Академический Документы
Профессиональный Документы
Культура Документы
net/publication/40124662
CITATIONS READS
43 226
7 authors, including:
Some of the authors of this publication are also working on these related projects:
HPLC Fingerprint Characteristics of Active Materials of Garlic and Other Allium Species View project
All content following this page was uploaded by Hendrik H Beeftink on 09 March 2016.
ABSTRACT
China uses solid-state fermentation (SSF) processes on a large scale for products
such as vinegar, Chinese distilled spirit, soy sauce, Furu, and other national foods
that are consumed around the world. In this article, the typical SSF process is
discussed, with a focus on Chinese vinegars, especially those that are prepared
through solid-state fermentation. Six well-known types are discussed in detail.
Finally, possible ways to improve the traditional vinegar production process are
discussed. The article discloses Chinese information about solid-state vinegar
fermentation that otherwise would be inaccessible to Western scientists due to
language barriers.
407
INTRODUCTION
Figure 1. General flowchart of SSF for Chinese vinegar depicting the four steps.
vinegar. Then, six major types of SSF-prepared Chinese vinegars are reviewed.
Finally, opportunities to improve the traditional SSF processes and the possible
implementation of such innovations are discussed.
HISTORY
China probably has the oldest historical records about cereal vinegar in
the world. The book Ceremony Notes (about 800 b.c.) (Xiao, 2000) recorded that
vinegar played an important ceremonial role during the Zhou dynasty (1000 b.c.–
256 b.c.). Also, in The Analects of Confucius (450 b.c.), there are many records on
vinegar (Xiao, 2000). In Techniques of Qinese (533–544 a.d.), 23 methods for vinegar
preparation are described in detail, among which the SSF method with cereals, a
repeated successive fermentation process, was a unique technique for vinegar
preparation (Bao, 1985).
Until the late Qing Dynasty (1644–1911 a.d.), when industrial-scale vinegar
production appeared (Zhang, 2000), Chinese vinegar was only domestically
produced on a small scale. It is generally believed that the production process of
Shanxi old mature vinegar was invented by Wang Laifu during the Qing Dynasty,
between 1644 and 1661 a.d. (Yan, 1997). The fuming technique that characterizes
this process is still used widely by all old mature vinegar manufacturers (Yan, 1997).
The Zhenjiang Henshun vinegar plant was established in 1840 a.d. and still is a major
producer of aromatic rice vinegar, with an annual yield of 60 million kilograms
(Ren and Jian, 2000).
ORDER REPRINTS
Raw Material
The main raw materials for production of traditional Chinese vinegars are
cereals and their bran (i.e., the outside layers of grains, containing about 50%
starch). In more recent years, however, many other starch and sugar-containing
materials, such as sweet potato and fruits, have found their way into vinegar
production, resulting in new types of vinegar. Table 1 lists the main raw materials
that are used for Chinese vinegars. The type of raw material is the basis for the
specific characteristics of different vinegar types (Zhu, 1991a). Wheat bran is the
main carrier of microorganisms in the SSF system; besides being a source of starch, it
also provides other nutrients, such as proteins, to microorganisms. Rice hull has less
nutritional value. It merely acts as a carrier of microorganisms and spacer to increase
porosity of the substrate mixture (Liu and Li, 1992).
Microorganisms
fermentation (Huang and Yin, 2000a). In almost every Chinese vinegar SSF process,
several species of acetic-acid bacteria are present: Acetobacter pasteurianus is
the predominant species in Zhenjiang vinegar, due to the high initial ethanol
concentration (Huang and Cai, 1999). A. aceti dominates in Sichuan bran vinegar
production, whereas in Jiangzhe and Fujian vinegars, A. xylinum is the main
bacterium. A. xylinum forms a pellicle on the surface of the static liquid (Lei, 2000),
which is different from traditional wine vinegar production methods (e.g., the
Orleans method and the Balsamic method) where a foam rather than a pellicle forms
at the surface (Adams, 1985). Other bacteria, such as Gluconobacter and lactic-acid
bacteria, are commonly found as well and their metabolites contribute to the
characteristic flavor and aroma (Lei, 2000).
Composition
than common vinegar. Xia et al. (1985) made a dynamic analysis of the formation of
main components in Chinese vinegar during SSF or traditional SmF. They showed
that during SSF, different components are formed continuously and simultaneously,
whereas in SmF, components are formed more sequentially. The traditional
SmF, however, is very different from modern SmF, as it uses mixed cultures like
in SSF; the quality of the traditional product is regarded as superior to modern
SmF vinegar (Liu, 1982). Similar traditional SmF processes are used in Europe to
produce high-quality wine vinegar (Tesfaye et al., 2002).
