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1、 General Whole soya beverages White paper A new commercial production method General Publisher Tetra Pak Processing Systems AB SE 221 86 Lund,Sweden Published October 2022 Tetra Pak International S.A No part of this publication may be duplicated in any form without the source being indicated.3 CONTE
2、NTS Introduction _ 4 Who is this white paper for?_ 4 Whats the opportunity?_ 4 Soya opportunities _ 5 Plant-based beverages on the rise and soya is a big part of it _ 5 The whole soya advantage _ 5 A variety of soya beverages _ 6 A bean full of challenges _ 8 Beany flavour _ 10 Defining quality for
3、soya products _ 12 The importance of mouthfeel _ 12 Innovation with customers at our Product Development Centres _ 14 Changing traditions in the East _ 14 Repeated innovation _ 14 Transforming a beverage line for full-fibre soya beverages _ 16 Soaking _ 16 Grinding _ 17 Trypsin inhibition/enzyme dea
4、ctivation via heat treatment _ 17 Fibre separation _ 17 Mixing/formulation of the product _ 18 Heat treatment _ 18 Deaeration _ 18 Homogenization _ 18 Filling _ 19 The magic is in process control _ 20 Great taste with no waste from the soya ingredient _ 20 Stability without stabilizers _22 How parti
5、cle size affects quality characteristics _22 Building a whole soya line _ 25 Tetra Pak your partner for soya beverages _ 26 References _ 27 4 INTRODUCTION Who is this white paper for?This white paper is primarily aimed at current soya beverage producers,other producers or co-packers of plant-based b
6、everages,and integrators serving the beverage industry.In general,this industry is thirsty for innovation and new products that meet growing consumer demands for nutritious plant-based products,at the same time meeting ambitious sustainability goals that cut waste.It will also be of interest to dair
7、y producers who are interested in developing a portfolio of soya-based products,or start-ups looking for new possibilities and product segments.The intended audience includes marketing specialists,product owners,product research&development,production managers,heads of technical operations,procureme
8、nt managers and CEOs.Whats the opportunity?This white paper describes an emerging new opportunity in soya beverages whole soya a full-fibre product that is healthy,nutritious and has a delightful new taste.At the same time,it is likely to contribute to your sustainability targets because it can use
9、100%of the bean,and thus doesnt generate waste or by-products.In other words,a new product with global appeal.And it might fit your business.5 SOYA OPPORTUNITIES Plant-based beverages on the rise and soya is a big part of it Plant-based beverages are booming in American and European markets,with a p
10、ositioning as an alternative to dairy products.In some markets where permitted they even use product names like coconut milk or soya milk.This is not advised,however,as the word“milk”is often legally restricted to bovine milk or dairy milk.We will refer to them as“drinks”or “beverages”here.Consumers
11、 are pursuing balanced diets,and plant-based beverages are replacing white dairy milk within a wide product range.This includes derivative products of dairy milk,such as yoghurt,and exploration of new ingredients and supplements.This is coupled to a change in consumer attitude plant-based beverages
12、are perceived as trendy and eco-friendly.The Asia-Pacific region is quite simply different,due to its longer history with plant-based drinks.In fact,they are a traditional category in that region and are not perceived as a substitution for dairy.And while traditional plant-based products may be faci
13、ng challenges,new plant-based products are emerging strongly.There are multiple factors driving the growth of plant-based beverages in this region:Lactose intolerance:it is estimated that over 80%of Asians have an impaired ability to digest lactose.Rising proportion of elderly population Younger gen
14、erations growing preference for trendy Westernized products Rising trend of healthier lifestyles and adoption of veganism Food safety is among the top three environmental concerns in Asia The whole soya advantage There is a global interest in“full-fibre”products for health benefits and digestive hea
