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1. SOY FOOD Processing

2. Overview Soy food production Soya - versatile product Soybeans belong to the legume family and are native to East Asia. They have been an important protein source in the Orient for millions of people for over five thousand years. Soybeans have been in the Western world since the 20th century. Soybeans can be grown on a variety of soils and a wide range of climates, ranging form tropical Brazil to the snowy island Hokkaido in the north of Japan. As soybeans mature in the pod, they ripen into a hard, dry bean. Although most soybeans are yellow, there are also rare varieties which are black, brown or green. Soya beans are very versatile: soya beans can be used as whole soya beans, soya sprouts, or processed as soya milk, tofu, tempeh, soya souce or miso. Soya is also used as ingredient for non-food products, such as soy candles and biodiesel. Soy candles are becoming more popular because they burn longer and healthier.

3. The increasing popularity of soya foods is mainly attributed to the large amount of health benefits which are associated with the use of soya beans. The role of soya in the prevention of chronic diseases continues to be a top priority for scientist around the world. The FDA has confirmed that foods containing soy protein may reduce the risk of coronary heart disease. Only people with soy allergy (about 0.5 percent of the population) should avoid eating food containing soy protein. Over the past years, there has been an increasing interest in the antioxidant effects of soya and in particular the health benefits of soya isoflavones, which seem to reduce menopause symptoms. Soya is very important for vegetarians and vegans. Soya has a high protein content and soya is rich in vitamins, minerals and fibers. The easiest way to consume soya is by drinking soya milk. High yield - A given area of land planted with soybeans can produce much more protein than land planted with other crops, or if the land were used to raise cattle. Overview Soy food production Soya - healthy product

4. Overview Soy food production Soya – Protein source Whole soybeans are an excellent source of protein (soybeans contain on average 37% protein!) and dietary fibre. Soy protein is the only vegetable whose protein is complete. Soy protein has attracted a lot of attention recently due to its ability to lower LDL (bad cholesterol) levels. Results from research have prompted health professionals to request the government to officially give a stamp of approval for soy's cholesterol-lowering effects. The Food and Drug Administration recently approved the cholesterol-lowering health claim for soy, indicating that daily consumption of 25 grams of soy protein (6.5 grams of soy protein per serving) may lower LDL cholesterol.

5. Overview Soy food production Cow‘s milk vs. Soymilk Source: Vandermoortele (UK) Ltd. (ALPRO soymilk) Nutritional value per 100 g Cow's milk Soymilk Whole Semi-skimmed Protein Fat Carbohydrate kJ kcal 3.4 g 3.5 g 4.6 g 269 64 3.5 g 1.5 g 5.4 g 208 49 3.6 g 2.3 g 3.4 g 204 49 Cholesterol 10 mg 5 mg 0 Lactose 4.6 g 5.4 g 0 Fatty acid composition Saturated Poly-unsaturated Mono-unsaturated 63.5% 3.0% 33.5% 63.5% 3.0% 33.5% 14.0% 63.5% 21.6%

6. Overview Soy food production World production of soybeans Source: UN Food & Agriculture Organization (FAO) Top Soybean Producers in 2005 (million metric tons) United States 83.9 Brazil 52.7 Argentina 38.3 China 17.4 India 6.6 Paraguay 3.5 Canada 3.0 Bolivia 1.7 Italy 0.5 World Total 214.3

7. Overview Soy food production What the soy bean is used for World Soybean Production 95 (million tons) Oil Crushing 75 Soy bean uses in 1986 Stock 15 Human Food 5 54 of meal 13 of oil 52 animal feed 2 food proteins INTO Where of

11. Raw material reception and storage Soy been dehulling Overview Soy food production Soy milk process steps Milling of the bean Separation of the fibres Enzyme inactivation and deodorization Homogenization Protein standardization Okara

12. Overview Soy milk production Soy milk production process

15. Overview Soy milk production Soy puree production process

16. Soya bean storage pneumatic conveying Overview Soy milk production Storage + bean feed

17. Overview Soy milk production Soaking tanks Soy been soaking: Soybeans are washed thoroughly and soaked in about three times their volume of water for a period sufficient to swell them completely. The soaking process softens the beans for grinding and leaches out flatulence-causing oligosaccharides. In the tropical climate, especially in summer, one should avoid soaking the beans for too long. Four to six hours of soaking time in the summer and eight to twelve hours in winter is sufficient in most locations. One kg of whole soybeans yields about 2.2 kg of soaked beans, having a volume of about 3 litres. soaking tanks + belt weighter

