Kikkoman soy sauce in the United States is made in Walworth, Wisconsin. This small town, located just outside of Lake Geneva, is home to the most productive naturally brewed soy sauce plant in the world. Since its establishment in 1973, the plant has been churning out approximately 29 million gallons of soy sauce annually. This accounts for about 30 percent of Kikkoman's total soy sauce production.
When I first visited the Kikkoman plant in Walworth, I was immediately struck by the immense scale of the operation. The facility itself is sprawling, with multiple buildings dedicated to every step of the soy sauce brewing process. As a sommelier with a deep appreciation for the art of fermentation, I was eager to learn more about the intricate techniques employed here.
The journey begins with the selection of high-quality soybeans and wheat, which are the key raw materials used in soy sauce production. These ingredients are carefully sourced from farmers who adhere to strict quality standards. Kikkoman takes great pride in supporting local farmers and promoting sustainable agriculture.
Once the soybeans and wheat arrive at the plant, they undergo a meticulous process of koji fermentation. Koji is a crucial element in the production of soy sauce, as it helps to break down the proteins and carbohydrates present in the soybeans and wheat. This step is critical in creating the rich, savory flavor that we associate with soy sauce.
Next comes the moromi fermentation, where the koji mixture is combined with brine and left to ferment in large fermentation tanks. This process can take several months, during which the natural enzymes and microorganisms present in the mixture work their magic, transforming the soybeans and wheat into a complex and flavorful liquid.
After fermentation is complete, the moromi undergoes a pressing process to separate the liquid soy sauce from the solid residue. This liquid is then filtered and pasteurized to ensure its safety and stability. Kikkoman takes great care in maintaining the traditional brewing methods while also adhering to modern food safety standards.
One of the most fascinating aspects of the Kikkoman plant is its use of large wooden vats, known as kioke, for fermentation. These kioke have been used for generations and are crucial in providing the unique flavor profile of Kikkoman soy sauce. The wooden barrels allow for a slow and steady fermentation process, which imparts a distinct depth of flavor to the final product.
In addition to the traditional brewing methods, Kikkoman also emphasizes sustainability in its production processes. The plant in Walworth utilizes energy-efficient technologies and practices to minimize its environmental impact. This commitment to sustainability extends beyond the plant itself, as Kikkoman works closely with local farmers to promote sustainable farming practices.
As a sommelier and brewer, I couldn't help but be impressed by the dedication and craftsmanship that goes into producing Kikkoman soy sauce in Walworth, Wisconsin. The combination of traditional brewing methods, sustainable practices, and high-quality ingredients results in a soy sauce that is truly exceptional. It is no wonder that Kikkoman has become a household name and the go-to choice for soy sauce lovers around the world.
The Kikkoman soy sauce plant in Walworth, Wisconsin, is a testament to the art and science of soy sauce production. It showcases the harmonious blend of tradition and innovation, resulting in a product that is both delicious and sustainable. Whether you are a professional chef or a home cook, experiencing the flavors of Kikkoman soy sauce is truly a treat for the taste buds.