Process2018-10-28T12:18:09+00:00

OUR PROCESS 

Whole soybeans are cooked in pressure-cookers and mixed with roasted coarsely broken wheat or rice. The mass is inoculated with a mould, Aspergillus oryzae (or A. sojae) and incubated in doughnut-shaped circular plates with perforated bottoms through which air is forced. After two days of incubation under controlled conditions of temperature and moisture, mould growth covers the entire mass, called ‘Koji’, which is mixed with chilled brine and transferred to deep fermentation tanks. Osmophilic yeast cultures are added and slurry (called ‘Moromi-mash’) is allowed to ferment at controlled temperature and occasional aeration for 4-8 months. In the refining stage, the fermented mash is pressed to separate the liquid from the solid residue. The liquid is filtered, clarified, and heated to 90-95 degree Celsius. to pasteurize and to develop the characteristic color and aroma. After final clarification the sauce is pasteurized again and bottled.

KOJI MAKING

Raw material, steam whole soybean, roasted crushed wheat or rice and seed mold (Aspergillus oryzae) are incubated in control temperature and moisture room for 2 days. The mold growth covers the entire mass which turns greenish as a result of sporulation. This mass is called “Koji”

MOROMI FERMENTATION

The Koji is mixed with brine containing 22 to 25 % salt (weight by volume) and transferred to deep fermentation tanks. Lactic acid bacteria and osmophilic yeast cultures are added and the slurry (called “Moromi”-mash) is allowed to ferment at controlled temperature and occasional aeration.

MOROMI PRESSING

The fermented mash (Moromi) is pressed to separate the raw sauce from the solid residue. The raw soy sauce is separated oil, filtered and standardizes the quality.

PASTEURIZATION

The raw soy sauce is heated to 90-95 degree Celcius. Heating is necessary to pasteurize the sauce and to develop the characteristic color and aroma.

BOTTLING

After final clarification the soy sauce is pasteurized again and bottled.