1.

Map of soy bean derivative product

FERMENTATION TEMPE, SOY SAUCE,

FOOD TAUCO, NATTO, DLL

NON - FERMENTATION
TOFU, MILK, ETC.
FOOD

COOKING OIL, WHITE

SOY BEAN CRUDE OIL
BUTTER, MARGARINE

WETTING AGENT,
LESITIN EMULSIFIER, STABILIZER,
SOLVENT, ETC.

BREAD, ICE CREAM,

PROTEIN YOGHURT, BABY FOOD,
CONCENTRATES ETC.

TUNGE PHARMACEUTICAL

ANIMAL FEED

2. Ten selected products

a. Material and process description
i. Tempe
Tempeh is kind of indoneia authentic food that made from soybean raw material
throught the fermentation process with Rhizopus sp. Making tempeh involving
several steps which are sorting, boiling, soakng, stripping, and fermentation.
Many researcher found that tempeh contain lot of nutrition. In making tempe has
three major stages. the stages in question are, first hydration and acidification of
soybean seeds by soaking for a long time (in tropical conditions approximately
overnight). then the second is heating soybeans through boiling or steaming. The
last one is fermentation using tempe mushroom. Tempeh mushroom that is
widely used is Rhizopus oligosporus. At the end of the fermentation process, soy
will lose its original flavor, synthesize vitamin B12, improve protein quality and
the presence of iron from the ingredients.
in the manufacturing process there are several important factors that can affect
the results of fermentation. the factors referred to are starting from the raw
materials used (soybeans), microorganisms (mold tempeh), and environmental
conditions (pH, temperature, and humidity). In the fermentation process, the
 substrate which is then used in the process of making tempe is boiled soybean
seeds and microorganisms that are used in the form of various molds including
rhizopus oligosporus, rhizopus oryzae, rhizopus stolonifer. in addition there is
also a supportive environment consisting of a temperature of 30 degrees, an
initial pH of 6.8, 70-80% relative humidity. besides using mold, laru can also be
used as a starter in making this tempe.
ii. Soy Milk
Soy milk is one of the soybean derivative products. In general the process of
making soy milk is found in several methods in its manufacture. However, in
general everything is not much different. The manufacturing process includes
several stages that begin with cleaning soybeans from all impurities and proceed
with washing them. The cleaned soybeans are then boiled for fifteen minutes
then after that they are soaked in clean water for a maximum of twelve hours.
After soaking the soybeans are washed until the skin is peeled off. Then the
soybeans that have been separated from the skin are mixed with hot water and
then stirred evenly. After looking evenly distributed then the solution can be
filtered using a filter cloth so that a soy milk solution can be obtained. Not finished
there, if you want to get another unique flavor variant can be added with
granulated sugar, vanilla, chocolate, and salt into a milk solution then stirred until
blended and heated to boiling.
If during the manufacture is not processed in a good way then soy milk will
have the potential to contain antigutrient compounds and off-flavor compounds
that come from the raw material. Antigutrient compounds in question are
antiripsin, hemglutinin, phytic acid, and oligosaccharides that cause flatulence or
the emergence of gas in the stomach that can cause bloating. Off-flavor
compounds referred to in soybeans are glucosides, saponins, estersogen, and
allergens. Some conditions that must be met in order to be considered as good
soy milk include; free from soy smell and unpleasant odor, free of antitrypsin, and
has good stability.
iii. Natto
Natto is a traditional Japanese food made from fermented soybeans. The
fermentation process is the stage where the conversion of carbohydrates into
alcohol or organic acids with the help of microorganisms in the form of yeast or
bacteria in anaerobic conditions. In its making natto uses the bacterium bacillus
subtillis during fermentation. Natto has a texture that is quite sticky and slimy with
a strong taste and a fairly strong aroma. In Japan, Natto is very popular as a
breakfast food. Behind that natto unexpectedly has many health benefits for
consumers. Natto has many nutrients in one portion which can keep consumers
healthy. Referring to the Japanese osteoprorosis-based population study or
JPOS, consumption of natto has many benefits in protecting consumers from
breast cancer, prostate cancer, menopausal symptoms, heart disease and also
osteoporosis, all of which originate from the isoflavone content in natto. Natto
has a probiotic which can help increase food digestion, as a defense against
toxins and harmful bacteria, and can help reduce gas in the body. Besides that,
natto is also good for skin delivered through vitamin pyrroloquinoline quinone or
POQ. Besides that, natto also has a role as a carrier or content of vitamin K in
not small amounts and so with protein.
Natto has various types ranging from Itohiki Natto which is generally known by
the public and can be categorized into three types namely Marudaizu, Hikiwari,
and Goto. Then there is also tera natto which does not have a sticky texture and
needs to be fermented in its manufacture. As for the ingredients needed to make
 natto, it is natto 0.1g bacteria and soybean as desired. In making natto begins
with washing the beans in a bowl and then rubbed together so that the dirt on the
beans can disappear and not bring bad effects later. After washing then soak for
fifteen hours at a water temperature of ten to fifteen degrees Celsius. Soaked
beans are then boiled for 30 minutes. The stew is then added to the starter which
has been dissolved. After finished mixing and stirring it will enter the next stage,
which is the fermentation process in the refrigerator.
iv. Tofu
1. Soaking, Grinding and Cooking the Soybeans.
Tofu production begins with soaking and grinding the soybeans. Soybeans can
be soaked anywhere from 9 to 10 hours at lower temperatures (22°C) or 4 to 6
hours at higher temperatures (32°C). If the beans are ground prior to soaking,
the soaking time can be reduced. In some cases, soybean hulls are removed
prior to grinding. Dehullers use soft, rotating rubber rollers to remove the hulls.
This improves the color and reduces the beany flavor of the final tofu.
2. Separating the Soy Milk.
Then the soy milk needs to be separated from the solid soy pulp or fiber, also
known as okara. This can be done through centrifugation and/or filtration.
Alternately, the soy milk can be separated from the okara prior to heating. In
some cases, the soy milk is concentrated prior to coagulation. This can be
performed though a variety of processes, including heat, reverse osmosis,
vacuum evaporation, or nanofiltration.
3. Coagulating the Soy Milk.
The coagulation step is the most important step in the manufacture of tofu. Its
purpose is to coagulate the protein and oil in the soy milk. Different coagulants
are used to produce different types of tofu. The three main categories of
coagulants that are commonly used are salts, acids, and enzymes
4. Pressing the Tofu.
Traditionally, tofu curds were pressed with hand-turned screw presses or
simple lever presses. Modern systems use hydraulic presses or centrifuges. For
standard firm and extra firm tofu, the soy curd is pressed to release the excess
liquid (whey permeate) using cheese cloth or muslin. The curd is pressed to
varying degrees depending on the desired final tofu texture. Firmer tofu is
pressed with higher loads than less firm tofu. Tofu can then be cut into its final
piece sizes and flavored or further processed as desired.

