JICA EPP Training R eview (2) Odor and Food I ndustry

1. JICA EPP Training Review (2)Odor and Food Industry October 2011 JEMAI Kenzo OHOKA

2. Soy Sauce (Kicap) • In Japan we have been utilizing processed soybeans for major food such as Tofu, Natto, and soy sauce (kicap). • Soy sauce is basically made from soybeans. It is widely known that Buddhist monks from China introduced soy sauce into Japan in the 7th century and in China they have been utilizing soy sauce for seasoning food for more than 2,000 years. • It is naturally brewed and matured (aged) for full flavor mainly from wheat and salt in addition to soybeans in Japan. • Soy Sauce has a complex, mellow flavor that complements and enhances all kinds of foods according to the Kikkoman Company.

3. Food Processing and Pollution • The soy sauce processing includes shell peeling, cleaning (water pollution), selecting/sorting (waste), boiling (air pollution), then, adding wheat or barley, fermentation and maturing (odor) for two or three months. • During food processing they generate waste water which will be treated and turn to organic sludge. They utilize biological treatment methods which is similar to those used in municipal sewage treatment facilities. • The food sludge, in general,is difficult to handle because of its high moisture and fiber content. The food waste or the sludge often contains protein, pectin, vitamins, and other nutrients that can be recovered for use or used directly as animal foods or a food supplement. Such recycling or reuse activities reduce overall pollutants and they are cost-effective.

4. Olfactory Senses • Perishable sludge easily generates a bad smell and the food wastetends to rapidly decompose. • Generally speaking, the soy sauce itself gives off a not good smell unless it is a very small quantity or it is fully contained or sealed. Sometimes it may be tolerable but everyday smell is not good for local people, especially new comers and smell-sensitive people having a keen nose. • Further, one’s olfactory senses can become numbed by strong odors.

5. Odor Control The relationship between the odor intensity and ammonia concentration (ppm) is shown in the left finger (source: Offensive Odor Control Law handbook), which indicates ‘I= k log C + a’, ‘I’ means odor intensity, ‘C’ means odorant concentration and ‘a’ is a constant.

6. Odor Control In order to control odors they utilize several methods including; 1) Combustion Open flare burning, direct flame combustion, and catalytic oxidation, 2) Scrubbing 3) Chemical absorption and adsorption

7. Odor Control:Combustion • Direct flame incineration (combustion) is the most effective method for removing strong odors from the effluent air. • Catalytic oxidation is a kind of combustion possibility applicable at lower temperatures. Lower temperatures suggest a lower fuel cost; however, it is not economically capable of treating large volumes of air. • Paper manufacturers, printing, painting facilities combust and decompose odor substances including VOCs into carbon dioxide and water at about 750 degree.

8. Odor control:Combustion • However, this method generates NOx. Water scrubbing of the odors has not been so successful because many of the components than produce the odors are insoluble in water and generates waste water. • Reactive scrubbing is possible and widely utilized. Chemical solvent, alkali, acid, oxidizing liquid and water shall be sprayed into odor substances, then mist and dust as well as odors can be collected and gas temperature will be cooled down at the same time.

9. Odor ControlWith Activated Carbons • Adsorption with activated carbons can be successfully done, but must avoid breakthrough of odorous substances. • Odor adsorption character must be identified and proper kind of activated carbons must be selected and utilized. • Constant monitoring is required. Coconut shell

10. Ozonation • Chemical breakdown by ozonation has been successful in Japan. For example, bad-smelling ammonia may be changed to nitrite and water by ozonation. Ammonia Ozone Nitrogen Water ATOM Nitrogen Oxygen Hydrogen

11. Offensive Odor Control Law • According to ‘Offensive Odor Control Law’ regulating standards are to be decided by each local government. • Basically there are three standards according to the location, i.e., three points, a boundary of the facilities, a gas emitting outlet (chimneys and/or stacks), and a waste water discharging point. • Each and every prefectural government needs to establish the three standards and municipalities (city/town/village) in the prefecture are required to control offensive odor.

