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Koji Biroreactors

Koji bioreactors are used to produce koji sauce and involve fermenting soybeans and rice with Aspergillus. The simplest type is a packed bed bioreactor using wooden trays, while larger rotating drum bioreactors with 1500 kg capacity mix the materials. The largest described uses a two-chamber system with rotating discs and a conveyor belt to continuously produce 4000 kg/hr of fermented rice koji over 24 hours in each chamber. Process parameters like temperature and humidity are controlled.

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Shalini M
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382 views

Koji Biroreactors

Koji bioreactors are used to produce koji sauce and involve fermenting soybeans and rice with Aspergillus. The simplest type is a packed bed bioreactor using wooden trays, while larger rotating drum bioreactors with 1500 kg capacity mix the materials. The largest described uses a two-chamber system with rotating discs and a conveyor belt to continuously produce 4000 kg/hr of fermented rice koji over 24 hours in each chamber. Process parameters like temperature and humidity are controlled.

Uploaded by

Shalini M
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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KOJI BIOREACTORS

- used in the production of Koji Sauce


- It is a Soy sauce made of Soy bean and Aspergillus
- Rice and other starting materials are also used
- Product also gets modified into various other products, ex. Sake
- Type of Bioreactor used on Koji Process
- Koji is the only or one of few products produced successfully in large scale
using solid State fermentation

- Koji is the first product to be scaled up into continuous scales


- Extensive studies on Koji large scale production

- Patented knowledge
- Not all details are publicly available

- Simplest type Koji Bioreactor


- Packed Bed Bioreactor – Koji Trays

- Capacity 1000 kgs (1 Tonne)


- Wooden Trays
- 20 cm height (bed volume)

- Covered with cloth


- Aeration system

- Mixed manually
- Labor intensive
David A. Mitchell, Marin Berovič, Nadia Krieger (2006) Solid-State Fermentation Bioreactors:
Fundamentals of Design and Operation. Springer, Heidelberg doi.org/10.1007/3-540-31286-2
- Rotating Drum type bioreactors
- 1500 kg capacity

- Typical motor powered Rotating drum


- Blades to mix
- Water supply system
- Air supply system

- Air is prepared, heated or cooled to a particular temperature


- Humidity is controlled
- Water quality is controlled

- Continuously rotating system


David A. Mitchell, Marin Berovič, Nadia Krieger (2006) Solid-State Fermentation Bioreactors:
Fundamentals of Design and Operation. Springer, Heidelberg doi.org/10.1007/3-540-31286-2
- Intermittently mixed system
- 15 tonne capacity
- Rice koji

- Rotating disc
- Circular conveyor belt (screw type)

- 2 chambers (Upper chamber and lower chamber)

- Upper chamber- substrate will remain for 24 hours


- After 24 hrs Screw conveyor rotates – substrate passes onto screw conveyor belt
- Substrates travels from upper chamber to lower chamber

- Lower chamber also has a disc and screw conveyor


- and agitator for bed mixing
- Empty upper chamber is filled with fresh substrate and inoculum

- Continuous system automated

- Parameter controlled

- Sensors installed

- Non-sterile conditions

- Production rate is 4000 kg hr -1


David A. Mitchell, Marin Berovič, Nadia Krieger (2006) Solid-State Fermentation Bioreactors: Fundamentals of Design and Operation. Springer, Heidelberg doi.org/10.1007/3-540-31286-2
- Inoculated organisms are either fast growing or slow growing

- Contamination does not affect fast growing organisms

- Contamination plus product spoilage – time required

- Slow growing organisms – contamination is a critical issue


David A. Mitchell, Marin Berovič, Nadia Krieger (2006) Solid-State Fermentation Bioreactors: Fundamentals of Design and Operation. Springer, Heidelberg doi.org/10.1007/3-540-31286-2

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