Download - internship report -ZARA FOODSTUFF INDUSTRIES
CHAPTER 1
INTRODUCTION
1.1 Briefing to industrial training
Every student of Bachelor of Food Technology Universiti Darul Iman Malaysia has to
undergo an internship program of fifteen weeks in any organization to get exposure to the real
time business environment. The real purpose of this internship program is to provide an
opportunity to the students to see the practical applications of their background professional
studies. The report is a reflection on my experience when I was interned in Zara Foodstuff
Industries, Johor Bahru.
1
I was assigned in Quality Assurance Department. This department is responsible in
controlling the quality of industry manufactured products and provide guarantee of safety of the
products. It covers the Quality Control Lab, Microbiology and Analysis Lab. In efforts to
improve the capability and quality of service, the this company has successfully obtained MS ISO
9001:2000 Quality Management Systems –Requirements in scope of manufacture of soy sauce,
chili sauce, tomato sauce and sri kaya.
My internship program in Zara Foodstuff Ind. was commenced on Monday, 4th January
2010. I was attached to the Quality Department for a period of 15 weeks. My supervisor, Mr
Fathuddin Hj Zakaria gave me a tentative outline concerning how my internship program would
be like.
1.2 Objectives of industrial training
The main objective of the Industrial Training is to experience and understand real life
situations in industrial organizations and their related environments and accelerating the learning
process of how student’s knowledge could be used in a realistic way. In addition to that,
industrial training also makes one understand the formal and informal relationships in an
industrial organization so as to promote favorable human relations and teamwork. Besides, it
provides the exposure to practice and apply the acquired knowledge “hands - on” in the working
environment. Industrial training also provides a systematic introduction to the ways of industry
and developing talent and attitudes, so that one can understand how Human Resource
Development works.
2
Moreover, students can gain hands-on experience that is related to the students majoring
so that the student can relate to and widen the skills that have been learnt while being in
university. Industrial training also exposes the students to the real career world and accustoms
them to an organizational structure, business operation and administrative functions.
Furthermore, students implement what they have learned and learn more throughout this
training. Besides, students can also gain experience to select the optimal solution in handling a
situation. During industrial training students can learn the accepted safety practices in the
industry. Students can also develop a sense of responsibility towards society.
In conclusion, there is strong evidence that industrial training is highly beneficial to
students’ development, and it is highly valued. The early exposure of real work life situation is
deemed necessary as this prepares students not only acquiring the theoretical aspects of the
knowledge, but far more important, is how this knowledge can be applied practically in real
workplace settings.
The students are well equipped to manage the period of industrial training successfully
and undoubtedly gain useful experience of applying their specialist and technical skills, as well as
developing their personal and communications skills. This internship also helps students to
prepare for the work environment and also teach the ergonomics of organizations in the real
world.
3
1.3 Objective of this report
This document provided details of my achievements in term of practical
implementation and understanding of working environment in Zara Foodstuff Industries for
about 3 and a half months. It also contains the findings on recent issues or problem that
occurred and must be confronted.
1.4 Scope of Industrial Training
The scope of my Industrial Training are basically on Quality Assurance officer duties
and responsibilities, the process flow of every product and its importance, knowing the ISO
amendment and the importance of Good Manufacturing Practice application in plant. Along
my internship period, I have to gain information from every step of production process and
relate them in term of food technology.
4
CHAPTER 2
ORGANIZATION BACKGROUND & STRUCTURE
2.1 Company profile
Zara Foodstuff Industries has in a relatively short period of time established itself as a
leading food product manufacturer. Commencing operations in 1987, when manufacturers
were trying to weather a period of recession, Zara Foodstuff Industries forged ahead, going
against the grain by expansion and astute business decisions. Its pioneer product which
provided the impetus for growth was soya sauce, deliciously thick and sweet or appetizingly
light and salty.
Today, Zara Foodstuff Industries has two technologically advanced manufacturing
facilities located at the Larkin Industrial Area, Johor, Malaysia, which produces four food
products under the Cap Kipas Udang brand, namely soya sauce, chili sauce, tomato sauce and
Sri Kaya (coconut bread spread).
5
There are about 105 staffs (local) in the whole factory (including office workers).
Operation starts from 8am – 5pm (Mondays – Fridays and half day on Saturdays) with lunch
break for 1 hour from 1pm to 2pm while operators operation hour start from 8am – 4.30pm
(Mondays – Saturdays) with half an hour lunch break. Tea breaks are scheduled at 10.15am and
3.15pm for 15 minutes.
Currently, soy sauce ‘Cap Kipas Udang’ and chili and tomato sauces had been exporting
to overseas markets such as Singapore and Brunei. They hope to expand their market to other
countries once they have improved their system by developing and implementing a food safety
system ‘HACCP’.
Their success has been rewarded with the certified ISO 9001 company in year 1999 by
SIRIM QAS for quality system management. They also won the ANUGERAH KUALITY
INDUSTRIES NEGERI JOHOR in year 2002 under category manufacturing organized by Johor
State. Currently they are in the process to get the HACCP certified from International body.
6
2.2 Organizational charts
Figure 2.3: Organizational chart
7
Group Executive Chairman
Plant Consultant 1
QA department
Plant Consultant 2
Plant Director
Production Advisor
Admin & Purchasing
Director
Human Resource Dept
Purchasing dept.
Admin and Legal Dept.
Group Finance Director
Managing Director
2.3 Quality Policy
To value customer needs and expectations by producing quality and safe product through
effective and continual improvement of world class Quality and Food Safety Management
System.