12. http://www.env.go.jp/air/akushu/guidebook/01.pdf

13. Offensive Odor Control Law

14. Odor Judgment Technician Certified odor judgment technician (2,990, FY2009): Photo: Offensive Odor Control Law handbook

15. Annual number of the complaints (~ 2009) • 15,937 (2010), No.1: Burning waste in a field (Illegal combustion) • About 48%, 7,645cases: residential/apartment houses and sewage • Plants and business entities: 6,058 cases (Food 124) • On-the-spot inspection (investigation): 2,076 and ‘Request of reports’: 329 • Administrative guidance: 1,550and ‘Order to improve’: 4

16. The year FY1998 • Total cases are 20,092 • Increased by 38.1%, plus 5,538 cases to 1997 • Outside waste combustion or ‘Burning waste in a field’ • 5,881 cases (1,041 in prior year, 1997) • Small size incinerators • Dioxins panic in the late 1990s • Administrative guidance: 7,174 （prior5,744, 1,550in 2009） • On-the-spot inspection 4,855 （prior3,712, 2,076in 2009）

17. Pollution Criminal Case • Soy sauce manufactures may have lots of extra brine (NaCl) which can be useful for producing pickles. One of the soy sauce manufactures in west Japan was accused and the investigation papers pertaining to the case (pollution criminal case) were sent to the Public Prosecutors Office (Niigata) in 14 March 2007. • According to the police authority they discharged waste water exceeding the local environmental effluent standards 6 times during January and February in 2007. • BOD is 80 times bigger than the effluent standard and SS was 56 times of the effluent standard according to the local newspaper.

18. Pollution Criminal Case • The waste water was mainly generated from pickling process (cucumber pickles). The supervisor in charge of the waste water treatment knew that the treatment equipment was under malfunction but ignored it. • The police authority revealed that the manufacturer dramatically increased their production but the waste water treatment capacity was not changed, nor increased i.e. untreated waste water was illegally discharged into Shinano River. Source: Mainichi

19. Food waste water Some of the food process industries have following secondary treatment methods; 1) Anaerobic process 2) Arerobic lagoon systems 3) Activated sludge processes 4) Trickling filters and rotating biological discs

20. Fermentation • Fermentation refers a process in which an agent causes an organic substance to break down into simpler substances. In a wider sense it means the transformation of an organic substance into new compounds by the action of ferments, whether in the form of living organisms or enzymes. • The anaerobic breakdown of sugar into alcohol and carbon dioxide is an example of fermentation. Fermentation in terms of Japanese food/beverage is generally applied to rice wine, beer, vinegar, soy sauce, miso, as well as sour foods such as pickled cucumbers, kimchi (Korean hop pickles) and yogurt. • The most popular ferment would be yeast which is used as a leavening in baking. • They utilize malt (or malted rice) for manufacturing Japan food such as soy sauce, miso, and rice wine. The fermented food shall be matured or mellowed with effective functions by microorganisms and enzymes.

21. Cucumber Pickles • Cucumber, olives, tomatoes, pepper, cabbage and other vegetable pickles are consumed worldwide. • Usually they are soaked in a brine and/or vinegar and matured/fermented for certain period. About half of cucumber pickles are now made directly into ‘fresh-pack’ products and rest by ‘pure culture’ fermentation. Ingredients (row materials) are put into the retail jar. • Inside the jar, the bacteria will react, producing the desired acidity and flavor. Little recovery work has been done on the brines and vinegar including herbs, some essential oils, and other flavorings. • The traditional brining process, not like ‘fresh-pack’ or ‘pure culture’, produces large amounts of waste brine.

22. Brewing Industry • Brewing beer process is basically divided into 9 steps: Malting, Milling, Mashing, Lautering, Boiling, Fermenting, Conditioning, Filtering, and Filling. • By malting the grain sprouts small root shoots. Mashing is the process of mixing milled malted grain with water, and heating this mixture so that the enzymes in the malt can break down the starch in the grain into useful sugars. • Lautering means the separation of the extracts during mashing from the spent grain to create wort (grain juice).Boiling the wort with hops ensures its sterility (germless),and thus prevents infections. • Malting and brewing are the basic process

