At Frontline Food Consultants and Engineers, we provide the best food consultancy solutions for the manufacturing of quality soy products such as tofu and tempeh. Tofu and tempeh are primary ingredients in vegetarian and vegan diets. These are appreciated because of their rich protein content, their ability to be used in so many ways, and the health benefits that they accord people. Our team of food technologists and food scientists support you in all aspects of production which means your soy products will meet quality, taste, and nutritional goals.

New Product Development helps you shape your tofu and tempeh product to meet specific target market customers’ palates, traditional or modern. Our food industry services also include Technological Support in order to assist in the necessary processes such as extraction of soy milk, coagulation for tofu production and fermentation for making tempeh. These are the stages in which our Process Improvement services are aimed in order to sustain the quality of your products, their firmness and taste.

We also provide you with Regulatory Compliance & Documentation services to give you the satisfaction that your soy products are safe to be consumed, properly labeled, and properly certified as organic if required. Our Audits & Training make sure you retain production best practices in all your production lines, so as a pack of tofu and tempeh hits the production line, it meets your required standards. By collaborating with FFCE, it is possible, therefore, to be ablated of soy production that is not only healthy but also attractive in the market with respect to better health among people.

What are soy products?

Tofu and tempeh are two common soy products obtained from soybeans which are well known as protein foods and are used in many recipes. Tofu is manufactured by heat-coagulating soy milk into curds and then pressing them into a definite shape. It is characterized by its flavorless character and a fantastic pick up of different deploys allowing its use in either sweet or savoury dishes. Tempeh, on the other hand, is prepared through the fermentation of cooked soybeans – the finished product being a firm, dense cake possessing a nutty taste, and nutritionally superior to the raw soybeans, because of the fermentation process.

Production of tofu and tempeh involves several stages when establishing a facility for their production. Tofu manufacture from soybeans involves first soy milk extraction and the second process is the coagulation of the soy milk with a coagulant, such as calcium sulfate or magnesium chloride. That is, the curd is pressed into blocks of varying firmness – silken, soft, firm, or extra-firm tofu, as the case may be.

Tempeh making involves boiling and removing the skin of the soybean and then introducing a particular love of fungus (Rhizopus oligosporus) which incubates the beans for 24-48 hours. This ferments the beans together and forms a cake which is sliced into small portions and sold in packers. For preparing tempeh the main equipment needed includes chambers with controlled temperature and humidity. Moreover, during the fermentation process, it is also important to ensure free from contamination and germs environment. Other packaging solutions that help to maintain the freshness of the product and keep it fresh for sale for a longer time are also important, especially with the products that need to be supplied to regions far from the processing plant.

Types of Soy Products

Tofu

  • Profile: Tofu is a smooth, and nutritious food made from soy milk that has been coagulated. It is available in smooth smoothness silken texture to as extra firmness and is a culinary ingredient in most recipes.
  • Applications: Tofu can be eaten in soup, stir-fried dishes, salad or used in preparing desserts. It is very receptive to flavors and can be prepared based or toasted, fried or mixed.

Tempeh

  • Profile: Tempeh is made from soybean that has been fermented and has a nut-like taste and a much firmer consistency than the tofu. This is prepared from whole soybeans with the aid of Rhizopus mold that results in a dense cake-like substance.
  • Applications: It is usually included in sandwiches, stir-fried foods and salads. It contains more fiber than tofu and brings an entirely different texture and taste.

Soy Milk

  • Profile: Soy milk is a beverage prepared from soaked soybeans crushed with water. It has become a common milk substitute that can be drunk as a beverage but may also be incorporated in recipes.
  • Applications: Can be taken in a liquid form with milk, incorporated in breakfast meals such as cereals and in other recipes. It comes in sweetened and unsweetened baskets as well as flavored products including strawberry and banana.

Soy Protein Isolates

  • Profile: Soy protein isolates are essentially concentrated forms of protein from soya and contain very low levels of fat and carbohydrates. They find their application where protein supplements are needed and in meat substitutes.
  • Applications: It is extensively used in protein bars, shake mixes and vegetable protein meat substitutes. It offers them high protein content that has no special taste or smell making it ideal for many uses.

Soy Sauce

  • Profile: Soy sauce is readily, prepared from soybeans, wheat or barley malt, salt, and a fermenting agent. It puts a flavor of saltiness and a taste that is hard to describe known as umami to your meal.
  • Applications: They are applied in the preparation of marinades, and sauces and adopted as flavoring agents in some preparations. It is widely used in Asian food and is made in varieties of basic, dark soy sauce and low-sodium soy sauce.

Soy-Based Meat Alternatives

  • Profile: They imitate meat’s flavor and texture; thus are usually made from soy protein and other plant protein sources. They contain among others burgers, sausages and nuggets.
  • Applications: Popular as a source of protein and used in place of meat in different preparations, for individuals who can afford to do without animal products.

