How Are Soya Chunks Made?

In recent years, soya chunks have emerged as a popular and affordable source of plant-based protein. Made from soy flour, these bite-sized nuggets are not only nutritious but also absorb flavors beautifully, making them a versatile addition to various cuisines. Whether you’re a seasoned vegetarian, experimenting with plant-based cooking, or simply looking to increase your protein intake, soya chunks are a fantastic ingredient to add to your kitchen arsenal.

In this blog, we’ll explore more about soya chunks production, its nutritional value and some trendy recipes to transform everyday dishes into hearty, protein-packed meals.

What Are Soya Chunks?

Manufacturers make soya chunks, also called textured vegetable protein (TVP) or soy meat, from defatted soy flour. These small, dehydrated nuggets take on a meat-like texture when cooked, earning them the nickname “vegetarian meat.”

Soya chunks are valued not only for their protein content but also for their ability to absorb flavor, making them a versatile ingredient in various cuisines. They are an excellent source of plant-based protein and are widely used in vegetarian and vegan cooking.

Must Read: Know All About Plant Based Meat

How Are Soya Chunks Made?

The production of soya chunks involves transforming soybeans into a meat-like, protein-rich product through several steps, including oil extraction, extrusion, shaping, and drying. Here is the detailed process:

1. Oil Extraction

The journey of soya chunks begins with soybeans, which are rich in oil. The first step in the process is to extract the oil from the soybeans. This is typically done using a mechanical or chemical extraction method:

• Mechanical Extraction: In this method, soybeans are crushed, and the oil is physically squeezed out using an expeller press. This leaves behind soy meal or soy flour, which is defatted but still rich in protein.
• Chemical Extraction: A solvent, often hexane, is used to dissolve the oil from the crushed soybeans. The solvent is later removed, and the remaining product is defatted soy flour. This method is more efficient for large-scale production.

The leftover product from both processes is defatted soy flour, which is the primary raw material used to make soya chunks. This flour contains all the valuable proteins, carbohydrates, and fiber from the soybeans but without the oil.

2. Extrusion

The defatted soy flour is then processed using a technique called extrusion. This is a key step in giving soya chunks their unique texture, which resembles meat. The process involves:

• High-Pressure Cooking: The soy flour is mixed with water and fed into an extrusion machine. In this machine, the mixture is exposed to very high temperatures (140–160°C) and pressure.
• Protein Denaturation: The heat and pressure cause the proteins in the soy flour to undergo denaturation. This is where the protein molecules unfold and reorganize themselves into a fibrous structure, creating a texture that mimics the chewiness of meat.
• Formation of Textured Vegetable Protein (TVP): This step results in the creation of Textured Vegetable Protein (TVP), the basic form of soya chunks. The texture is spongy and has the ability to absorb flavors, making it an ideal meat substitute.

3. Shaping

Once the soy flour is extruded and forms TVP, the next step is shaping. The extruded material is pushed through molds or dies that cut the product into the desired shapes:

• Nugget Shapes: In the case of soya chunks, the TVP is cut into small, round or irregular nugget-like shapes. Other forms, such as granules or flakes, are used in different soy-based products.

At this stage, the soya chunks are soft and spongy but still need to be dried for storage.

4. Drying

After shaping, the soya chunks are sent through a drying process:

• Dehydration: The shaped chunks are placed in large industrial drying machines where they are exposed to warm air. This removes moisture and creates a shelf-stable product that can be stored for long periods without refrigeration.
• Hardened Texture: Once fully dried, the chunks become hard and lightweight. In this dried form, they are easy to transport and store, and they have a long shelf life.

5. Packaging

Finally, the dried soya chunks are packaged into bags or containers for retail distribution. Since they are shelf-stable, they do not require refrigeration and can be stored in a cool, dry place for months.