Koji Preparation
sticky
rice soak cook cool mix
water koji,
yeast
saccharification acetic-acid
alcohol fermentation fermentation
(liquid) rice hull (solid)
wheat bran
parent Pei
salt
Materials kg Products kg
Sticky rice 500 Aromatic vinegar
Koji 30 (6.5% acetate) 1450
Wheat bran 850 waste 2625
Rice hull 475
Water 2200
Salt 20
sorghum
grind soak mix steam
rice hull
wheat bran
saccharification acetic-acid
cool mix alcohol fermentation fermentation
(solid) (solid)
wheat bran
yeast, water
parent Pei
Materials kg Product kg
Sorghum 500 Fumed vinegar
Wheat bran 350 (6% acetate) 400
Rice hull 350 or
Koji 300 Old mature vinegar
Water 2400 (>10% acetate) 120
Salt 25
B
Figure 2. Flowchart of solid-state fermentation of Chinese vinegar. A, Cook method
(Zhenjiang aromatic vinegar); B, steam method (Shanxi old mature vinegar). (Data from
Huang and Cai (1999).)
ORDER REPRINTS
Water
(2 d)
Figure 3. Typical flowchart of preparation of Chinese great koji. Koji cakes are piled in line
in the ‘‘koji house.’’ At different stages, temperature is controlled by adjusting the spacing
among the cakes and opening or closing windows. The period indicated in the bracket may
vary a little between winter and summer. For more details, see text.
Great koji (Da Qu, in Chinese) and mini koji (Xiao Qu) are the most
traditional koji. Figure 3 is a chart of the typical preparation of Chinese great koji,
which was used to produce traditionally distilled spirit and vinegar (Huang and
Cai, 1999).
Every step of the process schematized in Fig. 3 must be carried out carefully to
ensure high-quality koji (Wang, 1999), and practical experience and hands-on
knowledge are very important. The fermentation actually consists of three stages,
each at a different temperature. As a result, specific fungi proliferate (Wang, 1997).
These different temperatures are obtained by controlling the heat transfer among the
cakes (by adjusting the spacing) and the heat transfer from the koji room to the
environment (by closing or opening the windows). The important processes are
metabolic heat production, heat convection, and water evaporation. Finally, most of
the water in the great koji evaporates and most microorganisms lose viability. Only
temperature-tolerant fungal enzymes remain and play an important role in the
subsequent saccharification (Wang, 1995).
The preparation of mini koji is similar to that of great koji, with the dominant
microorganism being Rhizopus rather than Aspergillus (Huang and Yin, 2000a).
Other kinds of koji are much simpler to prepare. Instead of great koji, more and
more companies use wheat koji, which is prepared from a pure culture of Aspergillus
sp. and wheat. Bran koji is another pure-culture product. The preparation of
pure-culture koji and the relevant reactors have been described elsewhere (Kitamoto,
2002). The preparation of koji is laborious and time consuming. Some
manufacturers tried to replace the saccharifying action of koji with enzyme
mixtures, but found that the quality of their products was negatively affected
(Hou et al., 1996).
ORDER REPRINTS
Acetic-Acid Fermentation
In the cook method, the fermented broth or solids from the alcohol fermentation
are mixed with wheat bran and vinegar seeds (i.e., parent vinegar Pei from the last
batch of acetic-acid fermentation or, as an alternative, an inoculum of acetic-acid-
producing bacteria such as Acetobacter). For the steam method, wheat bran and rice
hull are mixed with the main starch materials before alcohol fermentation, so only
vinegar seeds need to be added after alcohol fermentation. Wheat bran is used as a
substrate and as a carrier for the bacteria, whereas rice hull is used both as a carrier
of the bacteria and a spacer increasing porosity, thus increasing the exchange area
and promoting oxygen uptake and heat discharge. The ratio of the main substrate to
the bran and rice hull is generally 1 :1.2 : 1.4 (Liu and Li, 1992). The manufacturers of
Sichuan bran vinegar use pure wheat bran as the only solid substrate.