15、lth,and this has carried over to soya drink production,as full-fibre soya beverages can use 100%of the protein and other nutrients present(see Table 1).Its profile of high fibre,high protein and low calories meets a growing consumer trend.As it utilizes a maximum of the food raw material,this also a
16、dds to its sustainability profile.Not generating waste or by-products is in the interest of the producers everywhere.6 Table 1 Nutritional comparison of whole bean soya,extracted soya,and white dairy milk Using the whole bean in beverage processing brings with it a number of advantages:The most sign
17、ificant attribute is the high dietary fibre content in the bean itself(11.5g/100g).These fibres aid the workings of the intestinal tract,helping to relieve constipation and clear residual matter,which can in turn assist in the prevention of intestinal cancer.Okara retains a high proportion of the ca
18、lcium in soya beans and about 40%of soya bean protein.Soya bean carbohydrate also contributes greatly to intestinal health.The abundant oligosaccharides contained in soya bean carbohydrates nourish the friendly bacteria in the gut.The greatest appeal of okara is its low cost and low calorie count.Ag
19、ainst this background,its easy to see why a whole soya formulation could be appreciated,particularly where soya is already extensively used,in Asia.There is no fibre removed.There are no added ingredients or stabilizers,so it is a clean-label product.If produced correctly,it has a pleasant taste and
20、 a creamy,smooth texture to the product.It also means there is less waste and more healthy nutrition in the product.It will reduce the cost of raw material and waste treatment.A variety of soya beverages In a highly differentiated marketplace with large regional differences,there are many types of s
21、oya beverages.In the following table,the top two sections represent high-value products that often command a premium price.The second section,high-fibre soya beverages is the focus of this white paper.Nutrients 100%whole bean Extracted bean White milk Protein%3.0 3.0 3.0 Fat%1.8 1.8 3.5 Carbohydrate
22、s%0.7 0.7 4.7 Fibre%1.2 0.26 0 Kcal/100g)134 134 263 Protein/Kcal%2.2 2.2 1.1 Fibre/Kcal%0.9 0.2 0 7 Table 2 The soya beverage spectrum Whole soya is also a beverage or a base for other plant-based products like“-gurts”(non-dairy yoghurt-inspired foods),spreads,and ice cream.It utilizes the whole be
23、an,no fibres are separated,hence the entire bean is digested,and no okara is present as a side product and made into cattle feed,biogas or waste.In our perspective,a full-fibre soya beverage is a traditional product made by re-thinking the established production line concept,utilizing regular equipm
24、ent in a new way.This yields a clean label advantage,and super shelf life stability without stabilizers or emulsifiers.Type Description High solids or rich soya beverages Made by water extraction from whole soyabeans,using a bean-to-water ratio of 1:5(approx.4%protein)High-fibre soya beverage(whole
25、beverage)A formulation where most or all dietary fibres from the soya bean are still present in the final beverage Dairy-like soya extract The composition is similar to that of dairy products.The bean to water ratio is approximately 1:7(protein content 3.5%).It is slightly sweetened,and oil and salt
26、 are added to similar properties to that of dairy milk Barista soya beverages Formulation includes specific stabilizer/emulsifier to ensure stability,good foam,pH of 7+,with low beany base,can be mildly flavoured with vanilla/milk/cream aroma Lower solids soya beverages Sweetened and flavoured drink
27、s(approx.1%protein)with a bean to water ratio of 1:20 Soya extract-based fruit juices or milk-like beverages Mixtures of soya extract with fruit juice,other plant extracts or dairy milk 8 A BEAN FULL OF CHALLENGES The soya bean was discovered about 5,000 years ago,and is believed to have been cultiv
28、ated as a food crop in the New Stone Age in China.From there it spread by land and sea to other parts of Asia,and eventually in modern times to Europe.But there is no single standard soya bean.There are currently many varieties grown under very different conditions around the globe,with varying rain