v. Soy Sauce
Modern industrial production has been widely applied for Japanese-type soy
sauce production, either in Japan or in Indonesia, which applied the modern soy
sauce process technology and used defatted yellow soybean flakes and wheat
for raw materials. The modern technology allows a more controlled koji and brine
fermentation with the use of pure microbial cultures, temperature controls, and
mechanical mixing. The full equipment process for automatic koji preparation
replaced the traditional process. The equipment consists of a continuous
soybean cooker as well as continuous wheat roaster, automatic inoculators with
an automatic mixer, large perforated shallow vats equipped with forced air
devices, temperature control device, and mechanical turning device during
incubation. The length of koji preparation, nevertheless , is almost the same as
in the traditional process , 48 h.
 By the use of modern technology, the length of brine fermentation could be
reduced from 1 to 3 years in the traditional shoyu production to less than 1 year
(4-8 months) in modern industrial production in Japan The length and condition
of brine fermentation either in traditional or modern production in Indonesia are
the same, 4 months and at the same spontaneous condition subject to tropical
weather. This is because the soy sauce aroma found in shoyu is less important
for Indonesian soy sauce. In the final process, moromi filtration using modern
equipment with high pressures is applied. Currently, the membrane technology
using nanofiltration has been developed to provide the standard color for soy
sauce products in modern industries