23. Malting • Alcoholic beverages such as beer and malt whisky are made from cereal grains etc. Basically a starch source including wheat, barley, corn grits, sometimes rice or potato are soaked in water for a few days. Softened grain is piled in heaps or placed in germination (sprouts) bins at constant temperature and humidity for about a week. • The grain sprouts small root shoots (germinates) and, simultaneously the crude starch in the grain is converted to soluble sugars by enzymatic action. The germination process also creates lots of enzymes which can convert the starch in the grain into sugar. • As the germination proceeds, the grain is turned intermittently to assure even sprouting. When the sprouts are about two-thirds the length of the grain, the germination is halted. Then the grain is dried in kilns, where it is gently roasted until it becomes dark and crisp. The dry-roasted grain is called malt in the USA.

24. Brewing • The dry malt is crushed to form mash. The mash is heated after adding hot water and the remaining starches are being converted to malt sugar. Then the cooked mash is filtered and drained from the grain. The clear amber malt extract ‘wort’ is boiled with hops. Hops will be adding a bitter flavor and aroma to the beer. The spent hops are removed out of the liquid called ‘wort’, which is gradually cooled down and the undesirable proteins coagulate and settle out. Proteins in malt will spoil the beer taste and its transparency (clear amber).

25. Brewing • Yeast will be added to the wort in the fermenting vats. There are two fermentation stages; in the primary fermentation tanks, the malt sugars are converted into alcohol and CO2, then undergoes ‘bottom fermentation (the yeast sinks)’ or ‘top fermentation (the yeast floats on the wort)’. • During the secondary fermentation the yeast is skimmed off or the beer drawn off and the beverage is stored in casks and barrels to age become clarified. Then finally, they are bottled and distributed in the market.

26. 一 アンモニア 大気中における含有率が百万分の一以上百万分の五以下 • 二 メチルメルカプタン 大気中における含有率が百万分の〇・〇〇二以上百万分の〇・〇一以下 • 三 硫化水素 大気中における含有率が百万分の〇・〇二以上百万分の〇・二以下 • 四 硫化メチル 大気中における含有率が百万分の〇・〇一以上百万分の〇・二以下 • 五 二硫化メチル 大気中における含有率が百万分の〇・〇〇九以上百万分の〇・一以下 • 六 トリメチルアミン 大気中における含有率が百万分の〇・〇〇五以上百万分の〇・〇七以下 • 七 アセトアルデヒド 大気中における含有率が百万分の〇・〇五以上百万分の〇・五以下 • 八 プロピオンアルデヒド 大気中における含有率が百万分の〇・〇五以上百万分の〇・五以下 • 九 ノルマルブチルアルデヒド 大気中における含有率が百万分の〇・〇〇九以上百万分の〇・〇八以下 • 十 イソブチルアルデヒド 大気中における含有率が百万分の〇・〇二以上百万分の〇・二以下 • 十一 ノルマルバレルアルデヒド 大気中における含有率が百万分の〇・〇〇九以上百万分の〇・〇五以下 • 十二 イソバレルアルデヒド 大気中における含有率が百万分の〇・〇〇三以上百万分の〇・〇一以下 • 十三 イソブタノール 大気中における含有率が百万分の〇・九以上百万分の二十以下 • 十四 酢酸エチル 大気中における含有率が百万分の三以上百万分の二十以下 • 十五 メチルイソブチルケトン 大気中における含有率が百万分の一以上百万分の六以下 • 十六 トルエン 大気中における含有率が百万分の十以上百万分の六十以下 • 十七 スチレン 大気中における含有率が百万分の〇・四以上百万分の二以下 • 十八 キシレン 大気中における含有率が百万分の一以上百万分の五以下 • 十九 プロピオン酸 大気中における含有率が百万分の〇・〇三以上百万分の〇・二以下 • 二十 ノルマル酪酸 大気中における含有率が百万分の〇・〇〇一以上百万分の〇・〇〇六以下 • 二十一 ノルマル吉草酸 大気中における含有率が百万分の〇・〇〇〇九以上百万分の〇・〇〇四以下 • 二十二 イソ吉草酸 大気中における含有率が百万分の〇・〇〇一以上百万分の〇・〇一以下