
the growth of bacteria. Remove the soybeans from the water and
pressure cook them for 1 hour. You will need to prepare the wheat
flour depending on what kind you have; if using wheat kernels, roast
the kernels with sand, separate the sand, and then crush the kernels
into wheat. If using prepared wheat flour, steam the wheat for 30
minutes. Prepare a brine solution  with 18% sodium chloride.Mix the
soybeans and flour until each soybean is covered in flour. Add the
mold starter. Spread the soybeans on a bamboo tray and cover for 5-7
days to allow the mixture to ferment. After fermentation, take this
product (called 'koji') and place it in a glass jar. Add the brine (1
part brine for every 1 1/2 parts koji). Ferment this mixture for 1
month. After fermentation, add the yeast starter (1% per volume of
koji/brine mixture). This mixture must then be fermented between 6
months and a year, depending on taste. Stir it once per week to speed
up the process. After this fermentation is complete, strain the
mixture through a presser. The liquid is your soy sauce. Place the soy
sauce in a bottle and pasturize it for 20-30 minutes. Congratulations,
you now have soy sauce!

As for the materials to manufacture soy sauce on a larger scale, check
out the links below:

A list of bottling equipment manufactureres can be found at:

Specific Mechanical is a company that specializes in stainless steel
equipment for the brewing industry, and could probably supply much of
the equipment necessary to set up a soy manufacturing center:

To find suppliers of soybeans, check the United Soybean Board website
(They have a large list of links that will lead you to suppliers of
soybeans and soy seed, should you decide to plant soybeans yourself.)

Kikkoman has a nice walkthrough of their brewing process here:

You may also want to check out this entertaining website, a virtual
walktrhough of the Yamasa soy sauce factory. It's clearly aimed at
kids, but is entertaining nontheless, and gives a nice graphic
representation of the soy production process:

Good luck!

-musashidam - ga

Suggested search terms:

soy sauce manufacturing process

soybean suppliers

brewing equipment
silvercouch-ga rated this answer:4 out of 5 stars

Subject: Re: Manufacturing soya sauce
From: seedy-ga on 10 May 2002 00:38 PDT
There are several descriptions of soy sauce manufacturing online.
Reporting on two of them as follows:
Quote:  "The main ingredients of soy sauce are soybeans (or defatted
soybean meal), wheat, salt and water. The heart of the manufacturing
process is a complex fermentation whereby the carbohydrates are
fermented to alcohol and lactic acid and the proteins are broken down
to peptides and amino acids. Chemical reactions between the original
components and the fermentation products create the colour ,
consistency and aroma of soy sauce. Formulations and processing
conditions differ from one country to another and in function of the
type of soy sauce to be produced."

Manufacturers of processing equipment for the production of the soy

Also, Kikkoman reports on the general process of manufacture:
Quote:  "   There are there main steps in production:

1. Production of koji – the base

Equal parts of steamed soybeans and roasted and milled wheat are mixed
together. By enriching the mixture with special micro-organisms
(starter cultures called aspergillus sojae), which are used
exclusively by KIKKOMAN, "koji” a dry mash is created. Important
enzymes are formed in the koji cells, which are later used to separate
soy protein.

2. Fermenting – Colour, Taste and Aroma is Created!

Salt and water are added to the koji and a mash, which we call
"moromi”, is created. This mixture of soybeans, white, salt and water
ferments and matures in large tanks. During this process enzymes
separate the soy protein with the aid of the brine (salt water). The
soy and wheat starch is now broken down and sugar is created. This
sugar partly turns into alcohol and natural acids. This valuable
natural fermentation process takes around six months.

3. Refining

Following the maturing process, the moromi is wrapped in cloths and
pressed. The pure raw soy sauce drains out. Now it has to be filtered
again and pasteurised so that the colour and aroma can intensify. The
finished soy sauce is then bottled.

Samples are tested regularly in the laboratory to guarantee high
quality standards. The leftovers from pressing — the so-called pressed
cake — is used as animal feed."

With regard to automated bottling of this product, thomas register
lists many manufacturers of commonly available equipment at:

You need to register with thomas register online (free) to search
their site.

Used equipment is often available from Aaron Equipment which is
located in New Jersey and is a premier dealer in used and
reconditioned production equipment such as the tanks, fementation,
loaders, and digesters which will be needed to setup a commercial soy
production operation.  they also generally list bottle filling,
labeling, and capping equipment in the packaging section of their
catalog (printed or online)

It appears that soy sauce, like the manufacture of yogurt, requires
proprietary starter cultures which will be one of the keys to flavor,
fermentation, and efficiency of the operation.

Good luck...we'll be looking for a sample...Thanks
Subject: Re: Manufacturing soya sauce
From: smile-ga on 24 May 2002 10:09 PDT
I like Alfred Vogels Kelpamare (Bioforce) as the best tasting soya
sauce. It is maybe also one of the healthiest (unless you are allergic
to iodine) of them. I don't like Kikkoman, which was mentioned above.

Here is the product description:

"Kelpamare is a distinctive and unique seasoning sauce that contains
concentrated sea weed (kelp). It adds flavour that enhances all meats,
stews, gravies, salad dressings, vegetable juices, omelettes etc.
Kelpamare is produced using only the finest organically grown
ingredients which have been stringently tested by quality control
checks at Bioforce.


Hydrolyzed vegetables and cereals, soy, water, natural vegetable
flavours and kelp concentrate.


Kelpamare is a fat and cholesterol free seasoning, containing the
iodine bearing kelp (Macrocystis pyrifera).

Salt content: 17% 


Bottles of 85 ml."

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