Analyses of the formation and characteristics of flavor and taste in a sesame meal‐based soy sauce

Abstract BACKGROUND Sesame meal, characterized by high moisture, viscosity and oxidative instability, presents utilization challenges and is frequently relegated to farmland fertilizer – a practice that underutilizes its rich protein content. METHODS This study developed three types of soy sauce using sesame meal supplemented with soybeans. For the first time, a dual‐strain co‐fermentation system employing Aspergillus oryzae 3.042 and Aspergillus niger AS3.350 was applied to sesame meal. The dynamic evolution of taste and volatile flavor compounds during fermentation was systematically analyzed via electronic tongue technology and gas chromatography–mass spectrometry. The sesame meal soy sauces were benchmarked against four commercial premier‐grade products, with flavor profiles evaluated using principal component analysis and orthogonal partial least squares discriminant analysis. Notably, the physicochemical indices of the sesame meal soy sauce complied with Chinese premier‐grade standards. RESULTS The dual‐strain‐fermented soy sauce demonstrated outstanding flavor complexity, sweetness and richness, achieving parity with premier‐grade soy sauce. Notably, it contained 2,3,5‐trimethylpyrazine and 3‐hydroxy‐2‐butanone, key compounds imparting distinctive roasted grain and creamy flavors, which collectively defined its unique sensory profile. Conclusion This research significantly elevates the utilization value of sesame meal while establishing a viable pathway for its commercial adoption in soy sauce production. © 2025 Society of Chemical Industry.