HANDBOOK OF

Soya Chunks Manufacturing

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Content

1.1 Soybean

1.2 Nutritional Content of Soybean (Green) per 100g:

1.3 Nutritional Content of Mature Soy Seed per 100g:

1.4 Soy Chunks or Textured Soy Protein (TVP)

1.5 Market Potential

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4

4-6

6

7-9

2.1 Raw Material

2.2 Machine

2.3 Equipments

2.4 Production Process

2.5 Control Parameter

2.6 Quality Parameter

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10-12

12-15

15-16

17-18

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3.1 Storage & Shelf Life

3.2 The factors that lead to spoilage/defects the soya chunks

3.3 Selection of Packaging Material

3.4 Frequently-used plastic-based packaging materials

20-21

21-22

22-24

24-26

4.1 Land

4.2 Power requirement

4.3 Man Power

5.1 Standards

5.2 Food Safety

5.3 Labeling Standards

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28-30

30-32

Chapter 2: Technical Aspects of Soya Chunks Processing

Chapter 3: Packaging of Soya Chunks

Chapter 4: Project Components

Chapter 5: Food Safety Regulations and Standards of Soya Chunks Powder

Chapter 1: Introduction

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Chapter 1

Introduction

1.1. Soybean:

The soybean or soya bean (Glycine max) is a species of legume native to East Asia, widely grown

for its edible bean, which has numerous uses. Soy beans contain significant amounts of phytic

acid, dietary minerals and B vitamins. Soy vegetable oil, used in food and industrial applications,

is another product of processing the soybean crop. Soybean is the most important protein source

for feed farm animals (that in turn yields animal protein for human consumption).

Soybeans are a globally important crop, providing oil and protein. In various United States, the

bulk of the harvest is solvent-extracted with hexane, and the "toasted" defatted soymeal (50%

protein) then makes possible the raising of farm animals (e.g. chicken, hog, turkey) on a large

industrial scale. Soybean products are used in a large variety of processed foods.

Soybeans can be broadly classified as "vegetable" (garden) or field (oil) types. Vegetable types

cook more easily, have a mild, nutty flavor, better texture, are larger in size, higher in protein, and

lower in oil than field types. Tofu, soy milk and soy sauce are among the top edible commodities

made using soybeans.

Traditional unfermented food uses of soybeans include soy milk, from which tofu and tofu skin

are made. Fermented soy foods include soy sauce, fermented bean paste, nattō, and tempeh. Fat-

free (defatted) soybean meal is a significant and cheap source of protein for animal feeds and many

packaged meals. For example, soybean products, such as textured vegetable protein (TVP), are

ingredients in many meat and dairy substitutes.

Soybeans can be processed to produce a texture and appearance similar to many other foods. For

example, soybeans are the primary ingredient in many dairy product substitutes (e.g., soy milk,

margarine, soy ice cream, soy yogurt, soy cheese, and soy cream cheese) and meat alternatives

(e.g. veggie burgers). These substitutes are readily available in most supermarkets

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1.2. Nutritional Content of Soybean (Green) per 100g:

Nutrients Quantity

Water (g) 68

Energy (KJ) 615

Protein (g) 13

Fat (g) 6.8

Carbohydrates (g) 11

Fiber (g) 4.2

Calcium (mg) 197

Iron (mg) 3.55

Magnesium (mg) 65

Phosphorus (mg) 194

Potassium (mg) 620

Sodium (mg) 15

Zinc (mg) 0.99

Copper (mg) 0.13

Manganese (mg) 0.55

Selenium (μg) 1.5

Vitamin C (mg) 29

Thiamin (B1) (mg) 0.44

Riboflavin (B2) (mg) 0.18

Niacin (B3) (mg) 1.65

Pantothenic acid (B5) (mg) 0.15

Vitamin B6 (mg) 0.07

Folate Total (B9) (μg) 165

Vitamin A (IU) 180

Saturated fatty acids (g) 0.79

Monounsaturated fatty acids (g) 1.28

Polyunsaturated fatty acids (g) 3.2

1.3. Nutritional Content of Mature Soy Seed per 100g:

Nutrients Quantity

Carbohydrates 30.16 g

Sugars 7.33 g

Dietary fiber 9.3 g

Fat 19.94 g

Saturated 2.884 g

Monounsaturated 4.404 g

Polyunsaturated 11.255 g

omega-3 1.330 g

omega-6 9.925 g

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Protein 36.49 g

Tryptophan 0.591 g

Threonine 1.766 g

Isoleucine 1.971 g

Leucine 3.309 g

Lysine 2.706 g

Methionine 0.547 g

Cystine 0.655 g

Phenylalanine 2.122 g

Tyrosine 1.539 g

Valine 2.029 g

Arginine 3.153 g

Histidine 1.097 g

Alanine 1.915 g

Aspartic acid 5.112 g

Glutamic acid 7.874 g

Glycine 1.880 g

Proline 2.379 g

Serine 2.357 g

Vitamin A equiv. 1 μg

Thiamine (B1) 0.874 mg

Riboflavin (B2) 0.87 mg

Niacin (B3) 1.623 mg

Pantothenic acid (B5) 0.793 mg

Vitamin B6 0.377 mg

Folate (B9) 375 μg

Choline 115.9 mg

Vitamin C 6.0 mg

Vitamin E 0.85 mg

Vitamin K 47 μg

Calcium 277 mg

Copper 1.658 mg

Iron 15.7 mg

Magnesium 280 mg

Manganese 2.517 mg

Phosphorus 704 mg

Potassium 1797 mg

Sodium 2 mg

Zinc 4.89 mg

Water 8.54 g

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Most of the soy products are produced from mature soy seed, hence it’s more vital to understand

the nutritional values of mature soy seed, to understand nutrition value of product produced from

them.