8
CHAPTER 3
PRODUCTS
3.1 Soy sauce
3.1.1 Introduction
Soy sauce production requires a complex fermentation process in which the carbohydrates
are fermented to alcohol and lactic acid and the proteins broken down to peptides and amino
acids. Soy sauce production is produced by solid state mold fermentation (koji) of raw materials:
soy bean and wheat followed by submerged high-salt ripening phase. During latter phase,
proteins and carbohydrates are hydrolyzed to amino acids and sugars and subsequent Mailard
reactions lead to the generation of a range of savoury aroma compounds.
9
3.1.2 Activities
During my industrial training, I have been placed at the fermentation area for 2 weeks to
learn more n details on the fermentation procedure and related action taken if any problem
occurs. The first thing that I have been introduced with is koji which I never saw before. Then,
further explanation on the process of making moromi is explained by Fermentation Leader, Mr
Shahrizal. Other than that, he also mentioned about the quality control plan that have been used
in order to overcome possible problem as the moromi is the ‘hardcore’ process to produce soy
sauce.
Within 2 weeks time, I have experienced on how to check the brine level, temperature
upper n lower part of moromi in the fiberglass and aroma of the moromi. These all parameters are
important as it will determine the quality of soy sauce later.
From my observation, the process shown only shows the physical appearance of the bean
water (moromi solution). My manager had asked me to reveal the story behind all processing step
in term of chemical and biological change during fermentation. The details are explained below.
10
3.1.3 Process Flow of fermentation
11
Cooking process (temp: 120ºC, 15-20 psi, 10 minutes (complete cooking period= 1 hour)
Soaking process: 4-18 hours
Washing bean with water(2 bag of bean/barrel for retort)
Koji preparation: Mixing bean with flour-starter and transfer it into wooden frame
Brine solution preparation: brine + 80ºB
Incubate the koji for 2-3 days in koji room
Transfer the incubated koji into the fiberglass
Addition of brine solution according to size of fiberglass
Spread thick salt: 3rd day of fermentation or after 3 times of mixing the koji with brine water
Figure 3.1.3: Fermentation Process Flow
12
Quality control
Fermentation process take place for 2 ½ months
Extraction of bean water: 1st extraction with specific amount according to size of fibreglass
Addition of brine solution: Brine: 74-76ºB with specific amount
2nd extraction of bean water
Addition of brine solution (74-76ºB with specific amount)into the fiberglass contains the remaining mash moromi
3rd extraction: (A) and (B)
Discard the moromi
3.1.4 Sequential Methods for fermentation process
i) Wheat- Starter production
Wheat flour must be dry fried at 60ºC to remove moisture and kill microorganism and
been cooled. The inoculums of Aspergillus sp. spores added and mixed well.
ii) Koji production
The soy bean has been cooked in a vertical retort for 5-10 minutes by maintaining the
temperature 110-120 ºC and pressure 10-15 psi. Mix well the wheat -starter with cooked bean in
the mixing tray by hand. The wheat-starter layer must not coated too thick. Mixture of soy bean,
wheat flour and fungal culture is placed on shallow flat wooden trays and incubated for 3-4 days
in shelf. They will be stored in koji room where the temperature and relative humidity are
controlled. Koji mold grows throughout the material becomes yellowish green as the result of the
sporulation of Aspergillus strains. They use of same trays to ensure that same organisms are
carried from one fermentation batch to another.
iii) Moromi and bean water production
Production of soy sauce starts with the fermented bean water which comes from moromi.
Once the fungus is well grown, usually after a few days, the koji is again mixed and placed in the
fibreglass for the second phase of the fermentation. Brine solution is added and it is from this
brine that the salty taste is derived. The fiberglass will be left open to sun light which to
encourage or enhance spontaneous fermentation by bacteria and yeast take place. After aging
13
period (2.5 months), the bean water (koji and brine solution) is siphoned off to give the first
extract for soy sauce production. The addition of brine water to the residue mash moromi will be
done as the bean water will be known as Bean water 2 as it is the second extraction. Addition of
brine will be repeated to the same fiberglass and consider the bean water as bean water 3 as it is
third extraction. The bean water is then transfer to the cook barrel for next process in producing
the soy sauce.
3.1.5 Chemical and Biological reaction during fermentation
i) Koji stage
Role of koji molds is to breakdown enzymatically the proteins and starches of the soy
beans and wheat in the koji preparation. The soy sauce koji contains proteases, amylases, and
lipases that hydrolyse their respective substrates in the subsequent submerged fermentation in
approximately 20% weight per volume salt brine. It was found that Aspergillopeptidase A
(molsin) was the most effective in improving the flavour of soy bean (Fujimaki et. al., 1968;
Noguchi et. al., 1970). During the submerged fermentation, some halophilic microorganisms such
as Pediococcus cerevisiae, Lactobacillus delbruekii, and salt-tolerant Saccharomyces rouxii
naturally developed, since in a fact that soy sauce fermentation depends on proteolytic enzymes
derived from those halophilic microbial strains to hydrolyze the proteins in the substrate to the
constituent amino acids and peptides. It was found that maximum proteolytic activity was
attained after an incubation period of 5-6 days at 37 ºC and that an acidic pH range induced better
growth and proteolytic activity. It is important that the fungus should grow over and through the
mixture, fully colonizing it and breaking down the component materials. However, it is also
important for the value of the product, that the fungus does not grow too much and begin to
produce spores in the koji. Additionally, patchy growth must be prevented.