29、fall,maturing at different times,and thus having different protein content and varying levels of critical enzymes.All of these variables may require a different approach to processing into beverages,depending on food processing traditions and consumer preferences.Timing is critical for harvesting,wh
30、ich usually takes place in autumn when the seed has reached maturity,with 13-14%moisture content.Seeds with a moisture content over 13.5%must be dried to control microbial growth and prevent germination.Because there are so many soya bean varieties,as well as quality variations,grading has economic
31、significance,and also affects the final use of the seed.Most countries therefore have established systems for grading and trading to promote fairness in how markets use this commodity.As an example,Table 3 shows the US standards.9 Table 3.US Standards for soya bean grading Besides quality variations
32、,genotype differences can also result in agronomic characteristics(how well they grow under which conditions)and chemical composition(differences in oil and protein content,fatty acid composition,etc.).There are two major types of soya beans,those that are food-grade and those primarily used to prod
33、uce oil.Of all legumes the soyabean has the highest protein content,about 40%of its dry matter.In addition,its oil(fat or lipid)content at about 20%is second only to that of the peanut(about 48%).Colour Light coloured cotyledon Light golden-yellow or clean white hull White hilium(the eye)Protein Sol
34、ubility Nitrogen Solubility Index(NSI)of the bean must be above 85%Protein Content Soluble protein content is important,but not the total protein content Moisture Content 10-12%is desired,but should not exeed 13%In excess of 14%,there is risk of enzyme activity leading to the oxidation of the fats S
35、eason of Maturity Fully ripened beans.Unripe beans may give a raw and bitter flavour Uniform sized beans Age Should not exceed 12 months.Prolonged storage may cause discolouring,lowered NSI,high viscosity and poor flavour 10 Table 4.Comparison of nutritional components of plants,per 100g of product.
36、Adapted from Queiroz Silva&Smetana,2022(Note:figures have been rounded off for easier comparison.The wide range of values is based on the varying quality of the raw materials,which may not all be commercial grade.)Beany flavour Traditional soya beverages have a residual soya bean flavour and aroma,p
37、lus a characteristic aftertaste.Many new soya beverage drinkers find this objectionable and frequently describe it as“beany”or“green”.However,we have ways of controlling or modifying this beany taste,and the process is the same for whole or dehulled soyabeans.This characteristic flavour is caused by
38、 the hydroperoxidation of polyunsaturated fatty acids catalysed by an enzyme known as lipoxygenase.Lipoxygenase catalyses the hydroperoxidation of linoleic acid and other polyunsaturated lipids,a reaction that occurs in the presence of oxygen,resulting in hydroperoxides.This reaction produces many v
39、olatile compounds such as ketones,aldehydes and alcohols,many of which create undesirable flavours.In a general sense,the beany flavour can be eliminated in two ways.The first is to breed soyabeans with less offensive qualities,and research is underway to create varieties with low linolenic acid con
40、tent,and varieties lacking in lipoxygenase(also known as LOX null soyabeans).Both methods improve flavour stability in oil.The second approach to minimizing the beany flavour is to handle it with special processing techniques,which is of course our main focus here.Plant source Carbohydrates(g)Fibres
41、(g)Fats(g)Proteins(g)Almond 2 27 8 14 42 67 14 29 Cashew 18 3 3 4 44 50 18 23 Coconut 10 20 2 4 28 62 3 8 Hazelnut 5 22 10 22 48 69 7 25 Hemp 9 38 4 38 25 49 20 32 Oat 60 72 2 18 5 8 8 17 Peanut 8 22 8 10 47 50 24 26 Quinoa 60 75 2 12 6 9 12 17 Rice 50 80 1 23 1 21 6 19 Sesame 11 24 6 12 50 61 18 20
42、 Soya 8 30 8 22 20 25 36 43 Tiger nut 16 69 6 21 9 45 3 12 Walnut 3 23 5 10 40 67 15 22 11 In general,there are three ways of eliminating lipoxygenase in whole-bean soya beverage processing:Grinding whole beans in hot water Heating whole beans followed by grinding Blanching whole beans followed by g
43、rinding However,the heat used to inactivate the lipoxygenase may also cause side effects,such as making soya proteins insoluble,losing protein functionality,or adding a cooked or toasted flavour.Correct processing parameters can avoid these issues.12 DEFINING QUALITY FOR SOYA PRODUCTS The key qualit