Depending on the process employed a vast array of soy products can be produced from these seeds,

though the nutritional value of the product depends on the constituent components drained and

retained for given product.

1.4. Soy Chunks or Textured Soy Protein (TVP):

Soya chunks or chunks are made from defatted soy flour, a by-product of extracting soybean oil.

It has a protein content which is equal to that of meat. It is quick and also easy to cook. You can

prepare many dishes using soya chunks such as soya chunks curry, kurma and even add them to

your pulaos, soups, stir fries, etc.

TVP is usually made from high (50%) soy protein, soy flour or concentrate, but can also be made

from cottonseed, wheat, and oats. It is extruded into various shapes (chunks, flakes, nuggets,

grains, and strips) and sizes, exiting the nozzle while still hot and expanding as it does so.

The defatted thermoplastic proteins are heated to 150–200 °C (300–390 °F), which denatures them

into a fibrous, insoluble, porous network that can soak up as much as three times its weight in

liquids.

As the pressurized molten protein mixture exits the extruder, the sudden drop in pressure causes

rapid expansion into a puffy solid that is then dried. As much as 50% protein when dry, TVP can

be rehydrated at a 2:1 ratio, which drops the percentage of protein to an approximation of ground

meat at 16%. TVP is primarily used as a meat substitute due to its very low cost at less than a third

the price of ground beef and, when cooked together, will help retain more nutrients from the meat

by absorbing juices normally lost.

Many TVP producers use hexane to separate soy fat from soy protein, and trace amounts of the

solvent are left after manufacturing. But the few rodent studies that have been done suggest it

would be almost impossible to get enough hexane from TVP to cause harm. Measured levels of

residual hexane in TVP are around 20 parts per million; and studies in rodents suggest that 5 g/kg

is the minimum dose at which undesirable effects may be observed.

TVP can be made from soy flour or concentrate, containing 50% and 70% soy protein,

respectively; they have a mild beany flavor. Both require rehydration before use, sometimes with

flavoring added in the same step. TVP is extruded, causing a change in the structure of the soy

protein which results in a fibrous, spongy matrix, similar in texture to meat. In its dehydrated form,

TVP has a shelf life of longer than a year, but will spoil within several days after being hydrated.

In its flaked form, it can be used similarly to ground meat.

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1.5. Market Potential:

The global soy food market was worth US$ 40.5 Billion in 2019. Soybean is a type of legume,

native to East Asia, which is low in saturated fats but high in protein, vitamin C and folate. It is a

good source of iron, fiber, calcium, magnesium, potassium, phosphorus and omega-3 fatty acids.

As a result of its nutrient content, it offers various health benefits such as lowering the blood

cholesterol level, increasing bone density and minimizing the risk of developing cancer. It is

widely used as an alternative of meat in several dishes and is added in various vegan-friendly food

products. The rising demand for plant-based foods is strengthening the growth of the soy food

market across the globe.

Soybean is used for preparing numerous products including soymilk, soy flour, tofu, tamari,

tempeh, edamame, miso, natto and teriyaki. Currently, the demand for tofu is rising around the

world, especially among the vegan and vegetarian population. It is an excellent substitute for

cheese, which can be consumed by lactose intolerant consumers. The growing sales of tofu can

also be accredited to its resemblance to meat in its form, color, taste and texture. Apart from this,

other soy food products such as snacks and beverages are also experiencing steady growth in their

demand worldwide on account of the growing health awareness among consumers. Further,

manufacturers are investing in research and development activities to introduce new variants of

soy food products to expand their product portfolio and attract new consumers. Looking forward,

IMARC Group expects the global soy food market to exhibit moderate growth during the next five

years.

Nutritious value and versatility of ingestible forms act as growth levers for the global soy food

products market. As consumers move towards health-conscious diets, soy food products present

an ideal alternative for dairy, meat, and poultry intensive diets. Recent surveys have revealed that

about 40% consumers below 35 years consume soy at least once a week, twice that of consumers

aging 55 years or older. As per latest data, nearly 80% of consumers have tried some of the most

prevalent soy food products or beverages. Driven by such factors, the global soy food products

market is expected to grow at an impressive CAGR over the forecast period, 2020-2030.

1.5.1. Growth Drivers & Trends:

Prevalence of heart diseases is creating a lateral shift in consumer preference for cooking

oil. Heart diseases are a leading cause of mortality in the US, causing about 650, 000 deaths

every year. Health-conscious consumers are looking for low bad-cholesterol heart-friendly

alternatives to conventional cooking oil. Although presence of alternatives such as olive

oil is hindering market growth, manufacturers are expanding their production capacities to

distribute their products at competitive pricing. According to the World Soy Oil Processors

Association (SOPA), the global soy oil production in 2019-2020 was more than 56 million

metric tons. Soy-oil is a healthier alternative; successful marketing campaigns are viewing

millennials and geriatrics as their target consumer base. Players must capitalize on soy oil

will to maintain their positive trend in the marketplace.

