Detailed Project Report (DPR) on Soy and Gluten Based Mock Meat

SOY AND GLUTEN BASED MOCK MEAT

[EIRI/EDPR/1547] J.C. 341

INTRODUCTION

Golden palaces of mock meat. Most towns have one; if you don't know where it is, ask your local vegan or vegetarian.

Staples in many vegetarian and vegan diets, meat analogs are food products that look, feel and taste like meat from an animal. Analogs blend plant-based proteins with flavoring, fat and coloring to replicate beef, poultry or seafood, and in some cases are used as filler in meat.

These meatless morsels are often made of wheat gluten (also called seitan). Gluten is the protein produced when combining wheat's two major proteins, gliadin and gluten in, with water or milk through the process of kneading.

The dough formed is elastic and high in protein so it makes an excellent meat substitute. Because seitan has a mild, neutral flavor, it easily picks up spices and flavors added when cooked.

Other meat analogs are made of soybean derivatives or a combination of wheat gluten and soy. Soybeans also make an excellent meat analog because they are high in protein and fiber. Soy protein is extracted through various methods including boiling and high-pressure extraction of the de-hulled soybean. Like seitan, most soy-based meat analogs are mild tasting and easily adopt flavors and seasonings added during preparation.

"Fake" meats have recently picked up steam in the U.S. market, but wheat- and soy-based meat replacements have been consumed for centuries in China, Korea and Japan. These plant-based protein sources are especially important as vegetarianism is promoted by several Asian philosophical and religious practices, including Buddhism, Taoism and Hinduism.

Today, some mock meats are shaped to look like the animal meat they're replacing. Stroll through your Asian market and you may find meat analogs realistically sculpted to look like whole chickens, drumsticks, shrimp, fish and ham.

Vegetarian and vegan clients may have questions about the healthfulness of "fake meat." As with most manufactured foods, there is a spectrum of healthfulness depending on the level of processing and ingredients. Generally, consuming a variety of meat alternatives is a great way to stick to an animal-free or a reduced-meat diet.

Wheat gluten and bean curd are relatively good sources of protein. For example, one standard brand of tofu contains seven grams of protein in a three-ounce serving, while one brand of vital wheat gluten contains 23 grams of protein in a quarter-cup serving.

Whether you're an omnivore trying to reduce animal protein intake or a lifelong vegan, shop around when looking for meat analogs. Not only do meat analogs vary in fat, protein and sodium content, but some have more fiber than others. Keep an eye out for additives such as MSG or coloring. Aside from taste, consider plate appeal as some have a more appetizing appearance than others.

Vegans should check the ingredient list carefully on mock meats as many have whey or eggs to help bind the product. Those with celiac disease, gluten intolerance or a soy allergy should check for the presence of wheat protein and soy derivatives.

Besides allergens, there are some other nutritional pitfalls to look out for when choosing a meat analog:

Some meat analogs contain added plant oils or have even been breaded and deep-fried. Check labels and look for non-breaded meat analog dishes (braised or steamed are best).

Once you have found the perfect nonmeat to try, don't worry that preparing it will require sophisticated culinary skills; you can cook most of these vegetarian vittles in the same ways you would any animal protein, by broiling, baking, grilling, sautéing or stir-frying.

Choosing mock meat can be a great, lower-fat way to meet daily protein needs and add some meat-free variety at home or on the go. Even non-vegans enjoy the novelty and surprisingly delicious taste and texture of the wide variety of meat analogs.

COST ESTIMATION

Land & Building (1.5 Acresr)                     Rs.3.90 Cr
Plant & Machinery                                        Rs. 7.80 Cr          
W.C. for 1 Month                                          Rs. 2.36 Cr        
Total Capital Investment                              Rs. 14.53 Cr              
Rate of Return                                              57%   
Break Even Point                                         36%

CONTENTS

INTRODUCTION

PROPERTIES OF TEXTURED VEGETABLE PROTEIN

USES AND APPLICATION OF TEXTURED VEGETABLE PROTEIN

MARKET SURVEY

OVERVIEW OF NEW MOCK MEAT

TO MAKE NEW FOOD, EXTRUDE!

MOCK MEAT: THE CELL CULTURE APPROACH

CHARACTERISTICS OF TEXTURED SOY PRODUCTS

TYPES OF SOY PROTEIN

ISOLATES

CONCENTRATES

FLOURS

SOYA PROTEIN AND ITS USES

FORMULATION OF SOY BASED MOCK MEAT

MANUFACTURING PROCESS OF SOY BASED MOCK MEAT

METHODS OF SOY PROTEIN TEXTURIZATION

DETAILS MOCK MEAT FROM GLUTEN

PROCESS FLOW DIAGRAM

METHOD OF PRODUCTION FOR SOY PROTEIN

PLANT LAYOUT

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)