The traditional acid fermentor is a clay jar (about 0.5 m3 capacity). Nowadays,
many manufacturers replace it with a concrete basin (about 8 m3), which in fact is a
deep-bed tray system with intermittent mixing. Rice hull is fed to the fermentor
during mixing. Compared with the thin-layer tray system, the surface area per unit
volume in deep-bed tray system is reduced and consequently, evaporation of ethanol
is reduced. At the same time, intermittent mixing and rice-hull feeding facilitate
oxygen diffusion. The most important variable at this stage is the temperature, which
is controlled by stirring and turning the substrate (Liu, 1982; Zhu, 1991b). If there
is sufficient oxygen, bacteria will propagate and metabolize rapidly and produce a
large amount of metabolic heat. When the temperature becomes too high, the
operator will ‘‘turn up’’ or mix, the substrate to disperse heat, and then press the
surface to reduce oxygen supply, thereby decreasing the rate of ethanol consumption
and heat production (Yu, 1985). The temperature is usually kept at 38 C to 40 C.
Generally, stirring and turning up the substrate is carried out once per day
(Guo, 2000). Some manufacturers use concrete basins with two bottoms (the upper
ORDER REPRINTS
Maturation
Shanxi old mature vinegar is the most famous vinegar in northern China. It has
a history of more than 300 years. In the province of Shanxi, there are more than 1000
vinegar manufacturers that produce mature vinegar, fumed vinegar, and old mature
vinegar. Only 120 producers sell their products outside the province (Wang, 1997).
Shanxi old vinegars use sorghum as the main raw material with a very large
dosage of great koji (about 60% of the raw materials) (Huang and Cai, 1999).
Production of Shanxi old mature vinegar takes about 18 months, although the acid
production itself takes less than 10 days. The most time-consuming stage is the
maturation process. Upon fermentation, half of the solid Pei is ‘‘fumed’’ (heated in a
jar with a lid at 70 C for 4 days) and then mixed with the remaining half and leached.
Flavor compounds are formed chemically during fuming. The filtrate is transferred
to a big jar and is exposed to the sun (solarized); in winter, surface ice is removed.
Solarization and ice removal entail a concentration increase of acetic acid and flavor
substances formed by chemical and enzymatic reactions.
Preparation of great koji is also lengthy, taking more than 1 month. One of the
major challenges is to improve the process in such a way that the total production
time is significantly reduced while preserving the typical flavor style of old mature
vinegar (Yan, 1997). Replacing part of the great koji with wheat bran and applying
new maturation methods (e.g., infrared vacuum concentration instead of natural
evaporation and maturation), together with modern formulation methods, might
increase productivity and consistency of quality greatly (Wang, 1997).
Zhenjiang aromatic vinegar is most famous in Southern China. Its main raw
materials are sticky rice and wheat koji. Henshun Group Co., Ltd., is the largest
manufacturer and its product, KingsanÕ vinegar, is sold in more than 43 countries
ORDER REPRINTS
(Ren and Jian, 2000). Zhenjiang aromatic vinegar is a typical example of the
so-called ‘‘cook method’’ for ethanol production. However, the acetic-acid stage is a
unique multilayer SSF with a fed-batch fermentation process in a series of two open
containers (big jar or basin). First, a certain amount of rice wine (about 14%
ethanol, v/v) is mixed with wheat bran, rice hull, and so-called vinegar seeds (i.e.,
starter culture) to form a semi-solid substrate in the first container (half volume).
The substrate is divided in 10 layers; every 24 h, the top layer is mixed with fresh rice
hull to increase porosity and transferred to the second container; after 10 days, the
first container is thus empty and the second one full (Chen and Chen, 1996). This
process is called ‘‘fed-batch fermentation by layers’’ (Guo, 2000). Ethanol oxidation
and acetic-acid formation mainly take place in the top layer of the second container,
which is exposed to the air. In the old days, feeding and mixing was done manually.
In more recent years, technicians of the Henshun plant modified the process by
introducing a concrete basin with mechanical mixing, thus reducing manual
labor input. As a result, productivity was greatly increased and the vinegar quality
remained unaffected (Zhou, 1990). These changes made Henshun the largest vinegar
producer in China; they changed the view that a traditional process could not be
altered without affecting the quality of the product.
Sichuan is a hilly province in Southwest China. Its climate, mild all year
round and misty in autumn and winter, is favorable for specific microorganisms
that are a basis of traditional SSF. Chinese spirit (Bai Jiu, in Chinese) and
bran vinegar are the main fermentation products in Sichuan. Both are produced
by SSF, and both are based on mixed cultures of natural origin. BaoningÕ vinegar
and ZigengÕ sun vinegar are the most famous Sichuan bran vinegars (Feng et al.,
2000).