14
ii) Mash Moromi stage
Fungal strains are important in hydrolyzing the raw material, bacteria and yeasts take over the
fermentation in the mash stage. Growth of bacteria in the mash was found to give rise to the
formation of organic acids, thereby making acidic conditions which was considered to be
necessary to remove undesirable flavours and add indispensable good flavours to the soy sauce.
(Sakaguchi, 1959). During fermentation process, there are some enzymes that will decompose
carbohydrates, protein and lipids content in soy bean such as amylolytic, proteolytic and lypolytic
enzymes. At this stage it is usually inoculated with yeasts and/or bacteria which grow well in
high levels of salt (osmophilic species) and are also able to grow under low levels of oxygen.
Inoculation with Saccharomyces rouxii (osmophilic yeast) and Lactobacillus delbrueckii (a lactic
acid bacterium) ensures that the process continues, although traditionally this part of the process
was probably more of a chance event. In the secondary phase of the fermentation therefore,
anaerobic conditions quickly develop and further growth of Aspergillus oryzae is prevented. The
sugars in the mixture are fermented by the yeast and lactobacilli so that after about a month, a
sour (pH 4.5), dark coloured liquid is formed which contains large amounts of amino acids,
particularly glutamic acid, simple sugars and a range of vitamins. Subsequently, the brown liquid
is drained off from the moromi and gently filtered. All the residual bean fibre and residue is
removed. It is then boiled to inactivate the degrading enzymes and kill the microbes.
3.1.6 Problems and suggestions
As we know, fermentation is a crucial process in soy sauce making. There must be a zero
problem and error to get high quality soy end product. But, there still some problems that can
contribute to contamination. Firstly, during koji making process, the cooked bean will be mixed
with the wheat-starter in a huge tray bare handed. This may introduce contamination to the soy
15
bean. As a suggestion, the workers may wear single use hand glove or in advance technology use
mixer, eg: ribbon mixer for more hygienic process.
As wooden trays are use in making koji, the condition of the tray must be care of.
Moisture must be avoided to prevent other microorganism grow on the frame of trays. This may
contribute a problem in quality of soy sauce later. As a suggestion, stainless steel trays may be
used but further research and observation must be taken to ensure the quality of koji is same or
better than present. The koji room must be in clean and free from any possibilities of rodents or
insects present. The utensil of making koji must be specifically store in specific place.
3.1.7 Soy sauce manufacturing
3.1.7.1 Activities
Along the internship period, I have been given a chance to check the soy sauce samples
along the process of manufacturing. The parameters that must be checked are pH, saline, brix,
taste, specific gravity and temperature.
3.1.7.2 Functional ingredients
Sugar is added to enhance flavor and also act as antimicrobial. Salt is also added for the
same purpose. The high salt concentration is necessary to help protect the finished product from
spoilage. Monosodium glutamate is use in enhancing the flavor and adds umami taste to the soy
sauce. Other than that, sodium benzoate is added to help inhibit microbial growth in finished soy
sauce.
16
Sugar syrup
Extraction
Palletizing
Sealing
Traying
Shrink wrapping
Capping
Labelling
Cooking95-105°C 60 min
Storage
Sugar, Caramel, MSGMixing
Sodium benzoate, HVP, Salt, Acetic acid, Caramel
Finished goods storage
Loading
Filtering and Cooling (PHE)
Filling
Bottle
Heating and Rinsing(>60°C)
Water
Salt WaterSugar
Blending
Cap
3.1.7.3 Process Flow of soy sauce manufacturing
Figure 3.1.7.3: Process flow of soy sauce
3.2 Chili Sauce and Tomato sauce Production
17
Garlic Dried chilli
Peeling
Grinding 1
Weighing
Blanching
Grinding 2 Rinsing
Tomato sauce*
Garlic, Onion, Papaya
Course grinding
Fine grinding
3.2 1 Introduction
Chili and tomato sauce are another products that been manufactured in this factory. Both
products undergone same process and only differs on ingredients and parameters on quality
checking. The products are categorized as shelf stable product.
3.2.2 Functional ingredients
These are the ingredients that contribute in giving the preferable flavor, texture and other
parameters that must be complied to produce the products. Modified starches are used in all
starch applications: in food products for example as a thickening agent, stabilizer or emulsifier, in
pharmaceuticals as disintegrant, in paper as a binder and many other applications. In tomato and
chili sauce modified starch contribute in giving the viscous texture and bind the excess moisture.
This may help in reducing the possibilities of microbial spoilage.
Other ingredient is xanthan gum. It has properties that have ability to produce a large
increase in the viscosity of a liquid by adding a very small quantity of gum, on the order of one
percent. The viscosity of xanthan gum solutions decreases with higher shear rates; this is called
pseudoplasticity. This means that a product subjected to shear, whether from mixing, shaking or
even chewing, will thin out, but once the shear forces are removed, the food will thicken back up.
Sugar is important in giving flavor and taste for the sauces and also reducing the chances of
microbial spoilage.
3.2.3 Tomato and chili sauce process flow
18
3.3 Seri kaya Production
3.3.1 Introduction
During my internship, I have observed the production flow of Sri kaya making from the
raw material to final product. I have been introduced to observe and analyze the raw material
sample to ensure the quality of the raw material. The specification for every raw materials differs
and all observation must be recorded in the specific form.
3.3.2 Functional ingredients
The oil from the coconut milk powder must be emulsified with all ingredients. By adding
whole raw egg, it will provide moisture to a mixture and holds the ingredients together. As the
food is heated, egg protein coagulates, thus binding ingredients together. Egg yolk contains
lecithin which acts a an emulsifier. Egg yolk prevents the two liquids from separating; the
emulsifiers in the yolks are liaisons between the two liquids and serve to stabilize the mixture.