Benefits of the Extrusion Process

• Nutrient Retention: The extrusion process preserves much of the protein content and essential nutrients found in soy, such as calcium and iron.
• Improved Texture: The fibrous, chewy texture of soya chunks makes them a satisfying meat substitute for both vegetarians and vegans.
• Low Fat: Manufacturers extract oil from soybeans, which makes soya chunks naturally low in fat—a healthy choice for those reducing fat intake while maintaining a high-protein diet.

Final Product: Versatile and Nutritious

Soya chunks, when properly prepared, have a neutral taste and are perfect for absorbing flavors from sauces and spices. They are widely used in Indian, Asian, and global cuisines as a nutritious meat alternative, particularly in curries, stir-fries, and stews.

Trendy Recipes with Soya Chunks

1. Soya Chunk Biryani: This protein-rich version of biryani replaces meat with soya chunks. Cook the chunks with fragrant basmati rice, spices like cardamom, cloves, and cinnamon, and garnish with fried onions and fresh coriander. This hearty, flavorful dish offers the familiar comfort of biryani with a plant-based twist.
2. Soya Chunks Curry: Indian homes often prepare a classic soya chunk curry by simmering rehydrated chunks in a rich, spiced tomato gravy. Add ginger, garlic, and garam masala for depth of flavour, and pair it with rice or roti for a fulfilling meal.
3. Soya Chunk Stir-Fry: For a quick, healthy meal, sauté soya chunks with bell peppers, onions, and carrots in a soy sauce-based dressing. Add sesame seeds and a dash of chili flakes for extra flavour. Serve it over noodles or rice for a complete meal.
4. Soya Chunk Tacos: In a fusion of cuisines, use spiced soya chunks as a filling for tacos. Toss the chunks in a mix of paprika, cumin, garlic, and lime juice, then layer them in soft tortillas with lettuce, avocado, salsa, and vegan sour cream for a fresh and satisfying meal.
5. Soya Chunk Salad: Add rehydrated and roasted soya chunks to your salads for an extra protein boost. Combine with fresh veggies like cherry tomatoes, cucumbers, and bell peppers, and drizzle with a light vinaigrette dressing. It’s a perfect, healthy option for meal prep or a quick lunch.

Soya chunks have become increasingly trendy due to their versatility, affordability, and high protein content, making them a go-to option for people adopting plant-based diets or looking to add more protein to their meals.

Nutritional Value of Soya Chunks (per 100g)

• Calories: 345 kcal
• Protein: 52g
• Fat: 0.5g
• Carbohydrates: 33g
  • Dietary Fiber: 13g
• Calcium: 350mg
• Iron: 20mg
• Sodium: 10mg

Soya chunks are a protein powerhouse with very low fat levels, making them an excellent choice for anyone looking to increase protein in their diet while reducing fat intake. They also contain high levels of calcium and iron, which are required for bone health and blood production, respectively.

Preparing Soya Chunks for Cooking

Before using soya chunks in cooking, they need to be rehydrated:

1. Soaking: To rehydrate, soak the dried soya chunks in hot water for 10–15 minutes. They will swell up and soften as they absorb water.
2. Draining: After soaking, drain the water and gently squeeze the soya chunks to remove any excess moisture.
3. Rinsing (optional): Some prefer to rinse the soya chunks under cold water after soaking to remove any residual bean-like taste.

Once rehydrated, soya chunks are ready to be used in a variety of dishes. Their spongy texture allows them to absorb spices, sauces, and marinades well, making them an excellent addition to curries, stir-fries, and stews.

Frequently Asked Questions

Here are a few interesting FAQs on Soya Chunks

Conclusion

Whether you’re looking to boost your protein intake, explore meat alternatives, or experiment with new vegetarian recipes, soya chunks offer a healthy solution. You can easily include soya chunks, a nutritious, versatile, and cost-effective plant-based protein, in a wide range of recipes.

Packed with protein, fiber, and essential nutrients like calcium and iron, soya chunks enhance dishes ranging from curries and stir-fries to tacos and salads.

While moderation is important, they offer a nutritious and satisfying option for a balanced diet.