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1.5.2. Growth Restraints:

Some studies have associated soy food products with possible side effects such as

menopause symptoms, cancer risk, and increased cholesterol levels. In addition, soy allergy

is among the most common food allergies, particularly in toddlers and infants. Studies find

that about 0.4% of infants are allergic to soy. While in some cases, the allergy subsides

during infancy, in worst cases, the problem continues through adulthood.

1.5.3. COVID-19 Impact:

While consumers have been increasingly shifting towards health-centric products, the

COVID-19 pandemic has provided further impetus to the trend. Amid nationwide

lockdowns in several countries, many leading meat plants have been shut down in order to

avoid further contagion of coronavirus. This potential of scarcity of meat supply is

influencing consumers to turn to plant-based meat products, with meat alternatives such as

tofu witnessing phenomenal sales in developed regions. Such trends are working in favor

of soy food products market amid the pandemic.

1.5.4. Region Wise Analysis:

North America remains the frontrunner in soy food products market owing to presence of

key soy oil processing locations - the US and Canada. According to SOPA estimates, the

US produced the highest soy oil at a substantial 11 Mn metric tons. Revenue opportunities

will also come from continued growth in consumer demand for soy oil and soy-based

products. Increasing health consciousness among consumers is driving financially

rewarding traction for soy food product manufacturers. Miso, tempeh, and tofu are some

of the most popular dairy and alternative meat products. Further, soy is also the only plant-

based protein to carry a Food & Drug Administration (FDA) heart health claim.

However, Asia Pacific (APAC) will emerge as a lucrative soy food products market. Rising

consumption of convenience foods owing to fast-paced lifestyle is creating a fertile

breeding ground for manufacturers. In addition, consumers are showing greater preference

for functional food products. As such, market players must tap these opportunities to

expand their footprint in APAC..

1.5.5. Indian Market:

India Soy Product Market is projected to record a CAGR of 3.8% during the forecast period

(2020-2025).

The market is primarily driven by the increasing number of consumers seeking non-dairy

beverage alternatives have led to substantial growth in the demand for soy milk beverages

market. In addition, new food production technology and new varieties of soybeans result

in new flavors creates competition with cow’s milk and dairy products.

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Furthermore, the various health benefits of soy milk such as less cholesterol, heart disease

reduction and the increasing number of health-conscious consumers are also few of the

factors driving the market.

1.5.6. Competition in Indian Market:

The India Soy Product Market is consolidated, owing to the presence of a fewer number of

regional and domestic players from different countries. Emphasis is given on the merger,

expansion, acquisition, and partnership of the companies along with new product

development as strategic approaches adopted by the leading companies to boost their brand

presence among consumers. Key players dominating the regional market include The

Hershey Company, Life Health Foods India Private Limited, and Chetran Foods Private

Limited. Other players in the Indian market include Pacific Foods Of Oregon LLC, The

Hain Celestial Group, Inc., SoyLife, Neon India, and Invigorate Foods Pvt. Ltd. among

others.

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Chapter 2

Technical Aspects of Soya Chunks Processing

2.1.Raw Material:

The Soy Flour or Soybean can both be used as raw materials but if soy beans are being used then

the process starts with soybean processing into soy flour. The conversion of soy flour into defatted

soy flour, then the actual soy chunks manufacturing process can start. The process discussed in

this material is soya chunks manufacturing from defatted soy flour, thus the raw material required

are Defatted Soy Flour & Packaging Material.

Defatted Soya Flour (Toasted) is obtained by milling from selected, pre-cleaned, cracked, dehulled

and solvent extracted `NON GMO` Soybeans. It is natural product which does not contain

additives or preservatives. Defatted Soya Flour (Untoasted) is obtained, by milling from selected

pre-cleaned, cracked, dehulled and solvent extracted `NON GMO` Soybeans through FDS (Flash

Desolventising System) technology. It is a natural product which does not contain additives or

preservatives.

2.2.Machine:

2.2.1. Flour Sifter:

It’s a sifter class machine which is used to perform sifting process and remove any larger

particulate impurities from flour. It’s used at starting of the manufacturing process to

remove any impurities from flour.

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2.2.2. Soy Chunk Extruder:

It’s a type of extruder that is specifically designed for soy chunks, in this case the soy flour

and water are mixed & cooked within the extruder itself followed by extrusion at high

pressure along with high temperature due to cooking. Which ultimately results in textured

food product.

2.2.3. Soy Chunk Dryer:

It’s a simple machine designed to remove moisture for freshly extruded soy chunks in order

to make them dry and ready for packaging. This machine is utilized after chunk extrusion

to help soya chunks retain there shapes.

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2.2.4. Nitrogen Flush Packaging Machine:

The functioning of machine is simple, it forms an open pouch by two step sealing followed

by filling, nitrogen flushing and final sealing to obtain the soya chunks filled packet.

2.3. Equipment:

2.3.1. SS Storage Vessel:

They are used to store various liquid solution at required conditions, Like after the soy milk

is prepared this equipment is used to store the soy milk. Therefore, they serve as machines

for temporary storage and transports the right amount of soy milk to the next device in

operation on the basis of device capacity.

