0% found this document useful (0 votes)
479 views13 pages

Textured Soy Protein Products

This article addresses all these aspects of developing processed soy foods. It focuses on textured vegetable products such as soy Nuggets and Granules. Developed and developing countries alike are finding ever-increasing consumer acceptance and use of soy as human food in various forms.

Uploaded by

Amit Mishra
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
479 views13 pages

Textured Soy Protein Products

This article addresses all these aspects of developing processed soy foods. It focuses on textured vegetable products such as soy Nuggets and Granules. Developed and developing countries alike are finding ever-increasing consumer acceptance and use of soy as human food in various forms.

Uploaded by

Amit Mishra
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 13

A Project Report on

Textured Soy Protein Products


(Nuggets & Granules [Soy Bari])

INTRODUCTION
In general, there are several key issues
associated with food processing such as screening and
purification of ingredients, applying physical and
chemical treatment aimed at adding food value,
assuring safety and efficiency/convenience in use, and
matching the product to consumers' tastes, preferences
and habits. A wide range of ingredients combined in
varying proportions along with diverse but specific
treatment of these ingredients provides a vast range of
possible permutations, which may be tailored to suit the
needs, tastes, flavor palatability and food value
depending on the specific target consumers.
Consumers' requirements to be addressed in processed foods fall into three major
categories:
a) Taste, flavor, texture, convenience, food habits and economy;
b Food and nutrition values and palatability of a formulation for different target
consumers from the point of view of health and nutrition;
c) Purity requirements, microbiological safety, nutritional quality/efficiency and
regulatory norms-on-foods.
This article addresses all these aspects of developing processed soy foods, while
focusing on textured vegetable products such as soy nuggets and granules. This article has
been prepared considering a semi automatic extruder 1ine with 200 kg per hour capacity, 20
working hours per day and 300 workdays per year.

THE PRODUCT
Soy Bean
Soy bean, like any other pulses, is a leguminous crop but with high nutritional value.
It has about 40 % good quality protein and 20% oil. Native to South East Africa and China,
soybean was imported into the USA over fifty years ago and now has grown to be a principal
agricultural produce of North America. Although a major producer of soybean, the USA uses
very little soy protein as human food, although consumption is increasing. On the other
hand, South East Asian countries use considerable quantities in the form of tofu, bean curd,
soymilk, etc. Developed and developing countries alike are finding ever-increasing
consumer acceptance and use of soy as human food in various forms. The future is therefore
bright for entry into this market.

Relevance to India
Soybean was imported into India about 35 years ago and was initially grown in some of
the northern states like Uttar Pradesh, Madhya Pradesh and Bihar. It is now being
increasingly grown in a larger number of states. The virtues and value addition potential of
the crop has resulted in increasing acreage planted under this crop. Today, even southern
states like Karnataka, Tamil Nadu and Andhra Pradesh have substantial areas under soybean
cultivation. As a result, solvent extraction and other soybean processing industries have
expanded considerably in these regions. Also, southern Maharashtra has grown into a strong
soybean cultivating area with a good number of solvent extraction industries. In general,
then, given the wide availability of the raw material, there are excellent opportunities for
greatly increasing the processing of soybean for value addition foods.
Major soy producing states are Madhya Pradesh (61 % of total Indian production),
Maharashtra (27%), Rajasthan (9%) and Andhra Pradesh (1%).