vi. Ice Cream

Ice cream is a partially-frozen mixture of milk, cream, sugar, stabilizers,
and emulsifiers. Ice cream is equally an emulsion, a dispersion, and a foam.
The dispersion and emulsion consist primarily of a freeze-concentrated
aqueous serum phase containing sugar and the dry matter contents
surrounding dispersed ice crystals and fat globules. Ice crystals range in size
from about 1 to over 150 μm in diameter, with an average size of about 35 μm
(Kusumaatmaja 2009). Fat globules are 2 μm or less in diameter. The foam is
formed by pockets of air (about 20 to 50 μm diameter) dispersed throughout
the emulsion and is supported by partially-coalesced fat globules. The best ice
creams on the market have a smooth and creamy texture.
That creamy texture, primarily associated with a high fat content, is also
determined, in part, by the average size of the ice crystals. Larger crystals
(greater than 50 μm) impart a grainy texture to the ice cream, whereas smaller
crystals (around 10 to 20 μm) give ice cream the desired creaminess. With
today’s consumers becoming more and more health-conscious in their food
choices, low-fat ice cream is becoming increasingly popular. The challenge with
low-fat ice cream, however, is achieving the same creamy texture of the full-fat
version. With less fat, ice cream commonly contains more water and, thus,
larger ice crystals (Cook and Hartel, 2010).
vii. Tauco
Tauco is one of the Indonesian traditional foods from Cianjur, in West Java.
Tauco serves as a flavoring agent because of its distinctive aroma and flavor.
Tauco is a durable food product because its salt content is quite high. To
produce tauco, two steps of fermentation processes can be used by employing
Aspergillus oryzae and Rhizopus oligosporus. The steps are yeast fermentation
and brine fermentation. During these fermentations, components inside the
tauco-forming feedstock change due to the existence of enzymatic process
produced by microorganism. Both types of fermentations are connected each
other. Thus, the product of the yeast fermentation influences the condition and
the final product of the brine fermentation. Fermentation was used to adjusted
the concentration of carbohydrates, amino acids, citric acid, and so on.
Soybeans are known to have biological activity as an antioxidant, estrogenic
effects, antiosteoporosis, and anticancer. Isoflavones are antioxidants that are
needed by the body to stop the reaction of free radical formation. Isoflavone
glycosides are a major component in soybean and non-fermented soy
products, while the soybean fermented product is found free isoflavones
(aglycone) in large quantities Vegetable protein foods widely used as a basic
material Food fermentation is soybean or type other beans, like peanuts, kara
 humpy, and gude nuts. Among these ingredients, soy is most often used as a
basic ingredient in fermented foods some countries, because of its protein
content high.
viii. Margarine
Although the nutritional significance of trans fatty acids is controversial, it
has been found that trans fatty acids may cause heart disease, and a
comprehensive review concluded that trans fatty acids consumed at 4.0% or
more of total calories may raise plasma lipid levels. An estimated 90–95% of
trans fatty acids in foods is produced by hydrogenation, which imparts firmnes
to margarines and shortenings by saturating some double bonds and shifting
others to a trans configuration. Margarines may have a trans fatty acid content
as high as 21% (5). Trans fatty acid consumption by typical U.S. consumers to
be between 11.1 and 27.6 g/d.
Unmodified soybean oil (SBO) with 30 to 40% saturated fatty acids was not
sufficiently solid enough to produce a margarine. But, SBO with elevated
saturated fatty acids levels of 17 to 38% might be blended with high-melting
oils, such as palm oil, interesterified palm oil, interesterified palm/SBO,
cottonseed hardstock, or soybean hardstock to qualify as margarine oils.
Undirected interesterification of an SBO containing 17% C18:0 provided a solid-
fat index and dropping point similar to that of liquid margarine oil, and SBO with
a C18:0 composition ranging from 20 to 33% was suitable for manufacture into
soft-tub margarine after undirected interesterification. In addition, soft-tub
margarine can be formed by interesterifying a blend of 20% fully hydrogenated
SBO and 80% SBO.
ix. Cooking oil
x. Yoghurt
Yoghurt is a fermented milk product obtained from the milk or the milk
products by the lactic acid fermentation through the action of Streptococcus
salivarius subsp. thermophilus, Lactobacillus delbrueckii subsp. Bulgaricus.
When a sufficient quantity of lactic acid is produced then the milk coagulates
and this coagulated milk is called yoghurt. The probiotic yoghurt, having
probiotic effect is a fermented milk product with adjuvant microorganisms.
There is numerous advantages of consuming fermented dairy products
containing probiotic bacteria. A high population of probiotic organisms in the
colon contributes to good intestinal health. Consequently consumption of
products such as yoghurt containing viable probiotic organisms adds benefit to
human gut health. Moreover, yoghurt supplies good quality proteins, also an
excellent source of calcium, phosphorus, potassium and contains significant
quantities of general vitamins. Yoghurt could be used for feeding, owing to its
higher Ca/Na ratio.
Yoghurts vary in appearance, flavor and ingredients. The quality and
composition of yoghurt of applied bacterial cultures affects the quality of the
yoghurt obtained as the result of the milk fermentation processes. There is a
symbiotic relationship between the two species of bacteriai. E Lactobacillus
bulgaricus and Streptococcus thermophilusthat‟s why there is more rapid acid
development than in the single strain culture. Various combinations of starter
cultures are selected during manufacturing of yoghurt to achieve desirable
characteristics of product and also to provide the consumers with a wide choice
of therapeutic benefits. Depending on its activity, manufacturer usually adds 2-
4 % yoghurt starter culture (Aswal etal., 2012).
a. Block diagram
i. Tempe

