Detailed Project Report (DPR) on soy protein, soy protein concentrate, texturized soy protein

SOY PROTEIN, SOY PROTEIN CONCENTRATE, TEXTURIZED SOY PROTEIN 

[CODE NO.4116] 

Among the different constituents of the seed, only the oil has so far been considered of value for human consumption and the oil cake residues left behind after extraction have been used mainly as live-stock feed and manure.   

Scientific research conducted during the past few decades in this country and elsewhere has shown that the oilsead meal, if properly prepared and processed, can serve as a valueable protein supplement to human dietaries and that the proteins isolated from oilseed meals are likely to find extensive use in specialised food preparations suitable for feeding infants and children.

Isolated vegetable proteins have certain advantages over the parent raw materials in that the are free from: (1) insoluble and indigestible carbohydrates which may swell and interfere in the digestion and utilization of protein particularly in children , (2) odoriferous  and bitter principles present in the  natural materials which may affect their palatability and (3) trypsin inhibitors, phytates etc., which may affect adversely their nutritive value.

Soyabean protein isolates are the only vegetable proteins that are widely used in imitation dairy products. There has been much research to develop improved soybean protein isolates with goods functional properties and imported flavour. Most isolates are derived from isoelectric precipitation so that the soyabean protein isolates have properties that are similar to those of casein in that they are insoluble at their isoelectric point have a relatively high proportion of hydrophoric amino acid residues and are calcium sensitive. They differ from casein in that they are heat denaturable and thus heat labile.

The soyabean proteins have relatively good nutritional properties and have been increasingly used as a principal source of protein. A main deterrent in their use has been the beany flavour associated with the product, However flavour is consistently being improved and use is expected to increase with its improved properties and lower cost as compared to caseinates.

Edible soybean protein concentrates are relatively new products. Their availability as commercial products dates from 1959. In the last 30 years or so, these versatile products have become important ingredients, well accepted by many food industries. In many applications, they simply replace soy flours. In others, they have specific functions which cannot be performed by soy flours.

Historically, the need for the development of soybean protein concentrates stemmed primarily from two considerations: to increase protein concentration and to improve flavour.

It is very difficult to avoid the occurrence of the green-beany flavour of soybeans in untoasted full-fat or defatted soy flour, prepared in the conventional way. Beany flavour is one of the major objectionable characteristics, limiting the use of conventional soy flours. One of the objectives of the further processing of flours into concentrates is to extract the particular components which are responsible for the bitterness and beany taste.

The maximum level of protein content in soy flour, even after nearly complete removal of hulls and oil, is about 55% (moisture-free basis). In certain applications, such as in meat products, a soybean protein ingredient with a higher percentage of protein is often preferable.