Extrusion Technology: A Means to Enrich Soya Foods


Extrusion cooking, one of the novel techniques of food processing with great
versatility and a wide range of application, has great potential in the food industry in
developing countries like India. Conventional thermal processing results in considerable loss
of nutrients like B complex vitamins (losses of up to 15-60%) and certain minerals like
calcium, iron and zinc. While extrusion cooking being a high temperature short time
process causes minimum losses while yielding a better product. In addition to processing
advantages and better nutritional quality, extrusion cooking produces a product with
improved microbial quality, as the process destroys heat labile anti-nutritional factors and
enzymes that cause problems during storage and deteriorate product quality.
Soybean, as it comes from the field, cannot be used directly for human consumption
even if cooked like normal pulses, since it requires much higher pressurized cooking. Also,
by simply cooking as a pulse, it has relatively less pleasant flavor and odor. In addition, raw
or undercooked soybeans contain certain anti-nutritional factors, which are of course
undesirable. Extrusion technology eliminates all these inhibiting factors. It cooks
completely, thus requiring no repeat cooking. Unpleasant flavors are greatly removed and
all anti-nutritional factors are completely eliminated, while nutritive values are maintained.
Extrusion of soybeans was first tried in the USA and patented. This technology was
first bought to India by a missionary foundation, the 'Soya Products Research Association', in
Bareilly (U.P State), for preparation of nutritional supplement food for feeding programs of
the Government of India.
Commercial exploitation of soy protein as human food using extrusion technology was
first realized by Mysore Snacks Foods Limited, Bangalore followed by the Khaira District Co-
operative Milk Producers Union at Anand, both mainly for preparing foods for feeding
programs. Commercial manufacturing and marketing of extruded products was started first
with the launching of Meal Makers by Mysore Snack Foods. Voltas and others soon followed.
Unique Features of the Product (Granules and Nuggets)
There are a number of benefits associated with these and other extruded soy products:

! The process totally destroys anti-nutritional factors associated with soy, thus making
the product completely safe for human consumption;
! The product is free of fat and cholesterol, while at the same time providing good quality
protein, which is important for all age groups under all conditions or with any diet
constraints;
! It is precooked and therefore does not require re-cooking. It becomes reformulated
within minutes of mixing with desired dishes.
! Already cooked and controlled in sophisticated conditions, it is light and easily
digested; it easily assimilates into the digestive system making ii highly palatable;
! The highly sophisticated and versatile extruder used for this process is automatic, thus
helping greatly in ensuring hygienic conditions throughout whole processing. The
product is microbiologically safe and secure;
! It is dry, hard and solid and is therefore quite convenient and safe to transport and store
for well over one year, as long as it is out of reach of water or moisture;
! Extrusion cooking of soy yields a product which is 100% vegetarian, but which goes
ideally with non-vegetarian preparations as well.
! The product is 50 - 52% protein on a dry basis, making it one of the richest protein foods
available.
! The product is bland in the neat form and therefore blends beautifully with any sort of
food preparation. It adapts itself naturally and completely and is therefore most
versatile.

MARKET TRENDS
Soy nuggets or granules, technically termed textured soy protein (TSP), are a potent
food product. They are versatile, economical and convenient for consumption by all classes
of consumers on all occasions. In India, with its rapidly growing population, this product has
unlimited potential. The product in bulk economy pack has already grown to a dominating
position, setting a market trend.

Trends
Although this growth was initially slow, the acceptance of TSP as a principal
ingredient in daily food has gained not only momentum over the years but has shown
commendable penetration into different markets and among different classes. By its
nature, the product goes exceptionally well with non-vegetarian and Indian spicy dishes. As
the product is a convenient, protein-rich and affordable substitute to fresh vegetables, it has
found particularly wide acceptance in regions and seasons that witness a scarcity of fresh
vegetables. At the same time, usage is increasing among the middle classes, given
increasing health concerns. Yet, there are still many sizable pockets of the market that are
unexploited and the potential for growth in the production and consumption of granules and
nuggets is very great.

Bulk Commodity Segment


The bulk commodity segment has been expanding at a rate well over 10% annually
despite only marginal promotional efforts. Production for this segment now stands at about
80,000 MT per year. As such, each year over 20,000 MT are added to this segment. Wide
availability/distribution in the already-strong portions of the market has accounted for most
of this growth. Regions of the country where the market is weaker have seen a slower pace
of growth, especially when distribution has been poor. However, the emergence of a larger
number of companies in the organized sector getting into this bulk field is bound to result in
wider and more intensive distribution and promotion. The southern and western parts of the
country, which are still under-exploited, will likely be the principal new markets for some of
these new entrants into bulk nuggets and granules production. In the past few years eastern
markers are growing very significantly for these products. Today, the bulk commodity market
is dominated by Ruchi Soya Ltd., which has about 50% share of the segment.