Coconut emulsion is the main flavor source that gives the taste of natural Seri Kaya.
19
Eggs Modified starch
Heating and Rinsing
Cooking
Glass bottle
Breaking
Homogenization
Weighing
Washing
Coconut powder Filtered water
Homogenization
FiltrationSugar, Salt
Filling
Capping
Retorting
Cooling
Labelling & sealing
Traying
Top sticker
Wrapping
Palletizing
Finished good storage
Loading
Cap
Cap seal & label
Tray
Top sticker
Sleeve wrapper
Xanthan gum Colour and Flavour
Water
3.3.3 Process Flow of Seri Kaya production
Figure 3.3.3 Process Flow of Seri Kaya production
20
CHAPTER 4
QUALITY CONTROL PLAN
4.1 Fermentation
I have been given an exposure to explore the quality control method for moromi solution.
As we know, moromi solution is a hardcore product as it is the starter to produce soy sauce. From
koji making to moromi production, strict observation and control system has been done. Koji
must fulfill the specification before proceed being used to produce moromi. The percentage of
spore growth and its colour are the parameters taken.
The bean water has been control its quality since the first day of fermentation. The brine
degree of brine solution must be at least 80- 90 ºB as this degree range is the best for moromi
fermentation. Moromi in the fiberglass will be exposed to sun light every morning for browning
process and drying the surface of moromi as the UV light from the sun kill the mold and other
pathogen microoraganisms on the surface.
To ensure the quality of the bean water, gradual checking applied. The observation and
check is done for every 2 weeks, 1 month and 2.5 months old moromi. The observation
parameters are same but with differs range of specification. The parameters are temperature of
21
the upper and lower part of moromi, aroma, colour, pH, salinity and brine level of moromi
solution. The equipments uses are pH meter, salinometer and brinometer.
During the fermentation period, the moromi must be treated with salt to avoid any
possible contamination from insects, animal and microorganism. The method of spreading the
salt onto the surface of moromi depends on level of contamination and condition of bean water
and moromi. Normally, the stiring is done after 2,4 and 8 weeks of fermentation period to help
and enhance aeration. Expose the moromi to sun light everyday if good weather and spread thin
salt if there is any contamination at early stage.
For extraction and addition of brine solution, the same hose will be used as moromi can
not contain excess water as moisture will spoil the moromi.
4.2 Soy sauce
Numerous analytical tests are conducted to ensure the finished sauce meets minimum
quality requirements. For example, in brewed sauces, there are several recommended
specifications. Total salt should be 10% of the final product; the pH level should be 4.6-4.85; and
the total nitrogen content should not be less than 6%. The fermented sauce must be made from
fermented mash, salt brine, andpreservatives (either sodium benzoate). This specification also
states that the final product should be a dark brown liquid and met all quality parameters. The
qualities parameters of soy sauce are the sensory characteristics such as taste, odor, as well as
analytical values for nitrogen content, alcohol level, and soluble solids.
22
4.3 Chili and tomato sauce
Laboratory analysis is needed to control the quality of the product and maintain the shelf
life duration time to time. There are some specifications that must be complied such as pH, Brix,
viscosity, consistency, cadmium presence, Total acidity as chemical analysis, Total plate count
and yeast and mold count for microbiological analysis.
4.4 Sri Kaya production
The incidence of spoilage in Sri Kaya products is very low, but when it does occur, it is
important to proceed with the investigation. Most of the problems may occur on bloated cap,
undesired colour and undesired texture. Abnormalities on bottle cap usually indicate improper
capping. The problem may due to the present of ‘air space’ and not vacuum capped. The texture
of Sri kaya must be fine and not lumpy and color is natural color of Seri Kaya. The specifications
that must be complied are brix, preservative present, cadmium presence as chemical analysis,
total plate count, yeast and mold count and Salmonella and E.coli detection as microbiological
analysis.
4.5 Corrective action
23
There are some steps and procedures taken if any non-conformance occurred. If there is
any problem with the products, the batch is not released. The must be keep in view (K.I.V) for at
least 2 weeks. During that time duration, the product will be check regularly to ensure that the
standard is complies. Before releasing each batch, some samples will be taken for company’s
observation. This is necessary when any complaints about the product are received from either
the customers or the retailers. Traceability of product is a vital to assist in identify which batch of
product have a problem that mentioned or complaint by the customers and helpful for product
recall.
The corrective action required to prevent recurrence is evaluated, documented, and its
effective implementation is monitored. All rectification is subsequently re-inspected to ensure
complete customer satisfaction.
4.6 Quality control equipment
Production and measuring equipment held is maintained in good condition, and capable
of safe and effective operation within a specified tolerance of accuracy. Test and measuring
equipment is regularly inspected or calibrated to ensure that it is capable of accurate operation, by
comparison with external sources traceable back to National Standards.
Equipment that used in quality checking for all product are refractometer, brinometer, pH
meter, viscometer, consistometer, hydrometer and thermometer.
4.7 Raw materials
24
The raw materials received will be placed in the warehouse which the temperature and
moisture is controlled (suitable to control any possible spoilage). The raw material will be placed
accordingly and well-arranged. The raw materials like onion and garlic which are not suitable to
be placed in open area, they will be stored in cold room. All raw material received will be check
its quality by Quality Assurance Officer following the standard specification and all data must be
recorded in specific document. Raw materials and finished good must follow the ‘First in first
out’ system. Use the “first in, first out” rule meaning that foods should be used in the order they
are delivered for raw material or produced for finished goods.