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2.3.2. SS Storage Tanks:

It’s a simple tank designed to hold required product.

2.3.3. Dry Bean Tank

These equipments are class of storage equipments which are specifically designed for dry

raw material of small granule composition.

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2.3.4. Food Grade Conveyor:

These are conveyors with food grade belt to maintain food safety standards set by

monitoring authorities.

2.3.5. Other Material Handling Equipments:

They are simply used to hold and transfer given material efficiently.

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2.3.6. Power Distribution Equipments:

They are used to safely receive and distribute electrical power.

2.4. Production Process:

Extrusion cooking has been defined as ‘the process by which moistened, expansile, starchy

and/or proteinaceous materials are texturized in a tube by a combination of moisture, pressure,

heat and mechanical shear. This results in elevated product temperatures within the tube,

gelatinization of starchy components, denaturization of proteins, the stretching or restructuring

of tractile components and the exothermic expansion of the extruder”.

Extrusion is widely used to accomplish this restructuring of protein-based foodstuffs to

manufacture a variety of textured convenience foods. When mechanical and thermal energy

are applied during the extrusion process, the macromolecules in the proteinaceous ingredients

lose their native, organized structure and form a continuous, visco-elastic mass. The extruder

barrel, screws and die align the molecules in the direction of flow. This realignment “exposes

bonding sites that lead to cross-linking and a reformed, expandable structure’ that creates the

chewy texture in fabricated foods.

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Traditionally the most popular raw material for production of textured vegetable proteins in an

extrusion system has been slightly toasted defatted soy flour. This defatted soy flour usually

meets the following characteristics: 50% protein minimum, 3.5% fiber maximum, 1.5% fat

maximum and PDI of 60 to 70.13 This along with greater simplicity of extrusion gives the

process a cost advantage over the spinning (Boyer) process which uses isolated soy protein. A

cooker-extruder is used to force the protein material through a die that controls the size and

shape of the texturized material.In operation, the extrusion is quite simple, but does require

considerable experience in the handling of the equipment. At first, the raw material is pre-

moistened to levels of 15-40 percent (with special additives sometimes added to the

preconditioning water). The mixture is agitated until homogenous. It is then fed to the extruder

while the screw is rotated at a substantial speed. Steam and water are used in alternate jacket

sections for heating and cooling. Cooling is usually carried out near the feed section of the

extruder. The meal mixture is advanced within the extruder while being heated to high

temperatures and subjected to elevated pressures.

The mechanically worked mixture becomes a viscous fluid-type substance that is forced

through a restrictor orifice after 30 to 60 seconds' retention time in the extruder. As the product

emerges from the die outlet, the superheated moisture contained in the meal enters the

substantially lower atmospheric pressure environment where flash-off evaporation of part of

the moisture expands the product into a porous structure. Evaporation also cools the product

substantially.

The expanded product is very porous and has a fibrous network structure somewhat resembling

that of meat.14 The product can be kept moist and used directly for food materials, or can be

dried and packed conveniently for later use. It rehydrates rapidly and completely within a few

seconds merely by adding water (usually about two parts for one part solids) to yield a product

with excellent food characteristics.

Finished products (chunks/granules) are then packed through packing spouts in bags.

Wholesale Packaging of products can be done through an Automatic Weighing and Bagging

machine, which can pack the chunks/granules in 10 kg-100 kg capacity bags. In general, 25 kg

and 50 kg size bags are used in wholesale. On an average, such bagging machine can give an

output of 250 to even 500 bags per hour. For retail packaging (i.e. 1 kg, 2 kg and 5 kg), a liner

carton machines with multi-head weighers can be used.

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2.5. Control Parameter: There are several parameters which control the output of the soy processing plant, some of the

important parameters are discussed below:

2.5.1. Production Rate:

Production rate, in terms of manufacturing, refers to the quantity of goods that can be

produced during a given period of time. Alternatively, the production rate is also the

amount of time it takes to produce one unit of a good.

Companies often strive for high production rates to help lower the time and cost of a project

or the production process. However, a higher production rate can also lead to a decrease in

quality if more mistakes are made as employees push to have more units produced or more

of a building completed.

2.5.2. Grinding Temperature:

During grinding, the temperature of the product rises to a level in the range of 42±95°C

which varies with the oil and moisture content of the foods, but foods lose a significant

fraction of their volatile oil or flavoring components due to this temperature rise.

The grinding temperature needs to be maintained in order to prevent variation in taste as

well as unwanted vaporization, for soybeans and several other products it’s maintained via

a water jacket system, whose water has its own cooling system.

2.5.3. Grinding Force:

The three types of forces involved in size reduction of solids are compression, impact and

shear. Compression is a grinding force, like when you pulverize cereal in a mortar. Impact

occurs when material is thrown against a surface causing it to disintegrate. For example, if

you take an egg and throw it against a wall causing it to splatter, that’s an example of

impact. Shear is a slicing force where you have one surface sliding over another.

For soybean and several other solid grains a combination of all is used but depending on

machine used we have one dominant force like in hammer will impact is dominant.