Branded Market Segment


This segment has substantial value addition and better margins, and is more
promotion-oriented. Ruchi Soya Ltd. (Nutrella™) currently has major market share. With
new entrants launching their product in the market and promoting it, growth in the branded
market of 30% per year for at least the next five years may be expected.

Scope for the Product: Demand Potential


Even with good growth in production/sales, there is still vast potential for much more
sizing up. For example, in Maharastra and Gujarat, which are two major and relatively
affluent markets, the potential for nuggets and granules is unexploited, at least on an
organized scale. This unexploited market is potentially not less than 5,000 MT/month
(conservative estimate). An aggressive company willing to promote / advertise would have
scope for considerable profit. Also, the south in general is untouched. And this is a part of
the country where it is generally believed that people are more accepting of new food ideas
than, say, in the north.

Marketing Suggestions
Market conditions suggest that the product in 20 kg bulk bags should be first
introduced, perhaps most profitably in the south and west regions. The branded product can
be marketed in 250 gm printed carton packs. Marketing/advertising would be required, for
example, demonstrations of special recipe preparations and use of the local print media.
MANUFACTURING PROCESS
Extrusion Technology
The extruder was first produced by Wengers in the USA. The machine consists of a
barrel in which the food material (soybeans) is carried by a turning screw, and is subjected to
intense frictional stress, which generates heat under high pressure. The heat and pressure
reach a maximum by the time the food material reaches the terminal end, where it is ejected
through the nozzle. The texture of the product undergoes considerable change during
passage through the barrel, from globular to fibrous, and when the material comes out
through the nozzles, it expands to give a porous texture preferred for human consumption.
Due to the high pressure and high temperature cooking in the barrel, anti-nutritional factors
get destroyed while maintaining the nutritional properties. The extruder is very flexible
equipment. It can be used for any flour or combination of flours. The texture of the product
can be varied from fully expanded, to tightly compact meat-like products. The length of the
cooking barrels can be changed. As the product emerges, it is cut using suitable rotating
cutter knives. The shape of the final product can be altered suitably be altering the dies and
the cutting arrangement.

The Extrusion Process and Controls


1. The raw material for extrusion is deoiled soy flour usually supplied by the solvent
extraction mills as flakes. The quality of the raw material has to be very carefully
checked in a quality control laboratory. The Bureau of Indian Standards has formulated
specifications for defatted edible grade soy flour. However, it is recommended that
each manufacturing unit should have its own specifications, which may vary from
product to product. Before the material is accepted, some of the criteria to be
checked are colour, nitrogen content, fat, fibre, ash, and sand silica content. The
quality of extrusion depends on these specifications.
2. When accepted, the material is passed through mills to get a uniform powdered grade
and sieved to separate all foreign materials.
3. The material is then elevated to the mixing bins, where it is blended with other
materials if needed and passed onto the extruder.
4. The material is fed to the extruder and a predetermined amount of water is injected.
Then, the material is passed through the first part of the extruder where in it is mixed
well to form dough. In the second part, the pressure is gradually increased. If
necessary, some steam is also admitted at this stage.
5. In the final stage the temperature and steam pressure in the barrel increases when the
material passes through the screws. Finally the material is ejected out of the fine
nozzles as strands.
6. The emerging strands are cut to the shape and size as required by the revolving knives.
The cut pieces are conveyed by a belt conveyer to the drying chamber where the
material continuously passes over conveyer belt in a hot air drier.
7. The dried material is conveyed over magnetic screen systems to remove any iron
particles, and taken to the nest of shaking sieves. After this, the material is graded.
8. The graded material is passed on to the packing room (which has to be kept clean and air
conditioned), and either mechanically or manually packed in cardboard containers or
bulk bags.
9. The final product before it goes into the packing room is sampled and tested in the
quality control laboratory, to ensure that it meets all quality specifications.
10. By varying the composition of the mix at the stage of the mixing bin, before the material
enters the extruder, it is possible to produce various types of foods.
11. The critical conditions in the process are:
?
Quality of the raw material and input rate, water flow rate;
?
Type of screw used, its quality and the die design;
?
Temperature conditions and movement of the material in the barrel;
?
The nature of the cutter and the speed of the cutting;
?
The design hot air drier and drying temperatures;
?
The quality control of raw materials, the finished product, the packing material,
etc.