SOY BEAN

SORTATION

IMMERSION

WATER WASHING WATER

PEELING RIND

WATER BOILING

COOLING

YEAST MIXING

LEAF BANDAGING

AGING

TEMPEH
ii. Soy Milk
SOYBEAN

CLEANING AND WASHING

WATER BOILING (± 15 MIN)

WATER IMMERSION (±12-24 HOURS)

WATER WASHING AND PEELING RIND

MILLING

HOT WATER (1:4) MIXING

FILTRATING

HEATING

SOY MILK

iii. Natto

SOYBEAN

CLEANING AND WASHING

WATER BOILING (± 6-24 HOURS)

NATTO SOLUTION POURING SOLUTION

WASHING AND PEELING

WARMING (± 24-48 HOURS)

FERMENTATING (± 24 HOURS)

NATTO
iv. Tofu
(A) (B)

Soymilk as material Regular Tofu

of tofu
Soymilk with 5-
Whole soybean
6% solid

Soaked and ground with Brought to around 75 degree

water Celcius

Coagulant
Soybean slurry (CaSO4 . 2H2O)

Heated at 95-100 C at 3 min Pressed in mould

Soymilk whey
filtered

residue Cooled and cut

Soymilk Regular tofu

v. Soy Sauce
 vi. Ice Cream

vii. Tauco
Soybeans Packing

Soaking
Cooking
(1-2 hours)

Fermentation II
Washing with clean
(put on 20% of salt
water
solution)

Filtering Drying and Grinding

Peel manually Fermentation I

Boiling Cooling
(1-2 hours on 25-30 Filtering (on room
C) temperature)

viii. Margarine
 Mixture is packaged
Soybean
in blocks or tubes

Artificial flavors,
Oil extracted by
synthetic vitamins,
high temperature &
and natural color
pressure
added

Remaining fraction
of oils removed with Gray color removed
hexane and other by bleaching
solvents

Oils, now rancid,

Oilsteam cleaned
steam cleaned to
again to remove
remove all vitamins
odor
& antioxidants

Oil with catalyst

Oils mixed with a subjected to Soap-like emulsifier
nickel catalyst hydrogen gas in mixed in
high pressure

ix. Cooking oil

x. Yoghurt

xi. Production capacity from three selected procuts