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KOJI Production Soak Pearl Barley Steam 1 ½ Hr Koji Developed Cool to 45C or less Add Barley Flour and Koji Mugi Spores (Gem Cultures) Incubate, Turn and Furrow (up to 3 days) Brewers Spent Grain Control Furrowed BSG Torque BSG Control Barley Farmery BSG Miso Production Soak Soy Beans Overnight Pack Top with Salt Incubate-Age Pressure Cook Soak Beans Strain Cooked Soy and Reserve liquid BLENDING Brewers Spent Grains KOJI Barley Control KOJI Salt Unpasteurized Seed Miso (Amano) Cooking Liquid Process 1 minute Scarp down Process 1 minute Or Farmery BSG Miso Torque BSG Miso Objective To demonstrate brewers spent grain (BSG) can safely support Aspergillus oryzae growth in koji production. To determine if flavour differences are contributed by different types of BSG for koji, which makes makes up 23% of final miso product. Brewers' spent grain as a substrate in miso production Introduction The increase in microbreweries emerging in Manitoba creates a growing source of brewers’ spent grains (BSG). BSG is currently either used as animal feed or discarded due to its low market value. This project demonstrates the potential to use BSG in a novel food product application. Miso, a Japanese condiment produced by fermenting soybeans with salt and koji, was selected due to the growing resurgence fermented foods. Control (Barley and Soy) BSG Lager – Farmery Brewery (pale malt) and Soy BSG Stout – Torque Brewery (dark malt) and Soy Materials & Methods 3 samples of miso were prepared for the study: Results BSG is a viable substrate in the production of miso. Koji growth utilizing BSG was slower than the control sample due to the lack of available sugars in BSG. Growth is important for enzyme production. Slow or inadequate growth within 3 day can produce aflatoxins or undesirable bacterial spore growth such as B. cereus. The benefits of using a fungal fermentation on the spent grains is that fungi themselves are more tolerant of low moisture, acidity and water activities allowing them to thrive on the low viable nutrient spent grains. Taste panel was conducted at Paterson GlobalFoods Institute with RRC Chef Instructors (n=6). The 2 BSG samples compared to the control sample, but the control sample was higher in the perceived umami traditionally associated with miso. The darker malt BSG provided more depth of flavour. Due to the short aging time for this project; 45 days, the potential of BSG miso was not fully explored in flavour development as well as the textural challenges that came with the fibrous husks particles in the final product from the BSG. Commercial miso is incubated/aged for minimum 1-2 months up to years, depending on the style of miso produced. Food safety controls where put in place to ensure safe production: • Temperature of BSG during steaming, Incubation temperature, relative humidity and length of Incubation. Incubation must not exceed 3 days, due to possible mycotoxin formation. • The relative humidity for optimal germination of fungal spores of A.oryzae is controlled to ensure mycelial growth occurs and limits sporulation. • The process was reviewed throughout for optimal aw, pH and potential mycotoxin production throughout the production. • To optimize the process and for additional aging, a higher percent of salt would be required to lower the initial water activity. Conclusions BSG are a suitable substrate for the production of miso, with some processing modification to optimize. Due to addition of koji in the miso base the different BSG sources contribute different flavour and colour attributes. Malt fibers change the texture compared to commercial varieties. Successful food preparations (broth, popcorn seasoning, chocolate ganache tart) were demonstrated with the various BSG miso’s. Sample Food Preparations Using BSG Miso Selected References • Pitt, J. (2009). Fungi and Food Spoilage. Boston: Springer. • Food and Agriculture Organization. (2016, 12 31). Brewers Grains. Retrieved from Feedipedia: http://www.feedipedia.org/node/74 • GEM Cultures, Inc. (n.d.). Homemade Soybean Koji. Lakewood, WA, USA: GEM Cultures. • Hutkins, R. (2006). Fermentation of Foods in the Orient. In Microbiology and Technology of Fermented Foods (pp. 419-436). Iowa: Wiley-Blackwell. • Ebine, H. (2004). Industrialization of Japanese Miso Fermentation. In K. Steinkraus, Industrialization of Indigenous Fermented Foods. Geneva and Ithica: Marcel Dekkar. • Barbesgaard, P., Heldt-Hansen, H. P., & Diderichsen, B. (1992). On the safety of Asperyillus oryzae: a review. Applied Microbiology and Biotechnology, 569-572. Acknowledgments: Chef Sean Audet and Matthew Wells Contact: Joel Lamoureux – Manager, Culinary Research & Innovation | [email protected] 204.632.3993 The first step is to create “koji” or “moldy grain” which provides a source of enzymes to break down the miso base. A thick mat of mycelium growth within 3 days prevents the production of mycotoxins. Second step is base fermentation. This two-step process allows bacterial and yeast fermentation to create the final miso over the course of the aging process. This project was funded in part by the Canada and Manitoba governments through Growing Forward 2, a federal-provincial-territorial initiative. Research conducted at RRC’s Paterson GlobalFoods Institute (PGI) made possible through funding from the Natural Science and Engineering Research Council (NSERC). Joel Lamoureux, Mavis McRae, Red River College Culinary Research & Innovation, Lee Anne Murphy, Manitoba Agri-Health Research Network Inc, and Dr. Claudia Narvaez-Bravo, University of Manitoba