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2.5.4. Grinding Speed:

It simply refers to speed at which the given material is being ground, it can be measured

either by actual material input & output or it can be defined by bade or hammer speed.

Other less common method include utilizing circumferential speed.

Hammer mill shaft rotate at a much slower speed than blade grinders, which may rotate at

speeds as high as 20,000 to 30,000 rpm; for example, the Steele model mixer-grinder by

Indian appliance manufacturer Preethi has a no-load speed of 23,500 rpm and loaded speed

of 11,500rpm.

2.5.5. Pore Size:

Filtration is a physical, biological or chemical operation that separates solid matter and

fluid from a mixture with a filter medium that has a complex structure through which only

the fluid can pass. Solid particles that cannot pass through the filter medium are described

as oversize and the fluid that passes through is called the filtrate.

The size of the largest particles that can successfully pass through a filter is called the

effective pore size of that filter. For soy milk this value is 400 nm

2.5.6. Cooking Temperature:

It’s simply the temperature at which given food item is to be cooked, Any processed food

product has an optimum range of cooking temperature at which it must be cooked to obtain

the desired product.

Low temperature results in insufficient cooking, while the high temperature results in

localized burning and the improper cooking temperature also corrodes taste. Therefore it’s

essential to maintain cooking temperature.

2.5.7. Cooling Temperature:

It simply refers to the temperature at which the given food product is being cooled, which

is usually followed after cooking, heating and during pasteurization. The improper cooling

may also affect taste and moisture.

2.5.8. Moisture Content:

Moisture is the presence of a liquid, especially water, often in trace amounts. Small

amounts of water may be found, for example, in the air, in foods, and in some commercial

products.

It can be indirectly controlled via other parameters like various temperature and sometimes

balance is maintained by adding extra water during certain process.

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2.6. Quality Parameter: There are several parameters which control the quality of end product, some of these important

parameters are discussed below:

2.6.1. Appearance:

The most important attribute of any food's appearance is its color, especially when it is

directly associated with other food-quality attributes. Other attribute include shape, surface

profile and visible texture. Food presentation is just as essential to the success of a food

product as its taste and flavour.

2.6.2. Taste:

The gustatory system or sense of taste is the sensory system that is partially responsible for

the perception of taste (flavor). Taste is the perception produced or stimulated when a

substance in the mouth reacts chemically with taste receptor cells located on taste buds in

the oral cavity, mostly on the tongue.

The various food product have their unique tastes any deviation from them will lead to

deviation in final dish, hence it’s essential to maintain uniform taste in processed food

products.

2.6.3. Nutritional Content:

Nutritional value or nutritive value as part of food quality is the measure of a well-balanced

ratio of the essential nutrients carbohydrates, fat, protein, minerals, and vitamins in items

of food or diet in relation to the nutrient requirements of their consumer.

Higher the nutritional content of a product higher is it’s quality, as appropriate ingredients

must have be added along with the base ingredient to elevate nutritional value.

2.6.4. Shelf Life:

Shelf life is the length of time that a commodity may be stored without becoming unfit for

use, consumption, or sale. It comes into play after appearance, taste and nutrition, given a

choice in products with same nutritional content and taste one tends to opt for the product

with more shelf life.

2.6.5. Packaging:

It also defines the quality of the product, apart from essentials like food grade packaging

material, the type of process and technology further elevates the quality of product, for

example anti-microbial packaging adds to product value thus quality.

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Chapter 3

Packaging of Soy Chunks

3.1. Storage & Shelf Life:

Food storage is defined as storage of given food item over particular period of time in edible state,

however in generally refers to food stored for a long period time.

Shelf life is defined in two ways:

"best if used by": Length of time food retains most of its original taste and nutrition.

"life sustaining": Length of time foods can be stored and still be edible.

There can be a big time difference between these two types of food products. Foods bought at the

grocery store can have a shelf life of a few days to several years, depending on the type of food,

the storage conditions, and the packaging.

The "life sustaining" foods are those that are packaged specifically for long term storage. The

estimated shelf life for many of these products has increased to 30 years or more.

The longer food is stored, taste and nutritional quality declines, depending on the quality of the

food when first packaged. However, studies have shown that freeze-dried and dehydrated foods,

properly packaged and sealed, even if stored past their designated time, retain their calories, and

calories will sustain life in an emergency and prevent starvation.

The shelf life of food stored depends on these 4 main criteria:

3.1.1. Temperature:

Foods stored at room temperature or cooler (75°F/24°C or lower) will be nutritious and

edible much longer than previously thought according to findings of recent scientific

studies. Foods stored at 50°F to 60°F (which is optimal) will last longer than foods stored

at higher temperatures. Heat absolutely destroys food and its nutritional value. Proteins

break down and some vitamins will be destroyed. Taste, color, and smell of some foods

may also change.

3.1.2. Moisture:

The reason long term food storage is dehydrated or freeze dried is to eliminate moisture.

Too much moisture promotes an atmosphere where microorganisms can grow and

chemical reaction in foods causing deterioration that ultimately can sicken us.

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3.1.3. Oxygen:

Too much oxygen can deteriorate foods and promote the growth of microorganisms,

especially in fats, vitamins, and food colors. That is the reason to use oxygen absorbers

when dry packing your own food products.