4.8 Personnel hygiene
Personnel hygiene is very important. All workers who have direct contacts to the products
must wear mask, head cover and glove to minimize the contaminations. If hand glove is not
practical, they must wash hands regularly. However, there are still workers who not wearing
mask and head covers in the production and packaging areas. Strict implementation must be
applied to ensure the safety and hygiene of the products.
4.9 Packaging system
25
All products have primary and secondary packaging. For soy sauce, the primary
packaging are glass bottle, crown cap and cap seal. Same goes to tomato and chili sauce but have
an addition of plastic bottle (HDPE) for 2.3 kg packing. While Ser kaya use glass bottle, twist cap
and cap seal for primary packaging. The secondary packaging is same for all products. They are
corrugated cardboard and plastic shrink wrap.
The principle of plastic shrink wrap is when heat is applied to this material it shrinks
tightly over whatever it is covering. Heat can be applied with a hand held heat gun (electric or
gas) or the product and film can pass through a heat tunnel on a conveyor. A shrink film can be
made to shrink in one direction (unidirectional or mono-directional) or in both directions
(bidirectional).
Films are stretched when they are warm to orient the molecules from their initial random
pattern. Cooling the film sets the film's characteristics until it is reheated: this causes it to shrink
back toward its initial dimensions.
26
CHAPTER 5
LABORATORY ACTIVITIES
5.1 Microbiology lab
5.1.1 Introduction
During my practical period, I have spent most of my time in microbiology lab to learn
more on starter culture for koji been made and practice ‘hands-on’ to produce the starter culture
called inoculums. Other than that, the inoculation of Aspergillus oryzae in a Petri plate must be
conducted to produce the inoculums. The lab is equipped with the basic equipment like oven,
laminar-air flow, utensils for inoculation, petri plates and analytical balance.
5.1.2 Preparation of Microbial Culture Media
27
As Aspergillus oryzae is the starter culture use to make the koji, Potato Dextrose Agar
(PDA) is use to inoculate the strain in petri plates. PDA recommended for plate counts of yeasts
and moulds in the examination of foods and dairy products. It is also used for the stimulation of
sporulation (slide preparations), maintenance of stock cultures of certain dermatophytes and for
differentiation of atypical varieties of dermatophytes by pigment production. PDA is a fungal
media (common organisms that can be cultured on PDA are yeasts such as Candida albicans and
Saccharomyces cerevisiae and moulds such as Aspergillus niger) and does not contain agar. The
nutritionally rich base (potato broth) encourages a very rich fungal and mold growth. Dextrose is
the fermentable carbohydrate as carbon and energy source.
5.1.3 Inoculums Production
Spores of Aspergillus oryzae grown on PDA agar are introduced into sterilized koji
materials, which consist of coarse blended soy beans and been incubated for 5 days in trays. The
tray are covered with aluminum foil and few small hole have been made to provide aeration and
oxygen for fungal to grow. This can also called starter. The colour of high quality
starter/inoculums is yellowish green and the growth must be at least 80% throughout the tray.
5.2 Analysis Lab
28
Food analysis was run to ensure every product conformed Food Act 1983. Many type of
analysis must be conducted to assure the product quality. Some of the necessary analysis are salt
content, 3-MCPD test, Total Nitrogen Content, Benzoic Acid content for soy sauce, Total acidity
and benzoic acid content for chili and tomato sauce, and Preservative detection for Sri Kaya
product. But, there is only one analysis that have been conducted in this lab which is Total
Nitrogen Determination for soy sauce. Others analysis have been conducted by external lab.
Analysis lab is equipped with complete Total Nitrogen Analysis Unit and chemical solutions that
requires for the analysis.
5.2.1 Total Nitrogen determination
5.2.1.1 Introduction
The purpose of conducting the experiment is to determine the nitrogen content
(percentage of nitrogen) in the soy sauce. The amount of nitrogen must not less than 0.6 per cent
w/v of total nitrogen according to Food Regulation 1985.
A food is digested with a strong acid so that it releases nitrogen which can be determined
by a suitable titration technique. The amount of protein present is then calculated from the
nitrogen concentration of the food. The whole experiment of determination can be divided into
three phases that have to be performed in a day. The three phases are The Kjeldahl method can
conveniently be divided into three steps: digestion, neutralization and titration.
Along my industrial training in the company, I have performing the similar experiment
eight times, each time with slightly different procedures. From the three phases of the
29
experiment, I was mostly involving directly in all phases by starting with preparation of the
chemical reagents and samples to be used in the experiment. The summary of the whole
experiment is described in Figure below.
