Soybean Processing and Utilization

 11^th Plan Research Thrust Areas

Thrust Areas		Programme
Soybean processing and utilization for nutritional security and fortification of conventional foods		Defatted soy flour (soy meal) utilization
		Development of technology for soy-cereal-millets based extruded/ bakery / conventional food products
		Fermented soy foods of traditional type using whole soybean okara and defatted soy meal
		Membrane Technology for protein concentrates and isolates
		Whole soy bean processing and utilization
		Development of processes and technology for sprouted soybean for production of full fat soyflour and its quality assessment
		Microwave application in full fat soy flour preparation (process and equipment)
		Use of enzymes for enhancing cooking quality of soy dal
		Technology and process for economic utilization of byproducts (soyhull, okara & whey) for enzyme production for food and industrial applications
		Assessment of proteins of soybeans in development of process technology for food usage of soy protein products.
		Processing equipment and pilot plants
		Development of an integral extrusion-expelling unit for soybean to produce medium fat soy-flour and soy oil (soy oil refining)
		Development of cost and energy efficient materials for feed and pressing worms and screw and cage bars of oil expellers.
		Development of pilot plants for demonstration, display and training leading to entrepreneurship and industrial linkages for following products/ technologies Soy based bakery products edible grade medium fat and fullfat soy flour soy iso-flavones roasted soy nuts soy protein isolates
		Quality of soy foods and standards
		Development of protocol  (production and packaging) and quality standards for safe soy food
Technology Transfer, HRD, Consultancy, Resource generation	It will be a continuing activity for entire period and shall include: Awareness training programme for rural women on soybean for food uses and nutritional improvement Training of upcoming entrepreneurs for establishment of soy-based enterprise Transfer of technologies to existing food industry Transfer of manufacturing technology of soy-processing equipment for cottage/ small scale Popularization of food uses of soybean in the country through intensive awareness and skill up gradation programmes HRD and International training in soybean processing and utilization Analysis of food samples of food Industry and entrepreneurs Revenue generation, consultancy and contract research and experimental sale of soy products

  Ongoing Research  Programme/Projects

Study of conventional food of different states and its nutritional enhancement through soybean incorporation

Development of a demonstration unit for production of soynuts

Establishment of demonstration unit for production of soy protein isolate (SPI) (1 kg of PI/batch) and soy protein concentrate (SPC) using defatted soy meal.

Development of process and technology for the production of soymilk, tofu, SPI and SPC from sprouted soybean and its quality assessment

Enhancement of shelf life of soy paneer and soymilk through application of selected techniques of preservation

Technology for plant and dairy ingredients based formulated and functional foods using extrusion cooking (A project under Indo-US Agriculture Knowledge Initiative).

Development of a process for production of soy protein concentrates and isolates by membrane separation technology

Development of process technology for production of soy butter

Development of process for production of improved quality soymilk with minimal beany flavour and flatulence

Studies on coagulants and processing conditions for enhancing tofu recovery and quality

Development of process technology for fermented and non-fermented beverages from tofu whey

A study on minimization of beany off-flavour from soy milk through deodorization

Significant Achievements

Equipment

•    Deep fat fryer (using thermic fluid) : It gives uniform temperature of frying medium and thus good quality snacks, soy nuts.

•     Integral Extrusion expelling unit for production of edible grade Medium fat Soy flour and soy oil (Laboratory unit) : Single unit gives good quality oil and medium fat soy flour. Good for chemical free processing of soybean for oil.

•     Hand operated unit for dehusking of millets : Useful for primary processing of millets for use in combination products.

Soy Products

The following soy based products provide product variety for consumers.  These are nutritious and have very  good acceptability.

•     Soy based Soy-Shrikhand

•     Soy based Soy Amrakhand

•     Soy based rasogulla

•     Soy based (vegetarian) kabab

•     Soy based sweet analog (soy milk burfi)

•     Soy fortified sugar free salty biscuits

•     Soy fortified kodo/kutki  biscuits

Technology and Approach

•     Packaging for soy-products better shelf life enhancement.