44、y parameters for a full-fibre soya beverage are:Flavour Mouthfeel Product viscosity Product stability Nutritional value Many producers have tried to achieve a whole soya beverage with full-fibre content from the whole bean,but have not succeeded.Many of the resulting products have a taste marked by
45、bitterness,or a gritty or itchy mouthfeel.This is common with poorly produced plant-based products.It is important to understand how some of these quality characteristics are defined,and how they interact.The importance of mouthfeel One of the most important quality measures for beverages is“mouthfe
46、el”.This is a highly subjective and complex quality measure.Mouthfeel consists of several building blocks such as viscosity,particle size,elastic properties,friction and lubrication.The importance of the different building blocks for the overall mouthfeel differs between products.Figure 1.Several bu
47、ilding blocks that contribute to the mouthfeel perception 13 Traditionally,and still most widely spread within the industry,is to evaluate mouthfeel in the human mouth,not with analytical instruments,but with a trained panel.Parts of the mouthfeel perception are fully possible to measure with an ins
48、trument,some are partly measurable and some are not possible to measure at all,as illustrated in Figure 1.The preference for a“good”product varies with age,cultural heritage and personal taste,but the mouthfeel can with proper training of the panellists be measured objectively,without mixing with pe
49、rsonal preferences.The taste and aroma sensations in the mouth are governed by principles quite different from those tactile sensations that govern texture perceptions.There are,however,interactions between taste,aroma and the mouthfeel building blocks that will disturb the sensory analysis.It is kn
50、own that the minimum particle size that the tongue can perceive depends upon the foodstuff.Changes in temperature will also affect mouthfeel.The particle size will be perceived differently in an ice cream(low temperature,ice particles)than a smoothie(room temperature,fibrous particles).Ice crystals
51、in ice cream will be perceived by the tongue already at 20 m,while starch granules will pass unnoticed at that size.The human mouth can,under some conditions,detect particles down to 5 m.The human mouth perceives a food with hard,irregularly shaped particles as gritty when the particles are only 10-
52、20 m,while products with soft,round particles are judged gritty at a larger particle diameter of 80 m.14 INNOVATION WITH CUSTOMERS AT OUR PRODUCT DEVELOPMENT CENTRES Changing traditions in the East Soya beverages,with or without the insoluble okara fibres present,have been consumed for over a thousa
53、nd years in East and Southeast Asia,prepared in the home.These home-based techniques back in the day didnt remove the okara,but it eventually became more fashionable to remove the fibre by filtration.On a commercial basis in modern times,it was judged to be better to remove okara in order to improve
54、 taste and mouthfeel,as we explained in the previous sections.Traditionally the extracted protein-rich okara was then used for animal feed,principally for the pork industry.But in recent years,as that industry in Asia has matured and become more nutritionally ambitious,they began rejecting okara as
55、animal feed,because it was considered to be inefficient for their purposes.This has left soya beverage producers with a problem,because if they cant sell off the extracted okara,they still have to use resources to handle it,and might have to pay to dispose of it.So the challenge then became:Can the
56、industry produce a whole-fibre soya beverage that makes use of the high protein present in the okara,while improving taste and mouthfeel to appeal to a broad range of consumers?After all,this would fit in with ongoing global trends,where the high protein and fibre content of the okara are considered
57、 healthy.A whole soya beverage would be eagerly welcomed by both producers and consumers.And producers wouldnt have to lose money by throwing away 30%of the soya beans protein content.Repeated innovation Given the widespread popularity of soya drinks in Asia,it is no mystery why Tetra Paks Soya&Tea