Figure 5.2.1.1: Main process of experiment
5.2.1.2 Principles of analysis
i) Digestion phase
The sample (bean water or soy sauce) to be analyzed is weighed into a digestion flask and then
digested by heating it in the presence of sulfuric acid (an oxidizing agent which digests the food),
anhydrous sodium sulfate (to speed up the reaction by raising the boiling point) and a catalyst
(selenium) to speed up the reaction. This phase conducted use Kjeldaltherm unit. Digestion
converts any nitrogen in the food (other than that which is in the form of nitrates or nitrites) into
ammonia, and other organic matter to C02 and H20. Ammonia gas is not liberated in an acid
solution because the ammonia is in the form of the ammonium ion (NH4+) which binds to the
sulfate ion (SO42-) and thus remains in solution:
N(food) (NH4)2SO4 (1)
ii) Neutralization phase
30
Preparation of samples and
reagent
Digestion process
Neutralization process
Titration process
After the digestion has been completed the digestion flask is connected to a receiving
flask by a tube. The solution in the digestion flask is then made alkaline by addition of sodium
hydroxide, which converts the ammonium sulfate into ammonia gas:
(NH4)2SO4 + 2 NaOH 2NH3 + 2H2O + Na2SO4 (2)
The ammonia gas that is formed is liberated from the solution and moves out of the
digestion flask and into the receiving flask - which contains an excess of boric acid. The low pH
of the solution in the receiving flask converts the ammonia gas into the ammonium ion, and
simultaneously converts the boric acid to the borate ion:
NH3 + H3BO3 (boric acid) NH4+ + H2BO3
- (borate ion) (3)
iii) Titration phase
The nitrogen content is then estimated by titration of the ammonium borate formed with
standard sulfuric acid, using a phenolphthalein as indicator to determine the end-point of the
reaction.
H2BO3- + H+ H3BO3 (4)
The concentration of hydrogen ions (in moles) required to reach the end-point is
equivalent to the concentration of nitrogen that was in the original food (Equation 3). The
following equation can be used to determine the nitrogen concentration of a sample that weighs m
grams using a xM HCl acid solution for the titration:
31
(5)
Where vs and vb are the titration volumes of the sample and blank, and 14g is the
molecular weight of nitrogen N. A blank sample is usually ran at the same time as the material
being analyzed to take into account any residual nitrogen which may be in the reagents used to
carry out the analysis. Once the nitrogen content has been determined it is converted to a protein
content using the appropriate conversion factor: %Protein = F %N.
5.2.1.3 Reagent preparation
For this experiment, I was assigned with tasks of preparing the reagent the day before the
analysis was carried out. The reagents that I need to prepare were Sulfuric acid concentrated
(H2SO4) 0.01N, Sodium hydroxide 40%, 20% and 10% and boric acid 2%. All these reagents
will be needed in the coming extraction process. Some of the reagents have to be prepared by
dissolving them in water while some other reagents have to be diluted in water. Since most of the
reagents are corrosive chemicals, therefore it must be handled in the fume hood and I was
required to wear a respirator (mask) and safety glove while performing the preparation, as well as
during conducting the digestion phase.
32
After all the reagents had been prepared, the experiment will be carried out on the
following day. I was involving directly in the whole phases of experiment and be monitored by
my supervisor.
5.2.1.4 Result and discussion
The samples used in this experiment can be sweet soy sauce and salty soy sauce. I will
show the result of four (4) experiments out of eight (8) that have been done in the Appendix. The
enclosed results are followed with the discussion and conclusion of each experiment.
33
CHAPTER 6
PROJECTS AND TASK DURING INTERNSHIP
6.1 HACCP documentation
6.1.1 Task description
The hazard analysis critical control point concept is a systematic approach to the
identification, assessment and control of hazards. It is very simple because it only identifies
potential food safety problems and determines where they could be controlled and prevented.
6.1.2 Methodology
I have been collecting the information of all possible hazards that may be present in
manufacturing soy sauce product by observing the working culture of the workers and how they
practice in limiting any possible hazard to the food products. I also used discussion method with
34
the other staffs to gather information. Finally, I gather information through the online journals
and books too. Since I was provided a computer with internet access therefore browsing the net
for information was indeed very easy.
6.1.3 Hazard Analysis
Hazard analysis has been conducted in a table form with specific information related. The
tables are enclosed in Appendix section of this report.
6.1.4 HACCP Plan Form
HACCP plan is a form where determine the Critical Control Point of the whole process. It
is including critical limits, corrective action and verification. These analyses has been
documented and attached to the Appendix.
6.1.5 Summary
From the HACCP Plan Summary, I have determined some Critical Control Points (CCP)
of soy sauce products in term of ingredients and processing steps. All Critical Control Points
must be control to ensure the hazard that may come across will be inhibited. There are two (2)
CCP that have been identified.
35
6.2 Waste water treatment plant analysis
Major aim of wastewater treatment is to remove as much of the suspended solids as
possible before the remaining water, called effluent, is discharged back to the environment.
6.2.1 Objective
The purpose of this observation is to find the best treatment medium to treat the waste
water in Zara Foodstuff Industries.
6.2.2 Methodology
The observation has been conducted for a months and the results are shown in the table
and graph below. The treatment of the waste water has been treated using two type of medium.
They are Active Orange, a brownish orange solution contain active microorganisms that will
digest the microorganism that give bad odour and acidic condition and Active Ball, a mud-like
composite that contain active microorganism that will play the same role like Active Orange.
The observation is based on the ratio of sample to treatment medium (sample: treatment
medium) as we do not know the exact amount of treatment medium to be used to treat the waste
water. Each treatment is represented by seven (7) samples and each sample represents each ratio.
The samples are labelled with A, B, C, D, E, F and G with different ratios. All ratios represented
with duplicate samples.
36
Label Ratio
(sample: treatment medium)
A 1 : 1
B 1 : 2
C 2 : 1
D 1 : ¾
E ¾: 1
F 1 : ¼
G ¼ : 1
Table 6.2.2: Samples ratio
The treatment using Active Orange was conducted with a total amount of waste water use
in each sample is 200ml. The amount of Active Orange is based on the ratio above. On the other
hand, usage direction of Active Ball has been stated on the packaging. The application of 1
Active Ball can be used to treat 1 m3 or 1000 litre waste water. For the observation, the sample
with a ratio 1: 1 is followed the application direction amount. The average weight of each Active
Ball is 190 grams and it can be used for 1000 litres waste water. The observation sample only
used 100 ml waste water. The treatment medium use is too little and the Active Ball must have to
be crashed into powder to be easily weighed.