The raw materials for Sichuan bran vinegar production process are herb koji
(including as many as 108 medicinal herbs), which is the liquid extract of smartweed
leaves (a marsh plant, Polygonum hydropiper, Laliao in Chinese) used to initiate
vinegar fermentation; and wheat bran, used both as carrier and substrate in the
fermentation process. Production of herb koji is rather selective for specific
microorganisms. Unlike most other processes, rice hull is not used in bran vinegar
production and neither is parent Pei (fermented bran as vinegar seed) (Li, 1999).
Instead, a special ‘‘vinegar mother’’ is prepared from steamed rice, herb koji, and a
liquid extract of the special smartweed. This mixture is fermented for 7 days, with
intermittent mixing of the semi-liquid broth to provide oxygen for propagation
(Huang and Yin, 2000a). The ‘‘vinegar mother’’ is then mixed with wheat bran to
finish the acetic acid fermentation. Enzymes, yeast, and bacteria from the ‘‘vinegar
mother’’ convert the bran starch into ethanol, and finally, acetic-acid. The 14-day
fermentation is a combined alcohol and acetic-acid fermentation. When the
fermentations finished, the vinegar Pei is stored in a closed jar for maturation
(about 1 year) before extraction.
ORDER REPRINTS
Fujian red rice vinegar is prepared by combined SSF and SmF. Red koji, in
which Monascus dominates, is used as the saccharifying agent and is produced by
SSF. Production of Fujian red-rice vinegar itself is a special type of repeated fed-
batch SmF (Liu, 1982). During saccharification and alcohol fermentation (about 70
days), water that has been boiled and then cooled is added to the mixture of steamed
sticky rice and red koji in three batches, thus initiating an acid fermentation that lasts
3 years. Acid formation is a static SmF with intermittent manual mixing. Generally,
50% of the three-year-old product is harvested as finished product; into its residue,
50% of two-year-old product is fed. Half of the one-year-old product is then fed into
the residue of the two-year-old batch; the other half is supplemented with a freshly
fermented alcohol solution (Liu, 1982).
Production of Fujian red-rice vinegar takes a long time because no inoculum
is used; all microorganisms arise spontaneously from the environment and it takes
a long time for the target microorganisms to proliferate and become dominant. In
addition, acid production occurs by static fermentation without forced aeration.
Hence, low concentrations of oxygen in the broth prevent rapid oxidation of ethanol.
ORDER REPRINTS
studying the Chinese traditional SSF processes may provide a foundation for
their large-scale industrial applications. The deep-bed tray system with intermit-
tent mixing, which is used in Chinese vinegar production, may have a potential
application for flavor production by aerobic fungi.
For the Chinese vinegar SSF process, koji preparation most closely resembles
the typical SSF system because it involves fungi. Acetic-acid fermentation involves
acetic-acid bacteria, altering the process a little. Bacteria, unlike fungi, can resist
mixing. So, at the stage of acetic-acid fermentation, the macrogradients of
temperature, nutrients, and product concentrations can be minimized by mixing.
Mixing also helps in dispersing metabolic heat and improves oxygen transfer, but
also speeds up evaporation of ethanol. Further research on the production processes
is required to better understand aspects such as pH development, oxygen diffusion
during nonstirring period, loss of bacterial viability, and loss of volatile components
through evaporation (e.g., ethanol).
CONCLUSION
NOMENCLATURE
ACKNOWLEDGMENT
This study was funded by TNO Nutrition and Food Research Institute.
ORDER REPRINTS
REFERENCES
Kitamoto, K. (2002). Molecular biology of the koji molds. In: Laskin, A. I., ed.
Advances in Applied Microbiology, Vol. 51. New York: Academic Press,
pp. 129–153.
Lei, M. (2000). Function of microorganisms and enzymes in vinegar production by
SSF. Chinese Condiment 9:20–22.
Li, Y. (1999). The living space of Sichuan bran vinegar. China Brewing 1:3–4.
Lin, Y. (1985). Viewpoints about improvement of aromatic vinegar. Chinese
Condiment 12:8–9.
Liu, J. (1982). Fujian Yunchun old vinegar. China Brewing 1:30–31.
Liu, C., Li, Y. (1992). Study on amount reduction of rice hull in vinegar production
with SSF. Jiangsu Condiment 2:10–14.
Mitchell, D. A., Lonsane, B. K. (1992). Definition, characteristics and potential. In:
Doelle, H. W., Mitchell, D. A., Rolz, C. E., eds. Solid Substrate Cultivation.
London: Elsevier Science Publishers Ltd., pp. 1–13.