COMMON PROBLEMS WITH SINGLE SCREW EXTRUDERS


1. Long barrel extruder should be for TVP and short barrel extruder is for snacks.
2. Cut flight screw should be at the end with no spacing for making snacks. While for
making TVP it should be (cut -flight) at the middle so that the material will get enough
time for texturization. Also there should be at least six-inch spacer after the screw
before die.
3. Extruders can be used to make soy fiber also. First soy hulls should be washed in running
water then dried followed by dry, extrusion. Soy fiber can be used in bakery products.
4. A pre conditioner is must for making good quality TVP. Functions of a pre conditioner are
o
for mixing water, raw material, and increase temperature to 60-80 C and holding.
Length of pre conditioner should be 1-3 min.
5. For making FFSF pre conditioner is not required.
6. Depending on RM (for low PDI More retention time) Pre conditioning time varies.
a. RM for TVP should be about 70 PDI/with 100 mesh.
7. Maximum of 0.5 of lecithin will improve texture and flow of raw material in extruders.
8. Additives:
a. H2O2, titanium oxide to improve color
b. Carmel for beef color
c. NaOH for texturization.
9. Bulk density moisture content, temperature and pressure.
a. Lower the moisture content lower will be the bulk density
b. Lower the temperature higher will be the bulk density.
c. Lower the pressure high bulk density.
10. To reduce pressure: increase holes in the die, lower shear locks, and reduce cut flights.
11. Vibratory screen at the end of drier can be used to collect uniform product.
12. Surging can due to inconsistent feeding. The feeding and die size and holes should be as
per extruder capacity.
a. Big capacity extruders but lower feeding.
b. Feeding of RM should match extruder capacity,
c. If last section is too hot (running cold water in the last section of barrel will solve
surging).
13. Not more than 5%-extruded fines can be re used for extrusion.
14. Plastic liner bags with nitrogen flush and heat sealing will help to have better shelf life.

PLANT MACHINERY
The important items of plant and machinery required for the project are given listed below:
Sl.No. DESCRIPTION
01 Main extruder with complete fittings
02 Plate Grinder mills
03 Granulator/flaker
04 Tray drier with electrical coil heaters
05 Weighing scales
06 Sealing machines
07 Bag stitching machines
08 Gravemetric filling Machines
09 Packing line fixtures
10 Quality control equipment
11 Generator set (optional)
This plant and machinery is a semi-automatic fine and requires only 5/6 labourers per
shift for production. Please see appendix VI for a sample TVP project.

PERSONNEL
This project will require the following personnel to manage the production and quality
control activities for 20 hrs productions per day:
PARTICULARS NUMBER
Plant Manager 1
Shift supervisors/chemists 6
Skilled Workers 5
Semi - skilled workers 7
Unskilled worker's 9
TOTAL 28
Apendix I

Mechanical Features of Single-screw extruder (From: Extrusion Cooking, Mercier, C.


Linko, P. and Harper, J.M. eds. American Association of Cereal Chemists, St. Paul, MN,
1989)

