Production Method
1. Sprouting. The selected soybeans are first cleaned and soaked in water before being allowed to germinate at a temperature of 32–38°C. After approximately three days, the sprouts grow to a length of about 12.7 to 38.1 mm. During the germination process, the soybeans are spread evenly on a perforated fiber fabric screen or sheet. Water is sprayed over the beans every 2 to 3 hours using a sprinkler system to maintain moisture without using water below the optimal germination temperature, which could hinder the process. This ensures that the sprouts develop properly and retain their quality.
The sprouting stage not only enhances the vitamin content of the soybeans but also makes them easier to peel in the next step. Additionally, it helps eliminate the strong soy odor and improves the overall flavor of the final product.
2. Soaking and Washing. At the end of the germination phase, the sprouted soybeans are transferred into a sodium hydroxide bath for about four hours. This treatment loosens the outer skin, making it easier to remove. Once peeled, the beans are then moved to a hydrogen peroxide washing tank, where the remaining odors are neutralized. This step is crucial in preventing any undesirable smells from affecting the taste of the soymilk or extracted products.
After hydrogen peroxide treatment, the soybeans are placed in a continuous water washing tank. The washing process removes any residual hydrogen peroxide and further separates the soybean hulls. A rotating drum or hydrostatic method is used, with high-pressure pumps recycling the water to effectively clean the beans. The soybean skins, which remain attached, sink to the bottom of the tank through an excretion device. The wastewater can be filtered or separated from the circulating water to ensure a clean process.
3. Neutralization. Following washing, the soybeans are treated with a weak acid solution—preferably hydrochloric acid, though Citric Acid or other non-toxic alternatives may also be used—to neutralize any leftover hydrogen peroxide. This step lasts around two hours and also helps remove any remaining skin fragments. After the acid treatment, the beans are washed again in fresh water tanks to remove any residual acid. The final wash must ensure that the pH of the liquid is at least 7. If not, additional water or a small amount of weak acid may be added to adjust the pH appropriately.
4. Milling. The cleaned and neutralized soybeans are then sent to a stone mill for grinding. The germinated soybeans are soft and have a consistent moisture level, which makes them ideal for milling. After grinding, enough water is added to create a smooth soy milk suspension, which is continuously stirred to maintain uniformity.
5. Cooking and Extraction. The diluted soymilk is cooked either in a pressure cooker or an open tank. Pressure cooking takes 5–7 minutes at around 121°C, while open-tank cooking requires about 20 minutes at 102°C. After cooking, the mixture is processed to separate the liquid from the solid particles. This is typically done using centrifugal extraction, ensuring a smooth and pure soy milk extract.
6. Precipitation and Water Removal. A mixture of calcium sulfate and magnesium chloride is added to the extracted suspension to form curds. The mixture is gently stirred until the curds settle at the bottom. Excess liquid is carefully removed without damaging the curd. The curd is then washed with tap water to eliminate any unreacted chemicals. It is then placed in a filter bag, and pressure is applied to remove additional moisture. This process continues until the curd is sufficiently dry.
7. Milling and Blending. The dried curd is finely ground using an emulsifying machine or colloidal mill to achieve a smooth texture. Nutritional ingredients such as oils, sugar, salt, vitamins, and minerals are then added to mimic the composition of natural milk. Fortified versions may include additional vitamins like A, D, C, and methionine. Before emulsification, all components are thoroughly mixed to ensure even distribution.
8. Sterilization and Homogenization. To prevent bacterial contamination, the emulsified product undergoes standard dairy sterilization. After sterilization, the mixture is homogenized under high pressure (around 211 kg/cm²) to keep the fat uniformly suspended and prevent separation. This step ensures a smooth and stable final product.
9. Cooling and Packaging. The homogenized milk is cooled to 4°C and packaged. Fresh milk is typically bottled and refrigerated for sale, while canned milk is sealed directly in cans and sterilized under pressure for 30 minutes. This method eliminates the need for freezing and extends shelf life. The final product is ready for distribution and consumption.
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