3.1.4. Light:

Exposure to too much light can cause deterioration of foods. In particular if affects food

colors, vitamin loss, fats and oils, and proteins. Keep long term food storage in low light

areas for longest shelf life.

Therefore, the soy products like soy milk, soy paneer have lower shelf life then the products like

soybean oil which in turn have lower shelf life then dry products like soy chunks.

Soy milk is sold in two varieties: refrigerated and non-refrigerated. Both types of soy milk must

be refrigerated once opened, and typically last 7-10 days in the fridge. Before they're opened, the

expiry date on the carton is a good indicator of its shelf life. Products often stay good after 10 days.

The soy milk sold on shelves is similar to canned food in that it lasts a long period of time in your

cupboard if it's not opened. It can have expiry dates that last as long as 8 months.

Soya paneer or Tofu is made by coagulation of water and soyabean with lemon juice . To increase

the shelf life different methods are used like immersion in liquid , smoking and both together. The

temperature is maintained between 24–37 degree Celsius and tofu could be stored for upto 5–10

days. Shelf life could be extended to 10–15 days without refrigerator by smoking and storing in a

strong salt brines solution acidifying it with lemon juice.

Products like Soy Textured Protein in its dehydrated have long shelf life and simultaneously have

high nutritional value, although the sensory quality showed a decline by the end of 12 months

storage period, the overall acceptability of the product on the 9 point Hedonic scale, remained very

good. It is inferred from various studies that packaging of TSP in HDPE‐500 Primary Sac and

HDPE woven Secondary Sac, keeps the product shelf stable up to one year even under diverse

climatic conditions.

3.2 The factors that lead to spoilage/defects the soya chunks are highlighted as below:

Blemishes - Scars, discoloration, sunburn, dark spots, black nose, or similar abnormalities in

surface appearance affecting an aggregate area greater than that of a circle 7 mm in diameter.

Dirt-preparation of packaging in an open area can lead to this problem. dirt can reduce the

quality of soya chunks.

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Insects and mites- as it is sweet and prepared from sugar it can be damaged by insects or mites

or contaminated by damage and contamination the presence of dead insects or mites, fragments

of insects or mites, or their excreta.

Scouring- Breakdown of the sugars into alcohol and acetic acid by yeasts and bacteria.

3.3. Selection of Packaging Material

Factors to consider include product damage, fines, stickiness, bag opening size, re-closure among

other things. In selection of packaging materials for sweet packaging the following need to be

considered:

3.3.1. Water Vapour Transmission Rate (WVTR)

Knowledge of WVTR of packaging materials and the effect of folding, creasing, crumpling of

materials on papers and aluminum foil show considerable effect. However, thermoplastic materials

are not much affected.

Effect of Folding and Crumpling on the WVTR

3.3.2. Gas Transmission Rate

Permeability to gases like oxygen decides the shelf-life of oxygen sensitive fruit items. The oxygen

transmission rates (OTR) of some plastic materials and the effect of folding and crumpling.

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Effect of Folding and Crumpling on the OTR

Besides OTR, permeability to volatiles and flavours is important in candies packaging. Polyolefins

have high values, whereas plastics such as polyester, nylons, ethylene vinyl alcohol (EVOH) have

good barrier properties for transmission of volatiles. The odour permeability’s (for volatiles used

in candies) of some materials.

Odour Transmission of Packaging Materials

3.3.3. Tensile Strength & Elongation

Tensile Strength and Elongation properties of materials need to be studied as their running on high-

speed machines should be suitable.

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3.3.4. Tear Strength

For a fruit processed product, tear strength is of importance as low tear values are necessary and

useful for opening packages by hands.

3.3.5. Heat Seal Strength

The performance of a finished package is determined by the effectiveness of the package seal i.e.

the permeability to water vapor, gases and volatiles increase if the seal is not perfect.

Thermoplastic films such as polyethylene give excellent heat seals.

3.3.6. Performance Properties

Apart from the above mentioned important properties, a material has to perform well on machines;

therefore knowledge of physical properties like slip, stiffness, blocking resistance is also

necessary.

Twist retention for twist wrap is also of importance. The initial function of packaging is to protect.

However, the emotional role played by packaging is also of importance, especially when the

confection is a gift. A sophisticated packaging using deluxe materials is often used as a way of

expressing feelings.

Packaging must also be specialized for specific target groups. A different pack size is required for

quick impulse buys at petrol stations and roadside shops than for the super markets selling

predominantly family sized packs.

3.4. Frequently-used plastic-based packaging materials

A very high quantum of polymeric materials, besides cellulosic and aluminum foil, are used for

packaging items. Paper board and metal containers are also used for certain applications. Although

a variety of packaging materials are available, the ultimate choice of the wrapper depends upon

the required shelf-life, performance of the wrapping machine, and the cost which is purely based

on the segment of the market targeted by the manufacturer.

The most common choice of packaging medium is plastic (generally flexible) as it provides the

required protection and preservation, grease resistance, physical strength, machinability, and

printability. Plastics being lighter in weight are, therefore, the most preferred material for

packaging of sweets.

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There are many changing trends in the packaging of soya chunks. Plastic films and their laminates

are increasingly used due to better properties and aluminum foil laminates due to price and better

flex crack property. Plastic-based packaging materials that can be used for soya chunks are listed

below.

