Soya+:
Attracting new consumer segments
Asia-Pacific is home to 93% of the world’s soya milk market. The challenge facing manufacturers is how to add value to a mature market and innovate in a category that is already heavily commoditised.
The use of functional ingredients, such as vitamin and minerals, collagen and others is one way to impart a premium image to the product, while also attracting new consumers to the category. The use of flavor ingredients or blending with other natural ingredients is another opportunity. Delivering wholesome goodness of soya could be another avenue that helps meet current consumer trends around wholesome nutrition, clean label package and a more richer product experience.
Leverage Tetra Pak’s support in conceptualizing and delivering your soya innovation. Our advanced, fit for purpose processing technology and unique packaging solution will help you commercialize these innovations to win in the marketplace!
The use of functional ingredients, such as vitamin and minerals, collagen and others is one way to impart a premium image to the product, while also attracting new consumers to the category. The use of flavor ingredients or blending with other natural ingredients is another opportunity. Delivering wholesome goodness of soya could be another avenue that helps meet current consumer trends around wholesome nutrition, clean label package and a more richer product experience.
Leverage Tetra Pak’s support in conceptualizing and delivering your soya innovation. Our advanced, fit for purpose processing technology and unique packaging solution will help you commercialize these innovations to win in the marketplace!
New-age soya - 100% yield, zero waste
One of the biggest challenges soya manufacturers face is the disposal of ‘okara’ – a by-product of soya milk. Tetra Pak has developed a breakthrough technology that re-uses the okara in the finished product – equating to a 100% yield of soya and a reduction in food waste. We call this new-age soya the Wholesome Soya solution.
With over 30 years’ experience in the processing and packaging of soya beverages, our team has the expertise to support you across the entire value chain, from winning concepts to commercialisation.
We offer full line solutions to extract and process soya with a deep understanding of the importance of parameters such as protein yield, fibre separation, taste profile, sedimentation and enzyme deactivation during the production of the perfect soya beverage.
With over 30 years’ experience in the processing and packaging of soya beverages, our team has the expertise to support you across the entire value chain, from winning concepts to commercialisation.
We offer full line solutions to extract and process soya with a deep understanding of the importance of parameters such as protein yield, fibre separation, taste profile, sedimentation and enzyme deactivation during the production of the perfect soya beverage.
Collaborate with Tetra Pak experts with unrivalled knowledge to revitalize your soya-based product range
A breakthrough in soya beverage processing
One of the key pain points for soya beverage manufacturers has been the issue of dealing with okara – the by-product of the soya extraction process. Tetra Pak has developed a breakthrough technology that re-uses okara rather than disposing of it, meaning wastage is eliminated from the extraction process. Re-using the okara means a creamier end product can be delivered, and no wastage results in reduced operational costs. We call this new processing technology innovation ‘wholesome soya’.
What is Wholesome Soya?
Are you interested in the production of high-protein yield soya beverages with no okara? This is what Tetra Pak’s Wholesome Soya solution delivers.
For every 1kg of soya beans used in the manufacturing process, typically ~1.5-2.0kg of okara is generated. This not only represents a loss of valuable product yield, but also poses a challenge from an environmental, hygiene and waste perspective.
Re-utilisation of the okara in a finished product has been the holy grail in soya beverage development. Over a number of years, Tetra Pak has developed and fine-tuned this breakthrough technology.
For every 1kg of soya beans used in the manufacturing process, typically ~1.5-2.0kg of okara is generated. This not only represents a loss of valuable product yield, but also poses a challenge from an environmental, hygiene and waste perspective.
Re-utilisation of the okara in a finished product has been the holy grail in soya beverage development. Over a number of years, Tetra Pak has developed and fine-tuned this breakthrough technology.