58、Centre(STC)has long been experimenting with soya formulations and processing techniques in the pilot plant in PDC Singapore,which has its own soya extraction system devoted to pilot studies and customer experiments.As early as 2006,the STC ran experiments based on customer requests,using enzymes to
59、break down fibres and reduce the particle size.At the time there were no mills or grinders available to further reduce particle size and produce an acceptable mouthfeel,and in the end,the customer decided not to proceed further.When the STC received new customer requests in 2017 regarding whole-fibr
60、e soya,they reviewed their past trials and examined the technological development that had occurred with grinders over a ten-year period.They knew that significantly better particle size reduction was possible.15 Over the course of two years,the STC ran trials in conjunction with Tetra Pak colleague
61、s at the Shanghai PDC,as well as with the companys soya-savvy research and technology groups in Sweden,with access to the latest generation of mixing and homogenization technology.In the first phase,they started with colloidal mills,or grinders,which used a special rotor-stator with double the usual
62、 cutting surface.Further experimentation added other milling(grinding)solutions that reduced particle size further,as well as a combination of grinding and homogenization.Further trials aimed at improving the taste of the products to understand the influence of processing on the mouth feel and taste
63、,i.e.the beany taste although acceptance of the beany profile differs from region to region.The first customer was happy with the mouthfeel of whole soya produced this way,and accepted the line based on adding equipment components grinders and homogenizers supplemented by Tetra Paks know-how regardi
64、ng processing design and parameters.Additional customers in Asia and beyond have been passionate about the new technology.They are now producing products that they can make healthy claims about,and promote a new creamy taste and texture.Its a premium product that commands higher prices in many marke
65、ts.Consumer reaction,as judged from market tests,has also been positive.Its perceived as a healthy drink,and many like the taste better than normal soya beverages.There are currently several lines up and running around the world,including a number capable of producing beverages or product base witho
66、ut fibre separation.This includes one in China making“soygurt”,a yoghurt-like product based on whole soya.Expressions of interest are coming in from every region on the globe.In summary,we didnt invent a beverage but we did invent a commercial production method that can be tuned and adjusted to many
67、 product requirements.In the rest of this white paper,well share some of the complexities of processing parameters and options that we have learned after hundreds of trials.16 TRANSFORMING A BEVERAGE LINE FOR FULL-FIBRE SOYA BEVERAGES In a traditional commercial soya beverage line,fibrous elements(t
68、he okara)are separated and removed during an early stage,after enzyme deactivation.In a whole soya beverage no fibre or other ingredients in the raw materials are removed.The focus instead is on reducing the particle size of the fibre,and carefully controlling the final texture and taste.This means
69、there is less waste and more healthy nutrition in the products.It will reduce the cost of raw material and waste treatment,and also bring a creamy and smooth texture to the product.It is a more sustainable way of making plant based beverage.In this section we compare a traditional vs whole soya line
70、,and outline the major steps involved in making the transition from one to the other.As shown in Figure 2 one of the major differences begins by high-shear mixing or grinding along with further particle reduction provided by homogenization.But thats just part of the story,so lets look at it step by
71、step.Figure 2.Traditional vs whole soya beverage lines Soaking Soyabeans are soaked by some producers to soften their cellular structure.The soyabeans are generally preheated at 40C,dehulled,crushed into flakes and cooked in hot water starting at 50C.After soaking,the soyabeans should weigh about 2.