6.2.3 Observation
After 3 weeks, the sample using Active Ball changes into dark colour (black) and odour-less and
this shows that the microorganism has been fully breakdown and digested while the samples
using Active Orange still have same colour like on Day 1 and have bad odour (stingy). The pH
change is obviously differs within a week where Active Ball treatment increase the acidity level
to a natural level.
37
6.2.4 Errors and problems
There are some errors occurred during the analysis. There is no control sample to compare
the result and the best control sample is distilled water. The other obvious error is the amount of
Active Ball may not be accurate as the amount use for each sample is too little that make it
difficult to measures accurately.
The most important thing is to first know the composition of waste water and examined
its BOD/COD level to determine the level of contamination. From the BOD level, we can find
the best treatment for the waste water. But in this analysis, there is no study run before conduct
the analysis.
38
Medium Sample Day 1 Day 7 Day 14 Day 21
1 2Averag
e1 2 Average 1 2 Average 1 2 Average
Active orange A 3.66 3.67 3.67 3.70 3.71 3.71 3.73 3.67 3.70 4.55 4.50 4.53
B 3.65 3.66 3.66 3.49 3.58 3.54 3.44 3.44 3.44 4.14 3.96 4.05
C 3.70 3.69 3.70 3.76 3.81 3.79 3.99 3.88 3.94 4.86 4.62 4.74
D 3.69 3.69 3.69 3.71 3.72 3.72 3.71 3.69 3.70 4.39 4.33 4.36
E 3.67 3.68 3.68 3.58 3.57 3.58 3.47 3.53 3.50 4.17 4.23 4.20
F 3.73 3.75 3.74 4.04 4.39 4.22 3.18 6.18 4.68 5.05 6.77 5.91
G 3.67 3.67 3.67 3.60 3.63 3.62 3.45 3.45 3.45 4.06 3.98 4.02
Active ball A 3.82 3.82 3.82 7.57 7.56 7.57 7.64 7.77 7.71 7.91 8.42 8.17
B 3.80 3.85 3.83 6.99 7.73 7.36 7.71 7.78 7.75 8.23 8.50 8.37
C 3.82 3.81 3.82 7.48 7.86 7.67 8.00 7.88 7.94 8.44 8.51 8.48
D 3.81 3.81 3.81 7.47 7.40 7.44 7.78 7.90 7.84 8.44 8.38 8.41
E 3.80 3.80 3.80 7.51 7.38 7.45 7.79 7.98 7.89 8.34 8.36 8.35
F 3.81 3.79 3.80 7.44 7.16 7.30 7.88 7.66 7.77 8.33 8.07 8.20
G 3.82 3.83 3.83 7.65 7.53 7.59 8.11 8.04 8.08 8.41 8.29 8.35
Table 2: Result on pH changes based on two type of treatment medium within 3 weeks
39
40
6.2.5 Conclusion
We can conclude that Active Ball is the best treatment medium to treat the waste water as it gives
higher rate of reaction with obvious changes after 1 week of treatment than treatment with Active
Orange. But further observation must be conducted to ensure the effectiveness of the treatment
medium application.
6.3 Findings on ‘white flakes’ issue
I have been given a task on finding the possible reason of the phenomenon of ‘white
flakes’ on the surface of soy sauce. The possible reason of this ‘white flakes’ to be appeared is
maybe caused by yeasts due to lack of brine percentage during fermentation. I have found some
facts that support the reason that I have stated above by reading of journals and books and also
have some ideas from my Dean. In traditional products, non-pasteurized products or products
with a low salt content, aspergilli, film and pellicle-forming yeasts may cause spoilage (Roling et.
al., 1994). In low-salt (<15%) sauces, some types of spoilage bacteria may also grow unless the
pH is low or preservatives (e.g. sodium benzoate) are present.
The principal contaminants of koji are coagulase-negative Staphylococcus spp. And B.
subtilis (Chiba, 1977). The contaminating Staphylococcus spp. grow symbiotically with koji
mold, and the combination becomes a problem when koji fermentation takes place at low
temperatures (at or below 25°C), whereas B. subtilis grows in competition with koji molds,
especially at higher temperatures. Wild salt-tolerant lactic acid bacteria may grow in soy sauce
and produce biogenic amines such as tyramine and histamine (Uchida, 1982; Stratton et.al.,
1991). Some wild salt-tolerant lactic acid bacteria may produce ornithine by decomposing
arginine in an abnormal fermentation, resulting in the accumulation of citruline as an
41
intermediate product. When such raw soy sauce is pasteurized, ethyl carbamate can be produced
by the reaction between citrullin and alcohol ( Matsudo et. al., 1993).
A salt-tolerant wild yeast Z. rouxii var. halomembranis can grow in moromi that has
progressed to the maturation process. This wild yeast is harmless to health, but has a high salt-
tolerance, and grows to form a membranous film on the surface of moromi or soy sauce resulting
in deterioration of the soy sauce aroma and flavour.
6.4 3-MCPD findings
3-MCPD (3-monochloropropane-1,2-diol) is the most common of the group of food
contaminants called chloropropanols. 3-MCPD can cause cancer in laboratory animals fed large
amounts over their lifetime. Although people usually consume chloropropanols only at low
levels, there is still concern that these chemicals may be a health risk. 3-MCPD has been detected
at low levels in many foods and food ingredients, such as breads, savory crackers, toasted
biscuits, cheeses, doughnuts, burgers, salami, malts, and modified starches. 3-MCPD is found at
higher levels in some soy sauces and the savory food ingredient, acid-hydrolyzed vegetable
protein (acid-HVP).
