Soya chunks making process

The process of making soya chunks, or textured vegetable protein (TVP), involves several key steps. Here’s a general overview of how soya chunks are produced:

1. Soybean Preparation

• Cleaning: Raw soybeans are cleaned to remove dirt, stones, and other impurities.
• Soaking: The cleaned soybeans are soaked in water for several hours or overnight. This process softens the beans and makes them easier to process.

2. Dehulling and Grinding

• Dehulling: After soaking, the soybeans are dehulled to remove the outer seed coat. This step is important for improving the texture and digestibility of the final product.
• Grinding: The dehulled soybeans are ground into a fine flour or meal. This helps in extracting the protein and facilitates the subsequent processing steps.

3. Protein Extraction

• Oil Extraction: The soybean flour is subjected to an oil extraction process, often using a solvent like hexane. This removes the soybean oil, leaving behind a high-protein meal.
• Protein Concentration: The defatted soybean meal is then processed to concentrate the protein. This is usually done through a process of washing with water or an alkaline solution, which helps to isolate the protein from other components.

4. Texturizing

• Extrusion: The concentrated soy protein is then subjected to extrusion, a process where it is forced through a machine under high temperature and pressure. This step is crucial for texturizing the protein. The protein strands align and expand, creating a fibrous texture that resembles meat.
• Shaping: During extrusion, the protein can be shaped into various forms, including chunks, granules, or flakes. The form depends on the intended use of the soya chunks.

5. Drying

• Drying: The extruded soya chunks are then dried to remove excess moisture. This step helps to preserve the product and improve its shelf life. Drying can be done using air or heat.

6. Cooling and Packaging

• Cooling: The dried soya chunks are cooled to stabilize the texture and prevent condensation.
• Packaging: Finally, the soya chunks are packaged for distribution. They are often packed in vacuum-sealed bags or containers to maintain freshness and extend shelf life.

7. Quality Control

• Quality Checks: Throughout the process, quality control measures are implemented to ensure the soya chunks meet nutritional and safety standards. This includes checking for protein content, texture, and absence of contaminants.

The result is a versatile, high-protein product that can be rehydrated and used in a variety of recipes, such as soups, stews, stir-fries, and meat substitutes. Soya chunks are valued for their ability to absorb flavors and provide a meat-like texture in plant-based dishes.