Moo-Young, M., Moreira, A. R., Tengerdy, R. P. (1983). Principles of solid
substrate fermentation. In: Smith, J. E., Berry, D. R., Kristiansen, B, eds. The
Filamentous Fungi, Vol. 4. London: Edward Arnold, pp. 117–144.
Murthy, M. V. R., Karanth, N. G., Rao, K. S. M. S. R. (1993). Biochemical
engineering aspects of solid-state fermentation. In: Neidleman, S., Laskin, A. I.,
eds. Advances in Applied Microbiology, Vol. 38. New York: Academic Press,
pp. 99–147.
Nagel, F. J. (2003). In Process Control of Solid-state Fermentation. PhD dissertation.
The Netherlands: Wageningen, 183.
Qiao, J. (1999). The new trade criteria of vinegar and soy sauce will be published.
Chinese Food Information 18:3–4.
Ren, Y., Jian, Y. (2000). The ‘‘vinegar king’’—China Jiangsu Hengshun Group Co.,
Ltd. Food Information 40:34.
Robinson, T., Singh, D., Nigam, P. (2001). Solid-state fermentation: a promising
microbial technology for secondary metabolite production. Appl. Environ.
Microbiol. 55(3):284–289.
Shi, G. (1999). Talk about Chinese Vinegar. China Brewing 6:39–40.
Suo, L., Zhang, Z. (1989). Prospect of production and development of Chinese
vinegar. Jiangsu Condiment 4:16–18.
Tang, J. (1985). Analysis of amino acids in vinegar. Shanxi Food Fermentation
1:51–53.
Tesfaye, W., Morales, M. L., Garcia-Parrilla, M. C., Troncoso, A. M. (2002). Wine
vinegar: technology, authenticity and quality evaluation. Trends Food Sci.
Technol 13(1):12–21.
Wang, B. (1995). Improvement of the solid-state fermentation process for vinegar.
Food Industry 5:28–29.
Wang, Y. (1997). Rebuild the advantages of Shanxi vinegar. Shanxi Food Industry
1:33–36.
Wang, Y. (1999). Analysis of solid-state process for Shanxi vinegar. China Brewing
3:7–11.
Wei, X. (2001). A milestone of condiments administration with industrial standard.
Chinese Condiment 1:3–8.
ORDER REPRINTS
Xia, S., Pang, Y., Liu, S. (1985). The dynamic analysis of the components of vinegar
during its fermentation course. Chinese Condiment 6:5–6.
Xiao, F. (2000). The history and culture of vinegar (1). China Brewing 4:31–37.
Xing, G. (1991). Review of the novel SSF process of vinegar. China Brewing 1:12–16.
Yan, J., Xiong, Y. (1997). Shanxi old mature vinegar. Shanxi Food Industry 1:33–36.
Yu, J. (1985). The points for attention in vinegar production by solid-state
fermentation. Chinese Condiment 2:27–29.
Zhang, P. (2000). Vinegar and soy sauce: necessities in life. China Brewing 4:33–34.
Zhou, L. (1990). The process of vinegar fermentation with pool instead of jar.
Jiangsu Condiment 1:9–15.
Zhu, B. (1991a). The technology of industrial-scale production of brewed vinegar
(2). Jiangsu Condiment 2:30–33.
Zhu, B. (1991b). The technology of industrial-scale production of brewed vinegar
(3). Jiangsu Condiment 3:30–33.
Zhu, B. (1992a). The technology of industrial-scale production of brewed vinegar
(5). Jiangsu Condiment 1:39–41.
Zhu, B. (1992b). The technology of industrial-scale production of brewed vinegar
(7). Jiangsu Condiment 3:28–30.
Interested in copying and sharing this article? In most cases, U.S. Copyright
Law requires that you get permission from the article’s rightsholder before
using copyrighted content.
All information and materials found in this article, including but not limited
to text, trademarks, patents, logos, graphics and images (the "Materials"), are
the copyrighted works and other forms of intellectual property of Marcel
Dekker, Inc., or its licensors. All rights not expressly granted are reserved.
The Materials are for your personal use only and cannot be reformatted,
reposted, resold or distributed by electronic means or otherwise without
permission from Marcel Dekker, Inc. Marcel Dekker, Inc. grants you the
limited right to display the Materials only on your personal computer or
personal wireless device, and to copy and download single copies of such
Materials provided that any copyright, trademark or other notice appearing
on such Materials is also retained by, displayed, copied or downloaded as
part of the Materials and is not removed or obscured, and provided you do
not edit, modify, alter or enhance the Materials. Please refer to our Website
User Agreement for more details.