Production Process of Soy Products

Ingredients Selection 

  • Objective: The second was geared at the taste, texture, and quality of non-GMO soybeans and other ingredients to be used.
  • Process: Picking soybeans with right quality of protein, flavor, and texture which is important in the production of the final product. Purchasing from known suppliers to maintain coherence and avoid compromise of produce quality.

Soybean Preparation

  • Objective: Make soybeans ready for soya processing by coming up with several soya products.
  • Process: Washing and depodding soybeans with a view of removing unwanted particles and oil and then soaking and dehulling the soybean. Since the soaking makes the beans to be tender it is easier to ground them.

Extraction and Blending

  • Objective: Soy milk from this or for making a base of other soy products.
  • Process: Soy milk is made by grinding soaked soybeans and an adequate amount of water. It is then filtered to minimize soy pulp giving a smooth soy milk to the consumers as the final product. Tofu – soy milk is coagulated by other coagulants for instance magnesium chloride or calcium sulfate.

Fermentation (for Tempeh)

  • Objective: Experience the defining taste and other qualities of tempeh.
  • Process: Soaking and germinating cook soybeans then introduce Rhizopus mold onto it and ferment the soybeans at the right temperature. During the fermentation process, the soybean proteins are produced into a firm cake with a soya-nutty note.

Concentration and Formulation

  • Objective: Isolate soy protein and develop stable products for soy-containing meat analogs.
  • Process: Reducing the moisture and oil content from soy milk or soy protein isolate in order to increase the protein level. Mixing nonstandardized primary ingredients along with other ingredients to give the specified texture or taste.

Cooking and Processing

  • Objective: Strengthen the texture and taste of soy products.
  • Process: Frying soy products to tender for instance felting tofu or to gain the desirable texture for soy-based meat look-alikes. These may include steaming, boiling, or even baking.

Quality Control and Testing

  • Objective: To safeguard the Standard, Quality and uniformity of the end products.
  • Process: Sensory analysis, nutrition content determination, and bacterial examination. In product control, it may involve items like pH, texture, and flavors to mention but a few.

Packaging and Labeling

  • Objective: They should safeguard the product but make it comprehensible for the consumers.
  • Process: Soy products are packed in material that retains their freshness and also avoids the possibility of contamination. STDs are other labels that can be found as nutritional information, ingredient declaration, allergens, and directions for use.

Packaging Solutions for Soy Products 

Soy Milk Tetra Pak & Plastic Bottles

  • Objective: Afford proper and shield packing material for liquid soy products.
  • Materials:
  • Tetra Paks: Provide good thim and oxygen excluding light to further enhance the shelf life of soy milk. They are also reusable and developed as single-use with some degree of shelf stability.
  • PET Bottles: It is easy to manufacture, less in weight, has a high impact strength resistant to shatters, and good barrier features, and are recyclable. Mainly operational for different types of soy milk including salty and sweet ones.

Sachets and Pouches (concerning, powdered Soy protein)

  • +Objective: Make the powdered products products handy for use yet very easy to store.
  • Materials:
  • Multi-layer Laminated Films: Possessing properties that prevent access of moisture, air, and light. Standardization of the pouches’ design allows for ease of use and significantly increases the product’s shelf life.
  • Stand-up Pouches: Ensure adherence to product protection; provide stability and minimal usage of packaging materials.
  • Tofu and tempeh are of Indonesian origin and are traditionally packed in plastic or glass containers.
  • Objective: Preserve the quality and keep the products from getting contaminated.
  • Materials:
  • Plastic Containers: Odor-resistant, and low density, ideal for tofu, and tempeh. More often they come with resealable lids to ensure they do not get in contact with air again hence maintaining their freshness.
  • Glass Jars: Made of inedible material that can be recycled offers a classic appearance, and will not come into contact with the contents.
  • Vacuum Sealing Or Retorting (In Particular Soy Based Products Such As Meat Substitutes).
  • Objective: FRESHNESS- Retain product quality and minimize the shelf life of the products.
  • Materials:
  • Vacuum Sealed Packs: To help reduce spoilage and to keep the soy-based meat substitutes tender and flavorful. Usually an attribute of frozen products in supermarkets.

Labeling and Branding

Label Materials and Design

  • Objective: Reach out the consumers and ensure they understand all the information about the product.
  • Materials: Selecting packaging materials that are high quality, and last longer to be able to endure storage conditions. Information on product labels should be concise and should include the nutritional value, the ingredients, the allergens, the national origin of the food and the method of preparation.

Creative Design

  • Objective: A clear distinction should be made in the product offerings that exist in the market.
  • Design Considerations: A label design can sometimes make a difference in product positioning on the shelves of stores by using the best design strategies. Bright colors, clean product logos, and information about the sustainability of products should be eye-catching enough to influence the buyers.