Wholesome Soya: A revelation
Tetra Pak’s Wholesome Soya solution enables you to:
• Eliminate all waste from the soya bean extraction process (enabling a 100% protein extraction yield)
• Remove the issue of disposal / utilisation of the okara
• Deliver a cleaner and improved environmental and sustainable manufacturing result
• Achieve an increased creamy mouthfeel, closer to a traditional soya product
• Support the ability to achieve a ‘clean label’ and more stable product as natural gums and emulsifiers can be utilised
• Reduced operational costs due to elimination of waste disposal costs
• Eliminate all waste from the soya bean extraction process (enabling a 100% protein extraction yield)
• Remove the issue of disposal / utilisation of the okara
• Deliver a cleaner and improved environmental and sustainable manufacturing result
• Achieve an increased creamy mouthfeel, closer to a traditional soya product
• Support the ability to achieve a ‘clean label’ and more stable product as natural gums and emulsifiers can be utilised
• Reduced operational costs due to elimination of waste disposal costs
Customisable Process Technology
At Tetra Pak we understand that a ‘one size fits all’ approach will not meet the needs of manufacturers. As such, we have developed several process options to ensure you can achieve the ideal quality wholesome soya beverage for your brand.
What is it that enables you to achieve a smooth mouthfeel and positive sensory experience for the consumer? Choosing the right particle size is a key element in producing the desired, consumer-ready product.
At Tetra Pak, we are able to develop these experiences for your customers. Our expertise and experience enables Tetra Pak to:
• Distribute the right particle size for a smooth mouthfeel
• Deliver commercially-viable solutions that optimise production and operational costs
• Conversion and maximisation of existing soya beverage processing lines including solutions that allow flexibility to switch between products
• Access land for agriculture
What is it that enables you to achieve a smooth mouthfeel and positive sensory experience for the consumer? Choosing the right particle size is a key element in producing the desired, consumer-ready product.
At Tetra Pak, we are able to develop these experiences for your customers. Our expertise and experience enables Tetra Pak to:
• Distribute the right particle size for a smooth mouthfeel
• Deliver commercially-viable solutions that optimise production and operational costs
• Conversion and maximisation of existing soya beverage processing lines including solutions that allow flexibility to switch between products
• Access land for agriculture
Line Solutions
The Wholesome Soya solution has the additional goal to reduce the existing process line requirements. Below is an example of stages required as part of the Wholesome Soya Line Solution.
The extraction system is also responsible for imparting a rich, creamy mouthfeel and flavour to the beverage – something that empowers you to design a unique product signature, allowing you to stand out on the shelf
The extraction system is also responsible for imparting a rich, creamy mouthfeel and flavour to the beverage – something that empowers you to design a unique product signature, allowing you to stand out on the shelf
Challenges & Solutions
With over 30 years of involvement in soy processing and packaging, we have experienced and overcome our customers’ soy-based challenges, from controlling taste profiles through processing, and optimizing manufacturing processes to minimise waste and maximise raw material yield. Part of this journey has seen us deliver advanced tailor-made solutions to meet the complexities of soy (and other plant-based) processing.
Turn Challenges into Opportunities
Key Challenges experienced in soya beverage manufacturing can include:
• Loss of yield due to okara
• Problem of disposal of okara – environmental, hygiene and cost concerns
• Delivering a more natural product, without too many additives
Our new processing solution for wholesome soy can help you overcome all the above challenges.
Best in Class Line Solutions
Tetra Pak has extensive experience in designing downstream processing – starting from mixing and blending to UHT systems to aseptic storage and then into aseptic fillers. We have delivered 100+ solutions for downstream processing of plant-based beverages and this gives us the expertise to design a solution most ideally suited to your specific requirement. Our experts will work with your team to co-create a manufacturing solution that meets your exact needs, while ensuring the best-in-class product quality and lowest total cost of ownership.
Best-in-class processing solution for soy extraction Line
We believe that your optimal solution is one that matches your specific production needs today and for the future – to make you more innovative, more effective and more competitive. And we believe that this optimal solution is born by applying our vast knowledge and complete range of innovative technology for food production in a close partnership with you.
Our best-in-class processing line to meet everyone’s needs incorporate:
• COMPLETE lines for formulation of various aseptic products
• A SUPERIOR soya protein YIELD
• FLEXIBLE solutions with the desired taste
• Major COST SAVINGS
Flexible solution for capturing the new trends
While soya stays strong in APAC, other plant-based alternatives are gaining ground too. Our Soya processing solution comes with the flexibility to handle other ingredients too – e.g. oats, so that you can convert these trends into new opportunities for your business..
The Tetra Pak Extraction System – Soya Extraction
Soya Extraction
Tetra Pak® Extraction unit
A three-part system for efficient performance
This is a system for the continuous extraction of soya base from whole or dehulled soya beans. It requires no soaking or blanching, which means lower water consumption and thus, less wastewater discharge to the environment.