Polyethylene (PE)

It is considered to be the backbone of packaging films. Since one of the greatest threats to

the quality of sweets comes from moisture, polyethylene with its low water vapor

transmission is of definite interest. Polyethylene films are fairly free of plasticizers and

other additives and are quite extensively used as a part of lamination. Its ability to heat seal

increases its value.

Low-Density Polyethylene (LDPE) is an economical material with low WVTR, however,

it has high permeability’s to flavors/volatiles, poor grease resistance, and are limp. High-

density polyethylene (HDPE) is stiffer, more translucent, and has better barrier properties

but needs a higher temperature for sealing.

Later additions include high molecular weight high-density polyethylene (HM HDPE) and

linear low-density polyethylene (LLDPE). HM HDPE is a paper-like film with high

physical strength and barrier properties but is less transparent than ordinary polyethylene.

HM HDPE is available in twist-wrap grades. Polyethylene films are also suitable for

making bags. A copolymer of polyethylene and polyvinyl alcohol and EVOH has

outstanding gas barrier properties especially when dry.

Polypropylene

Polypropylene films have better clarity than polyethylene and enjoy superior machinability

due to stiffness. Lack of good salability has been a problem; however, PVDC and vinyl

coating have been used to overcome this problem. Some varieties of PP have been specially

developed for twist-wrap applications as they have the ability to lock in position after

twisting. Paralyzed polypropylene with an opal finish and attractive gloss is also used. Both

as laminates and overwraps, PP film is now widely used for all types packaging

applications.

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Poly Vinyl Chloride (PVC)

PVC is a stiff and clear film having a low gas transmission rate. PVC can be used as small

wraps, bags, and pouches. PVC when co-polymerized with polyvinylidene chloride is

known as Saran. Since it is a costly material, it is only used as a coating to obtain barrier

properties and heat salability. PVC film is also used for twist wraps, as it has twist retention

properties and is excellent on high-speed machines.

Polyesters (PET) and Polyamide (PA)

Polyethylene terephthalate film has high tensile strength, gloss, and stiffness as well as

puncture resistance. It has moderate WVTR but is a good barrier to volatiles and gases. To

provide heat seal property, PET is normally laminated to other substrates. Nylons or

polyamides are similar to PET but have high WVTR.

Metal-Plastic Laminate Films

When polymeric films are metalized there is an improvement in their barrier properties.

Metallization is also used for decorative purposes and aesthetics. The films, which are used

for metallization, are PVC, PET, PP, and polyamides. To safeguard the interest of the

consumer the Standards of Weights & Measures (Packaged Commodities) Rules, have

imposed a limit on the weight of the wrapper.

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Chapter 4

Project Component of Soy Chunks

4.1. Land- The approximate total area required for a complete small scale factory setup is 3000-

4000 Sq. ft. approximately smooth production.

4.2. Civil work-

Processing plant Area- This area includes the machinery setup and foundation space for

all tools and equipment etc. The total processing plant area is approx. 1500 Sqft.

Inventory Area- This area includes the storage space for all the raw materials, finished

Product area. Total inventory area is approx. 500 Sqft.

Office Area – This space includes staff working region, their accommodation space,

canteen area, medical facility, etc. The total workshop area is approx. 500Sqft. This may be

considered above the ground floor.

Parking Space, Electricity Utensils Mounting Space, and Others. This could be approx.

500Sqft.

Land and building requirements may vary depending on the size of project.

4.3. Miscellaneous Assets-

Water Supply Arrangements

Furniture

4.4.Power requirement- The manufacturing unit requires 10-12 KW.

4.5. Man power requirement- For a small unit to begin with around 8-10 people is required

including skilled, non- skilled worker and a supervisor..

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Chapter 5

FSSAI Standards of Soy Chunks

5.1.Food Standards

The standards for Soya Chunks Whole and Soya Chunks powder are defined under Regulation

2.9.7 of FSSAI’s Food Products Standards & Food Additives regulations, 2011. Soya

Chunks whole is the dried mature fruits (seeds) of Coriandrum sativum L. Soya Chunks whole is

the dried mature fruits (seeds) of Coriandrum sativum L. It must have characteristic aroma and

flavour and shall be free from mould, living and dead insects, insect fragments, rodent

contamination and added colouring matter.

The standards for Dhania Whole are based on Extraneous matter, Split fruits,

Damaged/Discoloured fruits, Moisture, Volatile oil content on dry basis, Total ash on dry basis,

Ash insoluble in dilute HCl on dry basis and Insect damaged matter

5.2.Food Safety

Part I - General Hygienic and Sanitary practices to be followed by Petty Food Business Operators

applying for Registration

SANITARY AND HYGIENIC REQUIREMENTS FOR FOOD MANUFACTURER/

PROCESSOR/HANDLER

The place where food is manufactured, processed or handled shall comply with the following

requirements:

1. The premises shall be located in a sanitary place and free from filthy surroundings and shall

maintain overall hygienic environment. All new units shall set up away from environmentally

polluted areas.

2. The premises to conduct food business for manufacturing should have adequate space for

manufacturing and storage to maintain overall hygienic environment.

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3. The premises shall be clean, adequately lighted and ventilated and sufficient free space for

movement.

