Detailed Project Report on soy protein powder (2 tpd)

SOY PROTEIN POWDER (2 TPD)

 [CODE NO.4341]  

1. Introduction

Soy protein is a protein that is isolated from soybean. It is made from soybean meal that has been dehulled and defatted. Soy protein is generally regarded as being concentrated in protein bodies, which are estimated to contain at least 50-60% of the total soybean soya flour/flakes

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 oilseed meal, if properly prepared and processed, can serve as a valuable protein supplement to human dietaries and that the proteins isolated from oilseed meals are likely to find extensive use in specialized food preparations suitable for feeding infants and children.

Isolated vegetable proteins have certain advantages over the parent raw materials in that they are free from: 

a. Insoluble and indigestible carbohydrates which may swell and interfere in the digestion and utilization of protein particularly in children, 

b. Odoriferous and bitter principles present in the natural materials which may affect their palatability and 

c. Trypsin inhibitors, phytates etc., which may affect adversely their nutritive value.

Soybean 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 soybean 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 hydrophobic amino acid residues and are calcium sensitive. They differ from casein in that they are heat denaturable and thus heat labile.

The soybean 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 50% (moisture-free basis). In certain applications, such as in meat products, a soybean protein ingredient with a higher percentage of protein is often preferable.

The starting material for the production of soy protein concentrates is dehulled, defatted soybean meal with high protein solubility (white flakes). The concentration of protein is increased by removing most of the soluble non-protein constituents. These constituents are primarily soluble carbohydrates (mono, di and oligosaccharides), but also some low molecular weight nitrogenous substances and minerals. There are three major methods for extracting these components in a selective manner, without solubilizing the major protein fractions. These are not different methods for manufacturing the same product, but each method produces a different type of concentrate, with distinct characteristics and specific uses.

Soy Protein 

Isolated soybean proteins (ISP), or soybean protein isolates as they are also called, are the most concentrated form of commercially available soybean protein products. They contain over 90% protein, on a moisture free basis.

The basic principles of ISP production are simple. Using defatted soy flour or flakes as the starting material, the protein is first solubilized in water. The solution is separated from the solid residue. Finally, the protein is precipitated from the solution, separated and dried. In the production of ISP for food use, in contrast to ISP for industrial use, care is taken to minimize chemical modification of the proteins during processing. Obviously, the sanitary requirements are also much more demanding.

Being almost pure protein, ISP can be made to be practically free of objectionable odour, flavour, colour, anti-nutritional factors and flatulence. Furthermore, the high protein concentration provides maximum formulation flexibility when ISP's are incorporated into food products. These and other advantages have been the source of highly optimistic forecasts regarding the widespread use of ISP. Although the volume of production increased and although several production facilities have been erected in the U.S.A., Europe, Japan, India and Brazil, the tonnage figures are far from those predicted when food grade ISP was first marketed.

The principal reasons for this situation are: the relatively high production cost, nutritional and regulatory limitations, the inability of ISP-based texturized products to compete with texturized soy flour and texturized SPC, and finally, the competition of other abundant "isolated proteins", particularly casein and caseinates. Nevertheless, it should be noted that many novel isolated proteins, such as those obtained from cottonseed, peanuts, fish, squid etc. have been much less successful than ISP. Many of these did not reach the stage of commercial production.

On an equal protein weight basis the cost ratio of these two products is nearly 3:1. The main reasons for the added cost will become evident from the description of the manufacturing methods for ISP.

"Soy Protein Isolate is the major protein aqueous fraction of soybeans prepared from dehulled soybeans by removing the majority of non-protein components and must contain not less than 90% protein on a moisture-free basis.

There are no official standard definitions or specifications for the various types of isolates. ISP is bought and sold on the basis of specifications formulated by the manufacturer or the user.

The conventional procedure for ISP production is based on protein solubilisation at neutral or slightly alkaline pH, and precipitation by acidification to the isoelectric region, near pH 4.5. The resulting product is "isoelectric ISP". It has low solubility in water and limited functional activity. Since spray-drying is the common drying method in the production of ISP, the primary physical form of ISP in commerce, is that of fine powders. Structured forms, such as granules, spun fibres and other fibrous forms are made by further processing.

It is intended to install a production facility of  Soy Protein products from Soya Flour/ Flake with production capacity  of 3000  Tons/Year as a Green Field Project.

COST ESTIMATION

Plant Capacity                                    2 Ton/Day

Land & Building (2755 sq.mt.)  Rs. 3.29 Cr

Plant & Machinery                             Rs. 2.86 Cr

Working Capital for 1 Month           Rs. 79 Lac

Total Capital Investment                Rs. 7.28 Cr

Rate of Return                                  16%

Break Even Point                            71%

• • INTRODUCTION
  
• • USES AND APPLICATIONS 
• • PROPERTIES/CHARACTERISTICS
• • COMPOSITION OF SOY PROTEIN
• • TECHNICAL INDEX OF SOY PROTEIN
• • RAW MATERIAL & PRODUCT YIELD 
• • MARKET OVERVIEW
• • BIS SPECIFICATION
• • PRESENT MANUFACTURERS OF SOY PROTEIN
• • BASIC PRINCIPLE - SOY PROTEIN
• • MANUFACTURING PROCESS STEPS/PROCESS FLOW
• • ETP FACILITY
• • PLANT & MACHINERY
• • UTILITIES REQUIREMENT (ESTIMATED - MONTH)
• • PRINCIPLES OF PLANT LAYOUT
• • PLANT LOCATION FACTORS
• • PROJECT MANAGEMENT
• • RAW MATERIALS SUPPLIER
• • PLANT & MACHINERY SUPPLIER/CONSULTANT/CONTRACTOR
• • GOVT. LICENSE DETAILS 
• • WASTE GENERATION & MANAGEMENT
• • POTENTIAL RISKS
• • ANTICIPATED ENVIRONMENTAL IMPACTS
• • MITIGATION MEASURES (PROPOSED)
• • HEALTH SAFETY & ENVIRONMENT
• • SAFETY & OCCUPATIONAL MEASURE
• • ENVIRONMENTAL/SAFETY LIABILITY
• • PROPOSED IMPLEMENTATION SCHEDULE
• • PROJECT FINANCIALS
• • RAW MATERIAL & PRODUCT YIELD
• • UTILITIES REQUIREMENT (ESTIMATED - MONTH)

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)