3-MCPD has probably been present in foods for a long time, but it was only recently that
scientists were able to detect it reliably. Its occurrence in hydrolyzed vegetable proteins is related
to the production process that uses acid hydrolysis. The source and formation of 3-MCPD in soy
sauces are still being studied. There are several hypotheses on the origin of the compound in soy
sauces, including the addition of acid-HVP as a savory ingredient or the use of acid hydrolysis in
the food’s manufacture. Not all soy sauces contain 3-MCPD. Only about 22 percent of soy sauces
42
tested were found to have detectable levels. The traditionally brewed soy sauces did not contain
the contaminant. The Joint FAO/WHO Expert Committee on Food Additives (JECFA) has
concluded that 3-MCPD is an undesirable contaminant in food and recommended that its
concentration in hydrolyzed proteins should be reduced to the lowest level technically feasible.
3-MCPD in soy sauce is produced as a contaminant by-product of a flavour enhancer
known as acid-hydrolysed vegetable protein. Flavour enhancers are commonly added to
commercially produced food products (for example frozen dinners, instant soups, snack foods)
and some soy sauces to make them taste more 'savoury'. 3-MCPD was originally detected in acid-
hydrolysed vegetable protein (HVP) and was subsequently found in HVP-containing soy sauces.
It is important to remember that not all soy sauces contain 3-MCPD. It is not present in
fermented soy sauces. Therefore, most of the mitigation measures employed by industry centre
around the careful control of the acid hydrolysis step during production of soy sauces.
6.5 Moromi mash waste – useful or useless?
Moromi mash waste is the residue after final extraction of moromi solution. It is a useful
byproduct containing nutritive ingredients of soybeans and wheat as well as functional
ingredients generated in the process of brewing. For example, it contains rich fat, highly
antioxidant fat-soluble Vitamin E, as well as Vitamin K1 which is indispensable for blood
coagulation and a lot of isoflavone that is antioxidant and acts like a female hormone. Through
the work of microbial enzymes, isoflavone is disconnected from malonic acid and sugar and
becomes aglycon.
43
Low quality waste of moromi mash is used to make into soy sauce oil for lamps through
elaborate processes, and used also as fertilizer. Other than that, the waste has long been used as a
safe feed for livestock in general. Analyses of the basic components, and the functional
components of lipophilic vitamins (E, K1) and isoflavones were made in November 2004 by
Kikkoman. Result shown in Appendixs.
44
CHAPTER 7
SUGGESTION AND RECOMMENDATION
Based on my 15 weeks experience, I’ve concluded that Quality Department of Zara
Foodstuff Industries are on the right track achieving their short and long term goals; provided that
they continues to cater client’s request on the timely manner, consistently improve workflow
efficiency by optimizing the usage of information and communication technology (ICT) and
available laboratory hardware, and strengthening knowledge and skills of its members through
professional consultation or training programme.
For laboratory facilities, there are still rooms for improvement especially in terms of the
quantity of basic equipments. For example, the loop for streaking strains is not in a good
condition. The most important things, the hygiene of workers must be enhanced and avoid any
possible cross contamination.
During this internship period, Quality department have gave me many valuables
knowledge, experience, and hence I would like to highly recommend any particular whom are
interested in gaining real-life working experience, knowledge which are in-accessible in
45
reference books and lecture, and last but not least to be skilful in lab work to pursue job in this
department.
46
CHAPTER 8
CONCLUSION
During 15 weeks of industrial training at Zara Foodstuff Industries, I have learned a lot of
things that prepared me with working experiences such as how microbiology laboratory operates,
how to do chemical analysis and how to test and check the products based on rules and regulation
in Food Act (1983) and Food Regulation (1985) and company’s specification. All analysis were
run to ensure locally-distributed or exported products are safe and in good condition.
I also learned how to work as independently and other practical and real-world situation
of which are not taught in the classroom. The objectives of industrial training are all achieved.
47
REFERENCES
1. Catharina Y.W. Ang, Catharina Yung-Kang Wang-Ang, KeShun Liu and Yao-Wen
Huang (1999). Asian foods: science & technology : Technomic Publishing Company Inc.
2. Stephen A. Osmani, Gustavo Henrique Goldma. (2008). The Aspergilli: genomics,
medical aspects, biotechnology, and research methods : CRC Press
3. KeShun Liu. (1997). Soybeans: Chemistry, Technology and Utilization : Aspen
Publishers
4. Yiu H. Hui (2006) Handbook of food science, technology, and engineering, Volume 1 :
CRC Press
5. T. Boekhout, Vincent Robert . (2003). Yeasts in food: beneficial and detrimental aspects :
Behr’s Verlag
6. Barbara M. Lund, A.C. (Tony) Baird-Parker, G.W. (Grahame Warwick) Gould,
GrahameW. Gould. (2000) .The Microbiological Safety and Quality of Food
7. S. J. Forsythe, P. R. Hayes. (2000). Food Hygiene Microbiology and HACCP: Aspen
Publishers (Original work published 1998)
48
8. http://www.bellaonline.com/articles/art32465.asp
9. http://www3.interscience.wiley.com/journal/119439828/abstract
10. http://www.springerlink.com/content/t22g2u4805171034/
11. http://www.bd.com/ds/technicalCenter/inserts/Potato_Dextrose_Agar.pdf
49
50