4. Floors, Ceilings and walls must be maintained in a sound condition. They should be smooth

and easy to clean with no flaking paint or plaster.

5. The floor and skirted walls shall be washed as per requirement with an effective disinfectant

the premises shall be kept free from all insects. No spraying shall be done during the conduct

of business, but instead fly swats/ flaps should be used to kill spray flies getting into the

premises. Windows, doors and other openings shall be fitted with net or screen, as appropriate

to make the premise insect free The water used in the manufacturing shall be potable and if

required chemical and bacteriological examination of the water shall be done at regular

intervals at any recognized laboratory.

6. Continuous supply of potable water shall be ensured in the premises. In case of intermittent

water supply, adequate storage arrangement for water used in food or washing shall be made.

7. Equipment and machinery when employed shall be of such design which will permit easy

cleaning. Arrangements for cleaning of containers, tables, working parts of machinery, etc.

shall be provided.

8. No vessel, container or other equipment, the use of which is likely to cause metallic

contamination injurious to health shall be employed in the preparation, packing or storage of

food. (Copper or brass vessels shall have proper lining).

9. All equipments shall be kept clean, washed, dried and stacked at the close of business to

ensure freedom from growth of mould/ fungi and infestation.

10. All equipments shall be placed well away from the walls to allow proper inspection.

11. There should be efficient drainage system and there shall be adequate provisions for disposal

of refuse.

12. The workers working in processing and preparation shall use clean aprons, hand gloves, and

head wears.

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13. Persons suffering from infectious diseases shall not be permitted to work. Any cuts or wounds

shall remain covered at all time and the person should not be allowed to come in direct contact

with food.

14. All food handlers shall keep their finger nails trimmed, clean and wash their hands with soap,

or detergent and water before commencing work and every time after using toilet. Scratching

of body parts, hair shall be avoided during food handling processes.

15. All food handlers should avoid wearing, false nails or other items or loose jewellery that

might fall into food and also avoid touching their face or hair.

16. Eating, chewing, smoking, spitting and nose blowing shall be prohibited within the premises

especially while handling food.

17. All articles that are stored or are intended for sale shall be fit for consumption and have proper

cover to avoid contamination.

18. The vehicles used to transport foods must be maintained in good repair and kept clean.

19. Foods while in transport in packaged form or in containers shall maintain the required

temperature.

20. Insecticides / disinfectants shall be kept and stored separately and `away from food

manufacturing / storing/ handling areas.

5.3.Labeling Standards (2.2.2)

Labeling requirements for packaged food products as laid down in the Part VII of the Prevention

of Food Adulteration (PFA) Rules, 1955, and the Standards of Weights and Measures (Packaged

Commodities) Rules of 1977, require that the labels contain the following information:

1. Name, trade name or description

2. Name of ingredients used in the product in descending order of their composition by

weight or volume

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3. Name and complete address of manufacturer/packer, importer, country of origin of the

imported food (if the food article is manufactured outside India, but packed in India)

4. Nutritional Information

5. Information Relating to Food Additives, Colors and Flavors

6. Instructions for Use

7. Veg or Non-Veg Symbol

8. Net weight, number or volume of contents

9. Distinctive batch, lot or code number

10. Month and year of manufacture and packaging

11. Month and year by which the product is best consumed

12. Maximum retail price

Provided that — (i) the nutritional information may not be necessary, in case of foods such as raw

agricultural commodities, like, wheat, rice, cereals, spices, spice mixes, herbs, condiments, table

salt, sugar, jaggery, or non –nutritive products, like, soluble tea, coffee, soluble coffee, coffee-

chicory mixture, packaged drinking water, packaged mineral water, alcoholic beverages or fruit

and vegetables, processed and pre- packaged assorted vegetables, fruits, vegetables and products

that comprise of single ingredient, pickles, papad, or foods served for immediate consumption such

as served in hospitals, hotels or by food services vendors or halwais, or food shipped in bulk which

is not for sale in that form to consumers.

Wherever applicable, the product label also must contains the following

The purpose of irradiation and license number in case of irradiated food. Extraneous addit ion of

coloring material. Non-vegetarian food – any food which contains whole or part of any animal

including birds, fresh water or marine animals, eggs or product of any animal origin as an

ingredient, not including milk or milk products – must have a symbol of a brown color-filled circle

inside a brown square outline prominently displayed on the package, contrasting against the

background on the display label in close proximity to the name or brand name of the food.

Vegetarian food must have a similar symbol of green color-filled circle inside a square with a

green outline prominently displayed.

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All declarations may be: Printed in English or Hindi on a label securely affixed to the package, or

Made on an additional wrapper containing the imported package, or Printed on the package itself,

or May be made on a card or tape affixed firmly to the package and bearing the required

information prior to customs clearance.

Exporters should review the Chapter 2 of the “FSS (Packaging and Labeling) Regulation 2011”

and the Compendium of Food Safety and Standards (Packaging and Labeling) Regulation before

designing labels for products to be exported to India. FSSAI revised the labeling Regulation and a

draft notification to that effect was published on April 11, 2018, inviting comments from WTO

member countries and the comments received are under review and the publication date remains

unknown.

According to the FSS Packaging and Labeling Regulation 2011, “prepackaged” or “pre packed

food” including multi-piece packages, should carry mandatory information on the label.