Complete Single-screw extruder configeration (Courtesy of Wenger Manufacturing


Company, Sabetha, Kansas)
Apendix II
RAW MATERIAL
Edible grade defatted soy flour, obtained from cleaned and dehulled beans, is the
principal input material. This is a by-product from solvent extraction plants. The material
must meet the required norms and specifications, as the extruder is very sensitive to
variations in the defatted soy flour. The quality of the end product depends upon these
characteristics. Soy oil extraction activity is concentrated in the states of Madhya Pradesh
and Uttar Pradesh, and, as a result, the major supply of raw material comes from these
states.
The major suppliers of good quality raw material are:
?
Ruchi Soya Industries Indore
?
General Foods Ltd. Indore
?
Prestige Foods Ltd. Indore
?
Rasoya Proteins Ltd. Mumbai
?
Shakti Soya Ltd. Coimbatore
?
Sonic Biochem Indore
?
Surya Agro Oils Ltd. Bhopal
?
Vippy Solvex Extractions Ltd. Devas
In the last decade, soy cultivation in the states of Andhra Pradesh, Gujarat, Karnataka
and Maharashtra has grown so much that oil extraction has also started in a big way and
technology for developing edible grade defatted soy flour is also being mastered in these
regions. Good quality-material should therefore be easily available from these units.

Indian and US Standards for Defatted Soy Flour


Characteristics Indian Standard1 US Standard
Moisture (max) 9.0 % 8.0 %
*Protein (min) 48 % 50 %
*Total Ash (max) 7.2 % 6.5 %
*Acid Insoluble Ash 0.4 % -
*Fat (max) 1.5 % 2.0 %
*Crude Fiber (max) 4.2 % 3.5 %
Aflatoxin ug/Kg (max) 30 -
Residual Solvent ppm (max) 170 -
Total Bact. Count /g (max) 50000 -
Cloforms /g (max) 10 -
Salmonella /g Nil -
1 IS: 7836: 1975; * Dry weight Basis
List of Edible Grade Defatted Soy Flour Manufacturers / Suppliers

Mr. Girish Matlani Mr. Davish Jain


Sonic Biochem Extractions Managing Director
38, Patel Nagar Prestige Foods Ltd.
Indore 452 001 30, Jaora Compound
Tel. No 0731 2466456-58/2468638 M.Y.H. Road, Indore 452 011
Fax: 0731-2462564 Tel: 0731 2556530,33,34
Fax: 0731 2556531, 32
Mr. Dinesh Agrawal or
Mr. Prabhudatta Jyotishi Mr. Anil Lonkar
General Foods Ltd. Managing Director
101, Mahakosh House, Nath Mandir Rasoya Proteins Ltd.
7/5, South Tukoganj, Indore 452 001 Plot No.1, Bajaj Nagar,
Tel. No 0731 2513281-83 2528113(D) South Ambazari Road,
Fax: 0731 2527250 Nagpur 440 010
Tel: 0712 2231386, 2232395
Mr. Pramil L. Sisodia Fax: 0712 2233379
Deputy General Manager - Sakthi Soya
180, Race Course Road, Mr. Krishnan
Marchinaickenpalayam Surya Agro Industries
Ambarampalayam (PO) Surya House
Pollachi 642 103 Z-5, Zone I, M.P. Nagar
Tel: 04259 253256,57, 253355 Bhopal 462 001
Fax: 04259 253354 Tel. No 0755-2556734/6/9
Fax: 0755-2556724
Mr. Prakash Mutha
Vippy Industries Ltd. S.M. Dyechem Ltd.
28, Industrial Area 3rd floor, 158, Zone-1,
Dewas 455 001 Maharana Pratap Nagar,
Tel. 07272 258885-46, 272156-57 Bhopal 462 001
Fax:07272 - 275552 Tel: 2557746, 2555699, 2555800, 2553846
Fax : 0755 - 2551036
Email: smd@bom4.vsnl.net.in
List of Extruder Suppliers