72、2 times their original weight.A wrinkled seed coat indicates oversoaking and possible fermenting and spoilage.Tetra Pak does not recommend soaking as other equipment manufacturers do,because we have found that the protein yield and product quality are equally good without soaking,when using our equi
73、pment.This is why we do not show it in our process above.17 Grinding Even for regular soya products,its important to have proper control over the grinding,so that you achieve an appropriately small particle size to facilitate the extraction of solids and nutrients to the clarified liquid soya extrac
74、t.But,if the slurry is too coarse,the rate of extraction is reduced.Thus,smaller particles will increase yield,but will be more difficult to separate and can cause problems later in the process or even in the package.Whole soya beverages initial grinding is done with the same grinders as traditional
75、 beverages.Trypsin inhibition/enzyme deactivation via heat treatment Trypsin inhibitors are the substances that prevent trypsin enzymes in the human body from breaking down proteins and thus retard the absorption of proteins.To deactivate them,the clarified liquid soya extract is pumped into a steam
76、 injection system where it is heated to and maintained at a required temperature for deactivation.The temperature and time requirement are based on 85%deactivation of the trypsin inhibitors,which corresponds to the maximum protein efficiency ratio.Heat treatment not only deactivates the trypsin inhi
77、bitors but also causes the formation of protein aggregates,which leads to an increased risk of precipitation and sedimentation.Increased pH due to deactivation also results in more aggregation,but these particles are looser and will break easily in the later homogenization stage.Whole soya beverages
78、 the process is the same.Fibre separation The liquid soya extract obtained from the grinding and extraction stage contains solids,which are collectively referred to as the sediment.Insoluble fibres referred to as okara are separated to avoid chalkiness and to achieve a good product stability.The oka
79、ra contains all the cellulose but also much protein,and if it is separated or extracted,it is either considered waste or animal feed.Fibre separation can be made with a decanter or filter solution.A rewash of okara can be applied to improve the protein recovery.The okara is mixed with water in a ves
80、sel from the first separation unit and the mix pumped to the second separation.The major advantage of this option is the possibility to increase the yield with an increase water-to-bean ratio and one often also gets a drier okara.Whole soya beverages a whole soya beverage does not need fibre separat
81、ion.However,there may be a product quality benefit to first separate the fibres to okara,grind it and add it back,fully or partly,into the beverage.This additional grinding can be done in several ways,depending on customer preference and the desired level of quality:18 Using a high-shear mixer combi
82、ned with a homogenizer The mixer could operate as a batch or inline process Using cavitation equipment.Mixing/formulation of the product The purpose of mixing is to disperse ingredients in the water so they:dissolve and hydrate raw materials form stable fat droplets/emulsions disperse small particle
83、s Soya base is by nature a foamy product;precautions needs to be taken in the mixer to avoid foam.Vacuum in the mixer will do this and it will also decrease air content in the product.The lower air content will improve running times in UHT and reduce wear on the homogenizer.Less oxygen in the produc
84、t will also increase shelf life.Whole soya beverages the mixing process is the same,but the ingredients may differ,for example,by requiring different stabilizers,or different amounts.Heat treatment After separation and final beverage blending,the product is heat treated in an ultra-high temperature(
85、UHT)unit at a temperature of at least 137C and minimum holding time of 4 seconds.Both steam injection and indirect heating are used in commercial production for soya beverages.The purpose of heat treatment is to make the food commercially sterile to secure food safety and shelf-life stability during
86、 ambient storage of the beverage.The microflora of soya is different from that of dairy milk,so the sterilization heat load for soya beverages is normally higher.Whole soya beverages the process is the same.Deaeration Deaeration is normally recommended to reduce oxygen level to get good quality prod
87、uct,reduce fouling and reduce foam in filling.Deaeration should take place before indirect heating;if direct heat is used instead,deaeration should take place after heat treatment.Whole soya beverages the process is the same,but depending on circumstances,there may be an increased need for deaeratio
88、n,as larger fibres are prone to retain air.Homogenization Downstream homogenization is by far the most common arrangement to avoid“sandiness”in the product,which can come from aggregates that form during heat treatment.This means that the UHT should be configured such that the product is homogenized