COST ESTIMATION

Plant Capacity                                    100 MT/Day  

Land & Building (10000 sq.mt.)          Rs. 5.94 Cr    

Plant & Machinery                            Rs. 15.61 Cr 

Working Capital for 2 Months      Rs. 28.49 Cr 

Total Capital Investment                 Rs. 51.29 Cr 

Rate of Return                                 49%

Break Even Point                             34%

• INTRODUCTION
  
• SOYA PROTEIN ISOLATE
• THE TYPICAL COMPOSITION OF AN ISOLATED SOY PROTEIN
• SOY PROTEIN CONCENTRATE
• COMPOSITION AND TYPE OF SOY PROTEIN CONCENTRATE
• Amino acid composition of SCP and soy flour (grams per 16g. notrogen)
• USES AND APPLICATIONS PROTEIN ISOLATE
• SOYA PROTEIN ISOLATE
• SEAFOOD PRODUCTS
• CEREAL PRODUCTS
• DAIRY-TYPE PRODUCTS
• INFANT FORMULAS
• OTHER USES
• PROPERTIES & CHARACTERISTICS
• PROTEIN ISOLATES
• PROTEIN CONSTENTS OF SOYA CONCENTRATES & SOYA ISOLATES
• CONCENTRATION
• ISOLATES
• COMPOSITION OF SOYA PROTEIN
• PRODUCTS MOISTURE FREE BASIS PER 100 GM.
• B.I.S. SPECIFICATION
• HEADQUARTERS
• SALES OUTLETS ADDRESS
• TELEPHONE NO/FAX/E-MAIL
• USES AND APPLICATION OF SOY PROTEIN CONCENTRATE
• 5-4-3 MEAT PRODUCTS
• 5-4-4 OTHER USES
• FORMULA FOR "SOY CONCENTRATE MILK"
• TEXTURED SOY PROTEIN
• CHARACTERISTICS OF TEXTURED SOY PROTEIN
• APPLICATION OF TEXTURIZED SOY PROTEIN
• MEAT EXTENDERS
• MEAT ANALOGS
• MARKET OVERVIEW OF SOY PROTEIN
• GLOBAL EXPANSION
• PRESENT MANUFACTURERS OF SOYA PROTEIN
• PRODUCTION PROCESS OF SOY PROTEIN ISOLATE
• PRETREATMENT PROCESS
• Cleaning
• Conditioning
• Peeling
• Softening
• Flaking
• LOW TEMPERATURE SOYBEAN MEAL PROCESSING
• SOYBEAN MEAL EXTRACTING
• LOW TEMPERATURE DESOLVATION
• SOY PROTEIN ISOLATE
• SOY PROTEIN ISOLATE PRODUCTION PROCESS
• EXTRACTION
• Acid Precipitation
• Neutralization, Homogenization, Sterilization and Spray Drying
• PROCESS FLOW DIAGRAM FOR SOY PROTEIN ISOLATE
• PROCESS OF SOY PROTEIN ISOLATE WITH PARAMETER
• STARTING MATERIAL:
• PROTEIN EXTRACTION:
• ALKALINITY:
• EXTRACTION TIME:
• TEMPERATURE:
• SOLID/LIQUID RATIO:
• HEAT TREATMENT HISTORY OF THE MEAL:
• AGITATION:
• SOLID-LIQUID SEPARATION AFTER EXTRACTION:
• EXTRACT TREATMENT:
• PRECIPITATION:
• SEPARATION AND WASHING OF THE CURD:
• DRYING:
• PRODUCTION PROCESS OF SOY PROTEIN CONCENTRATE
• THE AQUEOUS ALCOHOL WASH PROCESS
• SOLID-LIQUID EXTRACTION
• REMOVAL AND RECOVERY OF THE SOLVENT FROM THE LIQUID EXTRACT
• DESOLVENTIZING THE SOLIDS
• GRINDING
• THE ACID-WASH PROCESS
• HEAT DENATURATION/ WATER EXTRACTION PROCESS
• PROCESS OF SOY PROTEIN CONCENTRATE WITH PARAMETER
• PROCESSING DETAILS OF TEXTURED SOY PROTEIN
• SPUN-FIBER BASED TEXTURIZATION
• EXTRUSION TEXTURIZATION
• NITROGEN SOLUBILITY INDEX AND ITS PROCEDURE
• TECHNICAL INDEX OF SOY PROTEIN ISOLATE
• PROCESS OF PROTEIN FROM SOYABEAN
• PRODUCTION PROCESSES
• AQUEOUS ALCOHOL WASH PROCESS
• ACID-WASH PROCESS
• WATER EXTRACTION PROCESS WITH HEAT DENATURATION
• I. SOY PROTEIN CONCENTRATES
• 1. AQUEOUS ALCOHOL PROCESS
• 2. ACID WASH PROCESS
• 3. HOT WATER LEACHING PROCESS
• 4. OTHER PROCESSES
• II. MANUFACTURE OF ISOLATED SOY PROTEIN
• III. SOY ISOLATE
• PROTEIN CONCENTRATE FORMATION
• SOYA PROTEIN ISOLATE
• PROCESS DETAILS PREPARATION OF SOY PROTEIN CONCENTRATES & SOY PROTEIN ISOLATES
• 1. SOY PROTEIN CONCENTRATES
• 2. SOYA PROTEIN ISOLATE
• PRODUCTION PROCESSES OF SOYBEAN
• ANALYSIS OF COMMERCIAL SOY PROTEIN CONCENTRATES AND ISOLATES
• PROECESS FLOW DIAGRAM
• FOR THE MANUFACTURE OF PROTEIN FROM SOYABEAN
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT
• EQUIPMENT LAYOUT
• SAFETY
• PLANT EXPANSION
• FLOOR SPACE
• UTILITIES SERVICING
• BUILDING
• MATERIAL-HANDLING EQUIPMENT
• RAILROADS AND ROADS
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1.  Raw-material supply
• 2.  Markets
• 3.  Power and fuel supply
• 4.  Water supply
• 5.  Climate
• SPECIFIC FACTORS
• 6.  Transportation
• 7.  Waste disposal
• 8.  Labor
• 9.  Regulatory laws
• 10. Taxes
• 11. Site characteristics
• 12. Community factors
• 13. Vulnerability to wartime attack
• 14. Flood and fire control
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• DEPRECIATION
• FIXED ASSETS
• WORKING CAPITAL
• BREAK-EVEN POINT
• OTHER FIXED EXPENSES
• MARGIN MONEY
• TERM LOANS
• TOTAL LOAD
• LAND AREA/MAN POWER RATIO
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• ADDRESSES OF RAW MATERIAL SUPPLIERS
• SOYA BEAN
• SULPHURIC ACID
• CAUSTIC SODA
• SUPPLIERS OF PLANT & MACHINERIES
• LEACHING TANKS
• SPRAY DRYERS
• BOILERS
• SUPPLIERS OF EXTRUDER [WET AND DRY]
• LABORATORY TESTING EQUIPMENT
• ADDRESSES OF PLANT & MACHINERY SUPPLIERS (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)