Mr. S.Krishna Murthy M. Son Industries


Esskay Industries D-33, Sector-2,
No. 53 Infantry Road, NOIDA - 201301
Behind Medinova, Bangalore 560 001 India
Tel: 080 2864650 Phone: 91-120 2552177
Fax: 080 2861365
E-mail: esskayvo@vsnl.net Mr. Agarwal Pavankumar
Swastik Products,
Mr. A.K. Bhudiraja 9/1/3. Lonar vashate,
Ambika Agro Industries Kolhapur
12 Silver Park, Shiv Puri Phone : +91-231-667936
New Delhi 110 051 Fax: +91-231-680167
Tel: 011 22410924
09814275727 Mr. Manjeet Singh Arora
Reliance Engineering Works
Mr. C.V. Surendran Plot # 117
Spectoms Engineering Pvt. Ltd Opposite ESI Hospital
Makarpura Station Road, Maneja, Industrial Area Phase II
Vadodara - 390013 India Chandigarh 160 002
Phone : 91-265-2642641 Tel: 0172 652467, 400056, 605682
Fax : 91-265-2644592 Mobile: 09814694065; 874919; 3135599
Products: Extruders Fax: 610814

MR. MD. Akhtar Ali Gaur Mr. Aasha Singh


A. S. Engineering Works Gurunanak engineering Works
A 49B, SEC 10, D 107
NOIDA - 201301 Sect 7, NOIDA
Phone: 91-120-2523756 Tel: 2542530; 2519360
Fax: 91-120-2520344 / 2523756 Fax: 2535160
Products: Extruders
Fun Snacks Pvt. Ltd. Mr. S. Mukharjee
D-115, Okhla Industrial Area, Phase-I, Basic Tech Pvt. Ltd.
New Delhi - 110020 2-2B, Nandy Street
India Calcutta 700 020
Phone : 91-11-6813158 Tel: 033 24635067; 24644616; 24641866
Fax : 91-11-6818548
E-mail: gopal@del2.vsnl.net.in

S.S. Engineering works


B-25, Khanpur Ext
Devli Road, New Delhi 110 062
Tel: 26081475
Works: 250 Shutter Wala Gali
Khanpur, New Delhi 110 062

Cost Benefit Analysis of an economy TVP Plant*


Capital Investment
Cost of Equipment (Capacity 200 kg/hr) 800,000
Cost of Dryer 150,000
Working capital 50,000
Packaging equipment 100,000
Pre operational expenses 25,000
Total 1,125,000

Monthly expenses 8hr/day


Interest on Loan @ 12% pa (Laon 85% of CI) 10,367
Rent 10,000
Other Expenses 5,000
Sub-Total 25,367
In Rupees

Manpower TVP Snacks Instant wheat meal


Two marketing executives 2*5000 10,000 10,000 10,000
Two Production in-charges 2*4000 8,000 8,000 8,000
Raw material 225,000 183,000 90,500
Cost of Electricity @ Rs. 3.5/KW 16,250 16,250 16,250
Water, Sewer & Maintenance 7,000 7,000 7,000
Depreciation @ 15% pa 13,125 13,125 13,125
Publicity Rs. 0.5 per pack 37,500 37,500 25,000
Misc. Expense 20,000 20,000 20,000
Sub-Total 336,875 294,875 189,875
Total Expenses / Month 362,242 320,242 215,242

TVP Snacks Instant wheat meal


Production (kg/month) 15,000.00 15,000.00 10,000
Cost of Production (rs/kg) 24.15 21.35 21.52
No of packets per month (200 gm) 75,000.00 75,000.00 50,000.00
Cost of Packaging (Rs./pack) 150,000.00 75,000.00 100,000.00
Net Cost of Production/pack 6.83 5.27 6.30
Sales Tax 8% 1.28 0.96 1.12
Profit margin 15% 2.40 1.80 2.10
Dealer price (margin 10% ) 12.11 9.23 10.92
Retailer price (margin 20%) 15.31 11.63 13.72
MRP 16.00 12.00 14.00
Profit per month 180,000.00 135,000.00 105,000.00
Net profit per month 420,000.00 240,010.00 105,017.00
Annual Net profit 5,040,000.00 2,880,118.00 1,260,209.00

Return on Investment (ROI) 448% 256% 112%

*: These estimations are made on hypothetical basis only, assuming that plant may run at 100% capacity
and sale of produce.

You might also like

pFad - Phonifier reborn

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.

Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.


Alternative Proxies:

Alternative Proxy

pFad Proxy

pFad v3 Proxy

pFad v4 Proxy