•     Dietary fibre from soy hull and okara

•    Minimization of heat stable anti nutritional factors in soybean and sunflower by fermentation.

•     Isolation and purification of   isoflavones in soybean

Standards

Soy food Quality standards developed/modified for  fullfat soyflour, medium fat soy flour & defatted soyflour and approved/adopted by BIS.

Infrastructure

Strengthened the following  to enable soy product quality analysis, research use and for entrepreneurship training.

 

•     Bio-chemical lab

•     Microbiology Lab

•     Pilot plant for soy milk and paneer

 

Entrepreneurship Development Training : Activity is undertaken to promote soy food in daily diet in different parts of the country through establishment of enterprises. In X plan 125 cottage scale soy food enterprises have been established. 

 

No. of training	Number of trainees
31	390

 

Women training for domestic scale soy – processing:  Activity is undertaken to empower housewives to prepare nutritious soy food products for domestic consumption.

 

No. of training	Number of trainees
30	561

ICAR - DRDO Collaboration

·    Established soy milk/paneer unit at FRL Leh under ICAR-DRDO Collaborative Programme (May, 2004).  The facility is being used for preparation of soy milk and soy paneer for food uses, and demonstration to visitors.

                         

 Laboratories

 

The Soybean Processing and Utilization Centre (SPU)  established in April, 1985 at CIAE with a  mandate of   Development and Dissemination of Technology for Processing and Utilization of Soybean Proteins for Food applications, has established   laboratories and pilot plant facilities as :

·        Chemical analysis and quality control laboratory

·        Food processing and product development laboratory

·        Fermentation laboratory

·        Baking laboratory

·        Prototypes and pilot plant facility

 

• The quality control and fermentation  laboratories are equipped with different analytical and quality control instruments.  Some important and sophisticated laboratory instruments/ equipment available in the laboratory include Scanning type UV Spectrophotometer, Gas Liquid Chromatograph, High Performance liquid Chromatograph, Atomioc Absorbtion Spectrophotometer, .laminar flow, binocular microscope,  incubator, etc.   All types of analysis of soy based food and other similar products for product quality  and  different nutritional constituents can be done for total solids, protein estimation, Carbohydrate estimation, Oil content, isoflavones, total free amino acids, Trypsin inhibitor,  urease activity,  Phytic acid and flatulent galactosides and  estimation of total bacterial counts, total yeast and mould counts, coliforms, shigella and salmonella of mycotoxins like Aflatoxin, Ochratoxin.

• Product development is done using  extruders , spray dryer,  autoclaves, centrifuge, modern kitchen, etc. and  incorporating  newer/useful ingredients such as soy protein products/protein rich meals / millets, etc.

• Bakery laboratory  facilitates consisting farinograph, extensograph , falling number, viscometer are useful in determination of   flour properties,  dough rheology, viscosity.    Baking laboratory has facilities for preparation of soyfortified biscuits, cake and bread.

• Pilot Plant Facility has a number of  equipment  for dry as well as wet processing of soybean into different food products, etc.  Insta Pro dry extrusion cooker, Wenger extrusion cooker, Takai Tofu plant,  dehullers, cleaner-cum grader,  grinding mills, oil expellers,  product blender, soy milk and paneer plant, softel ice cream maker, flaking machine, blanching device, dryer,  weigh and fill machine, etc.   It is used for demonstration of  technologies to the visitors and entrepreneurship development training programme for production of various soy products like soy milk, soy paneer, soy dairy analogs, soyflour, bakery products, etc.

 

National and International Training Programmes of Division

In addition to the scheduled training the following training can  also to be conducted. 

•  Entrepreneurship development through soybean processing and value addition at small and medium scale (3 weeks duration) for upcoming entrepreneurs .  The course content will be preparation of soy milk, paneer, soy ice cream, bakery, oil extraction and industrial visits for entrepreneurship development.