Manufacture Miso in the UK reboot

by Paul Chaplin in Brecon, Powys, Wales

Manufacture Miso in the UK reboot
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Reboot Miso Production

by Paul Chaplin in Brecon, Powys, Wales

Above image was the first incarnation in the late 80s

Reboot Miso Production in the UK

Source Foods Miso Limited

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Organic Miso Production Scheme

Index

1. Anticipated Readership

2. Introduction

3. Glossary of Terms

4. Production Flow Chart

5. Process methods and techniques

1. Anticipated Readership & Authors Notes

This document has been prepared to communicate the food production scheme of Source Foods Ltd. (SFL) to local authority Environmental Health Officers and their departments (EHD). This disclosure is required in fulfilment of SFL’s obligations to produce & distribute food in accord with relevant UK law and local authority regulations. Internally, this document aims to contain and communicate all necessary information for operators to produce organic miso according to known best practice. This document may be modified from time to time in response to changes in legislation and production issues.

2. Introduction

The production of organic miso has been practised by the General Manger (Paul Chaplin) of SFL for over 30 years and only ceased when the local authority EH for the county he was producing in brought in new officers and insisted on the destruction of his entire stock. The reason for this destruction was somewhat vague and at best may be characterised as ‘differences of opinion regarding production methodology’ between the two parties. This difference of opinion was generally that Paul believes his understanding of relevant microbiological issues evidenced by 5,000 years of artisan and commercial production and research outweigh challenges made by the prescribed understanding and practices required by local EH’s, particularly under the auspices of HACCP.

The attitude of the EHO was as Paul had made up the product and had no experience, although he made miso like many Japanese operations and was very well respected for his contribution the world of miso. Unfortunately small minded vindictive people exercised their power with dishonesty to the disappointment of all regular and long-term customers.

Source Foods continues have enquiries from new and long term customers as well as the previous wholesaers pledge to stock when back in production

3. Glossary of Terms

Miso is a fermented food paste originally developed in Japan over 5,000 years ago. Consequently, many of the names and terms given to various processes, ingredients, and equipment, may be unfamiliar. The terms are listed as they occur in the document.

Miso – A fermented savoury food paste made from grain usually rice or barley, pulse most common being soy, sea salt, spores.

HACCP - Hazard Analysis and Critical Control Points, a plan to identify and mitigate against identified risks in production, e.g. manual mishandling, contamination risk, etc..

Koji – Cooked rice inoculated with spores to develop enzymes.

Koji Trays – Trays used to contain developing inoculated rice

Koji Room – A temperature and humidity controlled room in which trays of koji are developed.

Sho – Volumetric measure, approx 1.8L, used to measure rice, etc..

4. Production Flow Chart

This chart shows the relationship of the individual production processes of miso using methods adopted and developed by SFL.

This is by request as this flow would not load

5. Process Methods & Techniques

Goods-In & Storage

Goods inwards in this instance refers only to food stock ingredients. Dried Goods are delivered in labelled sacks and packets which are checked against carrier delivery notes to confirm product type, quantity, condition. Approved goods-in certification details are received in and recorded, and placed in approved storage facilities.

Soak Rice

Take required sacks of rice from storage and soak in water using a bottom-drained stainless vessel, according to the production schedule requirements including rice quantity, soak times.

Steam & Cool Rice

Drain the soaked rice and steam in the stainless vessel. Steam the rice according to the production schedule requirements and cooker operating instructions, including cooking temperature and times. When the rice is cooked, cool according to production schedule requirements using a tumbler at ambient temperature.

Inoculate Rice

Add spores to the cooled rice according to production schedule requirements using a tumbler at ambient temperature.

Develop Rice Culture

Measure the required sho of inoculated rice into koji trays and arrange them in the koji room to evenly develop. Maintain the required temperature and humidity throughout the koji room for the whole development period by frequent checking and attention, according to production schedule requirements.

Soak Beans

Take required sacks of beans from stores and soak in water using a bottom-drained stainless vessel, according to the production schedule requirements including bean/water ratio, bean quantity, soak times.

Steam & Cool Rice

Drain the soaked beans and steam in the stainlees vessel. Steam the beans according to the production schedule requirements and cooker operating instructions, including cooking temperature and times. When the beans are cooked, cool by spreading in trays until the correct temperature according to production schedule requirements.

Mix Rice & Salt & Beans

Mix together rice, salt, beans, and bean cooking liquid to achieve correct consistency according to production schedule requirements.

Pack into Fermentation Vats & Store

Pack the mixed ingredients into fermentation vats, then seal the vat to prevent contamination and weight the lid to displace naturally occurring gasses during fermentation. Label the vat and move to storage for fermentation.

Grind into Paste

Identify the vat(s) of fermented product ready for grinding into finished product according to production schedule requirements. Grind fermented mixture following machine instructions into labelled food-grade lidded containers to prevent contamination, and store ready for packaging.

Package & Label Finished Product

Identify the containers of product ready for packaging according to production schedule requirements. Clean the packaging area and labelling area, operate the filling machine according to instructions and production schedule requirements. Label the retail product according to prevailing legislation, package into labelled outers, and store ready for picking and dispatch.

Storage & Goods-Out

Finished stock is kept in labelled outers. It is picked and assembled into individual orders, and collected by carriers for customer delivery.

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