89、 after the main heat treatment.19 Whole soya beverages homogenization pressure is normally higher than for traditional beverages,400 600 bars,to break down particle size further.The main reason for this is to achieve a desirable mouthfeel.Filling After homogenization and final cooling,the product is
90、 sent to an aseptic tank for intermediate storage before it is packed.Shelf life is normally 6-12 months,depending on the type of packaging.Whole soya beverages the process is the same,with the same expected shelf life span of 6-12 months.20 THE MAGIC IS IN PROCESS CONTROL Whole soya drink is made w
91、ith a new thinking of the established production line concept,utilizing existing equipment in a new way,and a careful choice of extra processing components.As we have seen earlier,the key quality parameters for whole soya beverages are determined by a limited number of processing factors,which need
92、to be carefully planned and controlled,as Figure 3 shows:Figure 3.Main processing factors determining quality of whole soya beverages Its easy to disconnect the decanter(or whatever fibre separation is used),but to xgrind the whole bean fibre content to the correct level for a good mouthfeel does no
93、t come easily.We have run hundreds of experimental trials in our PDCs and other product centres in five countries,using a standard variety of soya beans sourced for trial comparison purposes from Canada.These trials allowed us to develop processing competence around controlling the final quality of
94、the whole soya beverage,which we explain below with illustrative data showing the relationship between ingredient characteristics,processing parameters,and resulting quality.Great taste with no waste from the soya ingredient Both heat treatment and particle size reduction make huge differences in qu
95、ality,but these steps need to be done in several carefully orchestrated steps,thorough grinding first and homogenization at the end,plus heating.For full-fibre soya beverage production,the particle size is the most important factor,as it affects all other quality parameters.This makes the settings o
96、f the fine grinders crucial for success.This demands a knowledge of both production processes and the perception of mouthfeel.And depending on the line configuration,there may be increases in energy consumption or machine parts wear and tear.(Since the soyabean seed coat is abrasive,it creates extra
97、 wear and tear on machine parts.)We used modern grinding solutions to stay in control of the taste even when the full bean is utilized,creating no waste from the soya ingredient and still a great taste.21 Figure 4.Grinding combined with heat load to reduce particle size,step by step Figure 4 illustr
98、ates how particle size decreases with each unit operation in the line,moving from left to right.First the grinder,then the high-shear mixer,followed by the homogenizer,and then the final UHT heating unit(which includes the downstream homogenizer).Figure 5.Relationship of homogenizing pressure to par
99、ticle size Figure 5 shows how homogenization pressure relates to particle size.As pressure increases,however,efficiency also decreases and the amount of particle reduction is reduced for the same pressure differential.In other words,as you increase the pressure,you get less payoff in terms of partic
100、le reduction.So finding that inflection point,where the graph turns upward,will provide the balance between particle breakdown efficiency and energy consumption.This inflection point will vary from one formulation to another.22 Stability without stabilizers Many of our trials were able to confirm th
101、at a stable product is achieved despite having 100%of the bean fibre present,and without any added stabilizers.We are currently investigating the limits of this stability.How particle size affects quality characteristics The following graphs show how particle size in the product affects certain perc
102、eived quality characteristics,based upon experimental trials in our laboratories.Figure 6.Relationship of particle size to perception of bitterness Our trial runs have also revealed that smaller particle sizes contribute greatly to a reduction of bitterness in taste perception tests,as shown in Figu
103、re 6.Finding the inflection point that matches desirable product characteristics leads to more efficient design of the homogenization and grinding steps.23 Figure 7.Relationship of creaminess perception to particle size Perception of creaminess also increases as particle size decreases,but by smalle
104、r increments.And in this case it follows a linear relationship,as shown in Figure 7.Figure 8.Relationship of particle size to perceived viscosity With viscosity,the effect is even more pronounced than the linear relationship to creaminess,as Figure 8 shows.As particle size decreases,the product is a
105、lso perceived by the palate as thinner,or less viscous.24 Figure 9.How different characteristics relate to each other on the particle size scale Figure 9 is our way of showing how some of the perceptual impressions relate to each other on the particle size scale.Samples towards the large end of the