Tetra Pak® Extraction unit delivers a superior soya protein yield, longer running time, lower water consumption and enables CIP (cleaning in place). All these benefits add up to major cost savings and reduced environmental impact, backed by performance guarantees.
Standard Capacity: 4,000 kg/hr or 7,000 kg/hr 4% or 5% protein soya base
Customised Capacity: Up to 12,000 kg/hr 5% protein soya base
Performance guarantees: Capacity/throughput, protein level in the soya base, protein yield %, sediment content
Application Examples: Low-beany soya milk, soya/cow milk, soya drinking yoghurt, soya juice, traditional beany soya milk, ready-to-drink products on the same line from other grains (e.g. rice, oat drinks and other legumes)
Soya Solutions to suit your requirement
Tetra Pak Extraction System – Soya Extraction allows you to control the taste of the soya beverage based on the taste preference of consumers in different markets – whether it’s the traditional beany soya profile – or the more neutral low-beany taste where soya is predominantly seen as a dairy replacement. This is possible because the system has been designed incorporating the key principles of chemistry and technology of soya flavour in mind. The system has also been optimised to maximise your protein extraction yield, thus minimising your cost of production.
Incorporating okara into the soya beverage allows environmentally-conscious consumers to enjoy their beverages knowing they are protecting the planet. Manufactures can benefit by enhancing their sustainability credentials and delivering a higher protein content to meet an existing trend – all while lowering costs.
Wholesome Soya: A new way of manufacturing soya beverages!
Incorporating okara into the soya beverage allows environmentally-conscious consumers to enjoy their beverages knowing they are protecting the planet. Manufactures can benefit by enhancing their sustainability credentials and delivering a higher protein content to meet an existing trend – all while lowering costs.
High Shear Mixer
If you’re using a powder soya base or combining other ingredients with your freshly extracted soya base, the Tetra Pak High Shear Mixer is highly recommended.
Intensive, high shear mixing disperses the powder, then efficiently dissolves and emulsifies the ingredients – essential for the final product quality. The vacuum option in the mixer allows the flexibility to minimise any incorporation and improve the end-product quality and stability.
Fast and reliable ingredients mixing
A complete mixing solution, the efficient mixing system reduces mixing time and produces homogeneous and lump-free products of superior quality, easily adaptable to a wide variety of product recipes and enable quick and easy product changes.
Capacity: 5,000 – 40,000 l/hr
Applications: Perfect for all kinds of plant-based beverages, involving mixing of ingredients such as stabilizers, vegetable oils, emulsifiers etc.
Intensive, high shear mixing disperses the powder, then efficiently dissolves and emulsifies the ingredients – essential for the final product quality. The vacuum option in the mixer allows the flexibility to minimise any incorporation and improve the end-product quality and stability.
Tetra Pak® High Shear Mixer
Fast and reliable ingredients mixing
A complete mixing solution, the efficient mixing system reduces mixing time and produces homogeneous and lump-free products of superior quality, easily adaptable to a wide variety of product recipes and enable quick and easy product changes.
Capacity: 5,000 – 40,000 l/hr
Applications: Perfect for all kinds of plant-based beverages, involving mixing of ingredients such as stabilizers, vegetable oils, emulsifiers etc.
Homogenisation
With the right homogenising efficiency, both sedimentation and creaming can be maintained at controlled, foreseeable and acceptable levels.
The product can be given the right quality with respect to the sensory characteristics – taste, mouthfeel, viscosity, etc. – and it might be possible to minimise the use of additives such as stabilisers and emulsifiers. Larger particles in rice beverages cause so-called chalkiness – a dry, grainy sensation in the mouth.
But by decreasing the number of particles that are larger than 150µm, homogenisation improves mouth feel. Also, by optimising homogenizing efficiency, “over homogenisation” can be avoided, resulting in both reduced energy costs and enhanced quality of the end product.
Pioneering design for lower pressure and energy savings with smart automation
Tetra Pak® Homogenizers reduce particle size and improve product quality. Available in non-aseptic and aseptic versions with a wide range of capacities and pressures, and for products with different viscosities.
