How Textured Soy Protein (TSP) is Made
The most effective way to produce high-quality Textured Soy Protein (TSP) is through precise and controlled extrusion processing. This ensures optimal protein functionality, superior texture, and consistency, which are key for making TSP a successful alternative to animal-based protein sources. We will take an in-depth look at the process and how to achieve a quality product.
The foundation of a successful TSP product begins with high-protein raw ingredients. Using ExPress® soy flour is ideal for high-quality TSP, as it is naturally low in fat and retains high-quality protein. To optimize the flour for texturization, it is essential to control protein, fiber, fat content, particle size, and the protein dispersibility index (PDI). High protein and high PDI soy flour will texturize more effectively, producing a superior product. Increasing protein levels by removing fiber and fat is crucial. Fiber removal is achieved through dehulling to separate the outer seed coat from the soybean. Fat removal is accomplished through Insta-Pro’s extrusion and mechanical oil pressing process, resulting in a low-fat soybean meal with 6-8% residual oil. The soy cake from the press is finely ground using a hammermill and pulverizer, ensuring a narrow particle size distribution for optimal performance. Maintaining a high PDI is also essential, as excessive heat exposure can denature proteins and compromise texture.
The extrusion process converts soy flour into high-quality TSP via the precise control of heat, time, and moisture to achieve the ideal texture and structure. A preconditioner is used to uniformly mix soy flour, additional dry ingredients, water, and steam, ensuring consistency before extrusion. Proper moisture levels and controlled heating in the extruder barrel are key to achieving optimal texturization. The extruder barrel applies direct heat while allowing adjustments to barrel screw configurations and steam locks, which influence retention time and texturization levels.
The shaping and cutting process is equally important for ensuring the final product meets exact specifications. The extruder barrel forces the TSP through precision-engineered dies, which dictate the shape, size, texture, bulk density, and water absorption properties. Die parameters such as quantity, shape, size, inlet taper, and land length must be carefully controlled. The cutting process further refines the final product, with adjustable cutter speed and blade configuration ensuring uniformity.
Post-extrusion processing is essential to preserving the quality of the finished TSP. Additional cutting steps may be required to achieve the desired size and shape while maintaining the bulk density and water absorption ratio. Cutting is most effective when performed while the product is still warm and pliable, reducing fines and ensuring consistency. The final product is then passed through a dryer/cooler, carefully lowering moisture and temperature levels for safe storage. A screening step may be required to remove fines and ensure uniform sizing before packaging.
By following this optimized method, TSP producers can achieve superior product consistency, improved texture, and enhanced functional properties that outperform other production methods. If you are interested in learning more about our TSP production techniques, please contact your Insta-Pro sales or service team member today.