106、scale(mm on the right)tend to be interpreted as gritty,and transition to sandy and powdery sensations as particle size decreases,moving to the left.Creaminess and smoothness are also located at the smaller end of the particle size scale.Thus,depending on local or regional consumer preferences as a g
107、uide,producers can use findings like ours as the basis of running their own trials,and adjust processing parameters to balance different processing steps against energy consumption in reaching desired product characteristics.Figure 10.Combined effects of particle concentration and particle size,on p
108、erceived mouthfeel In another series of tests,we compared the effects of particle density(concentration)as well as particle size,on mouthfeel(Figure 10).We started with two different samples:Sample A had smaller particles than sample B,and B was experienced as having a coarser mouthfeel than A at hi
109、gh particle concentrations(higher percentage of dry matter).But when the samples were diluted to a lower particle concentration,the differences in how samples A and B were experienced were much reduced.25 BUILDING A WHOLE SOYA LINE While we have shown process control issues can be complex,building a
110、 whole soya line is actually a bit more straightforward.An existing soy beverage production line can easily be converted or upgraded,with limited investments in new equipment.Moreover,the line will then be capable of producing both regular soy beverages and whole soy beverages.The specific elements
111、normally required to produce whole soya beverages are:Bypass piping and valves decanter,enabling setting up production of both whole and regular soya beverages A high-shear unit An additional homogenizer,specially designed to enable processing of products including fibres Bypass piping and valves hi
112、gh-shear treatment to enable production of both whole and regular soya beverages CIP pressure line for cleaning any bypasses and high-shear units Potential upgrade of downstream homogenizer integrated with heat-treatment There are different high shear units available and Tetra Pak can provide guidan
113、ce and ensure an optimal solution based on specific customer requirements.The system can be designed to prepare blends of wholesome and regular beverages.There are many design alternatives,which we at Tetra Pak have mapped out so that we can help you avoid common traps along the way.We have the equi
114、pment and the expertise for this solution,adaptable and customizable to meet your particular needs.26 TETRA PAK YOUR PARTNER FOR SOYA BEVERAGES We have more than 40 years of experience delivering processing equipment for soya beverage lines around the world.Our customer and solution experience is ba
115、sed on deep understanding and extensive specialist knowledge,combining technology with successful application knowledge.When it comes to soya,we know the ins and outs of taste and mouthfeel,fibre mechanics and breakdown,heat treatment and stability,protein yield,sedimentation and enzyme deactivation
116、.We are able to offer customized solutions targeting your requirements,and can help you design or upgrade lines based on your specific processing needs,with the lowest total cost of ownership.Our experience with soya has also allowed us to deliver processing solutions and equipment over decades to c
117、ustomers expanding to other ingredients such as oats,rice,nuts,cereals,legumes and seeds.At our Product Development Centres(PDCs)in Lund,Shanghai and Singapore,you can carry out beverage product trials together with our specialists with unique comprehensive expertise in food processing.You can exper
118、iment with recipes and use the latest processing equipment.Thanks to our well established industrial and technology profile,we can support your innovation and production,helping you meet the changing tastes and demands of your marketplace.The right plant design and processing design can offer you un
119、limited new business opportunities through new products,improved quality,and lower costs.We offer:Extensive knowledge of processing technologies,as well as how to implement them PDCs and dedicated technology specialists Valuable knowledge and experience through partnerships with suppliers of technol
120、ogy,ingredients and supplies Processing modules and line concepts for a wide range of technologies for mixing,heating,filtration,separation,homogenization and more.End-to-end offerings,handling everything from incoming raw ingredients to pallets of finished products on your loading dock.As an innova
121、tor,we actively explore and develop the challenges of the food and beverage industry.We collaborate with customers,universities,and other business partners to develop new applications and find the best solutions for producing new products with flexibility.For more information,visit our website:https
122、:/ Or contact your local Tetra Pak office.27 REFERENCES Queiroz Silvaa,Beatriz&Smetana,Sergiy.Review on milk substitutes from an environmental and nutritional point of view.Journal of Applied Food Research,Volume 2,Issue 1,June 2022,100105,https:/doi.org/10.1016/j.afres.2022.100105 28 Tetra Pak and Protects Whats Good are trademarks belonging to the Tetra Pak G Tetra Pak International S.A,Tetra Pak Processing system AB,2022