18. water tanks + plate heat exchangers + mills Overview Soy milk production S oaking station + mills

20. soaking tank bean discharge valve Overview Soy milk production Belt weighter belt weigher

21. eccentric screw pump perforated disk mill colloid mill 2.000 l hot water (90 °C) + 2.000 kg beans = 4.000 l slurry Overview Soy milk production Water dosing station + mills

22. Overview Soy milk production Perforated disk mill

23. Overview Soy milk production Colloid mill

24. Overview Soy milk production Separation of the fibres

26. okara pump Overview Soy milk production Decanter + okara Decanter CC458 (Westfalia)

27. Overview Soy milk production Pasteuriser and degassing tank

28. Overview Soy milk production Pasteurization + degassing Heating: To inactivate Trypsin inhibitor and for extended shelf life, storage and transportation of soymilk should be at 4 °C or a lower temperature. Technical data: Capacity: 3.000 l/h Heating temperature: 105 °C Holding time: 2 min Degassing temp.: 80 °C

29. control-PC plate heat exchanger fore-run vessel product pump Overview Soy milk production Pasteurization + degassing

30. Overview Soy milk production Deaerator Deodorization: To remove unwanted volatile off-flavours the clarified soymilk base is deaerated by means of vacuum in the deodorizer.

31. Overview Soy milk production Homogenizer Homogenization: Homogenization breaks down fat globules into very fine particles by forcing them under great pressure through minute valve openings, and distributes them evenly throughout the soymilk. Otherwise the fats would tend to lump together, rise to the surface, and separate as a distinct layer. Homogenization gives soymilk a creamier, more uniform consistency.

32. Overview Soy milk production Buffer tanks

33. Overview Soy milk production Milk storage tanks + standardization Standardization: The base soy milk has a dry mass of 16 to 18 %. Water is added to the soymilk base to obtain the desired protein content of the soymilk.

34. Standardized soy milk Soy drinks Overview Soy food production Soy food process steps Soy fermented products Addition ingredients Direct UHT heating Aseptic dosing unit Steril tank Aseptic packaging Addition cultures Incubation / Fermentation Fruit dosing unit Cooling Packaging Buffer tanks Fermentation tanks

35. Overview Soy Food production Soy drinks – overview

37. Soy Food production Soy drinks – Premix tanks

38. Soy Food production Soy drinks – Premix tanks

40. Soy Food production Soy drinks – Aseptic filling

41. Soy Food production Overview fermented products Soya Yogurt, Soya fresh cheese, Soya quarg Another way to extend the shelf life of soymilk is by culturing it with dairy yogurt cultures, e.g. Streptococcus thermophilus and Lactobacillus acidophilus. Culturing has the added advantage of reducing flatulence causing sugars, the oligosaccharides stachyose and raffinose, especially when using L. acidophilus culture. While cultured soya drinks can be made using thin soymilk, well formed soya yogurt requires thick soymilk (10 to 13% soymilk solids). Whey separation may be prevented by adding a stabilizer like agar, gelatin, or arabic gum to the soymilk. The stabilizer also gives a firmer consistency to the yogurt.

42. Soy Food production Overview fermented products

43. Soy Food production Fermented products - pasteurizer

44. Overview Soy milk production Fermented products - pasteurization + degassing Heating: For extended shelf life Technical data: Capacity: 3.000 l/h Heating temperature: 90 °C Holding time: 2 min Degassing temp.: 70 °C

45. Soy Food production Fermented products - fermentation tanks

46. plate cooler CIP-pump strecher dynamic mixer dosing pump mobile product pump Soy Food production Fermented products - mixing system + cooler

47. Soy Food production Fermented products - filling machine

48. Overview Soy food production Realised project - project overview Soaking tanks: 2 x 16.000 l Hot water tank: 1 x 4.000 l Slurry to decanter: 4.000 l/h Raw milk to heater: 3.000 l/h Heater: 3.000 l/h Buffer tanks: 5 x 15.000 l Premix tanks: 3 x 60.000 l Fermentation tanks: 4 x 6.000 l (joghurt and fresh cheese) 2 x 5.000 l (quarg) Cooler (ferm. prod.) : 3.000 l/h Okara tank: 1 x 60.000 l 1 x 20.000 l CIP station: 4 x 5.000 l CIP neutralization: 1 x 10.000 l Central Control system: Siemens S7 OTAS Plant