Capacity: 55 l/h to 63,600 l/h
Cost Effective Maintenance: Lowest operational, utility service and spare parts costs
Operational Efficiency: Highest homogenizer uptime
Applications: Efficient homogenization of both low and high acid products; wide range of applications
The product can be given the right quality with respect to the sensory characteristics – taste, mouthfeel, viscosity, etc. – and it might be possible to minimise the use of additives such as stabilisers and emulsifiers. Larger particles in rice beverages cause so-called chalkiness – a dry, grainy sensation in the mouth.
But by decreasing the number of particles that are larger than 150µm, homogenisation improves mouth feel. Also, by optimising homogenizing efficiency, “over homogenisation” can be avoided, resulting in both reduced energy costs and enhanced quality of the end product.
Tetra Pak® Homogenizers
Pioneering design for lower pressure and energy savings with smart automation
Tetra Pak® Homogenizers reduce particle size and improve product quality. Available in non-aseptic and aseptic versions with a wide range of capacities and pressures, and for products with different viscosities.
Capacity: 55 l/h to 63,600 l/h
Cost Effective Maintenance: Lowest operational, utility service and spare parts costs
Operational Efficiency: Highest homogenizer uptime
Applications: Efficient homogenization of both low and high acid products; wide range of applications
UHT Treatment
UHT treatment is the most critical process when it comes to long-life beverages. All plant-based beverages are typically low-acid beverages – similar to dairy beverages – which is why a similar UHT treatment is typically applied.
Tetra Pak has extensive experience in designing UHT products for dairy and non-dairy plant-based beverage applications, and we understand the unique requirements of UHT processing and the different flavours that can be created – and how to create these flavours.
For example, a direct UHT system with downstream homogenisation may be best suited to produce a low-beany soya beverage and may improve the neutral taste profile of the product significantly. On the other hand, for a beany soya product, indirect UHT may be suitable.
Our wide portfolio of different heat exchangers and experience of handling different applications enables us to provide best-in-class thermal treatment solutions for your product requirements – be it shelf stable, ambient products (UHT) or chilled products with an extended shelf life.
Tetra Pak has extensive experience in designing UHT products for dairy and non-dairy plant-based beverage applications, and we understand the unique requirements of UHT processing and the different flavours that can be created – and how to create these flavours.
For example, a direct UHT system with downstream homogenisation may be best suited to produce a low-beany soya beverage and may improve the neutral taste profile of the product significantly. On the other hand, for a beany soya product, indirect UHT may be suitable.
Our wide portfolio of different heat exchangers and experience of handling different applications enables us to provide best-in-class thermal treatment solutions for your product requirements – be it shelf stable, ambient products (UHT) or chilled products with an extended shelf life.
Tetra Pak® UHT Solutions
Application: Tetra Pak® UHT Solutions are processing unit for highly efficient, continuous ultra-high temperature treatment of plant based beverages. The UHT solutions are available in number of different process configurations – e.g. Indirect (Plate or Tubular Heat exchanger) or Direct UHT.
Whether it is a direct or indirect UHT unit, the common elements are: an aseptic design, a heat exchanger to heat the product to desired temperature and holding for a specific period of time. The end result is a product that can be stored at ambient temperatures. Tetra Pak® UHT solutions are suitable for plant based beverages such as soy, oat, nuts and other dairy alternative milk, plant based cream, plant based yoghurt drinks and formulated plant based beverage products. Combinations with other non-dairy applications such as juice, tea and coffee are also possible.
Tetra Pak® UHT Solutions are available as a stand-alone unit or as part of a complete line solution.
Capacity: 1 000 - 40 000 litres/hour
Key Highlights:
- Consistent product quality
- Minimized product losses thanks to low-loss balance tank function
- Improved uptime as a result of optimized cleaning
- Maximized operational efficiency due to minimized energy consumption
- Guaranteed performance
Success Starts with Extraction
Extraction is by far the most critical operation in soya beverage manufacturing. At Tetra Pak, we have the expertise and knowhow to design the best extraction solution based on your needs. A good extraction solution takes various factors into consideration, such as the desired taste profile, expected product yield, end-product and regulatory considerations. For example, a higher temperature extraction of soya gives a low beany taste, but also lower yield. We utilize our experience and expertise in product technology and process engineering to deliver a solution that helps you generate the best quality product for your consumer, at an optimum cost.
Soya extraction broadly consists of 3 steps:
