By Eben van Tonder, 15 March 25

Important note: We write SOPs in English and German; See Earthworm Writing & Research Studio & Earthworm Schreib und Forschungsstudio

Objective

Develop shelf-stable, crispy, meat-flavoured soy chunks for use as snacks or crunchy toppings. The goal is to create a product with a savoury, umami-rich profile and a satisfying crunch.

Process Overview

1. Raw Material Selection
2. Flavor Broth Preparation
3. Hydration & Flavor Infusion
4. Drying for Dehydration
5. Oil Coating (Optional)
6. Roasting / Frying
7. Final Seasoning
8. Cooling & Packaging

1. Raw Material Selection

• Base: Plain TVP chunks, preferably medium size with a uniform texture.
• Moisture Content (Pre-Processing): <10%.
• Quality: Non-beany, neutral flavour with light colour for easy flavouring.

2. Flavor Broth Preparation (Per 10 litres for 10 kg dry TVP chunks)

• Water (or broth): 10L
• Yeast Extract: 50-100g
• HVP (beef/chicken flavour): 50-100g
• Salt: 100-150g
• Sugar: 30-50g
• Onion Powder: 20g
• Garlic Powder: 20g
• Black Pepper: 10g
• Smoked Paprika (optional): 10-20g
• Soy Oil / Chicken Fat / Beef Fat: 100-300g
• Phosphate Blend (optional): 30-50g
• I+G (optional): 5-10g

Heat the broth to 75-85°C before using.

Alternative Option: Using Meat Broth

If you have access to meat broth (chicken, beef, or pork):

• Replace water with meat broth in the flavour infusion step.
• Adjust salt levels based on the broth’s existing salt content (reduce added salt by 20-50%).
• You can reduce or eliminate the HVP and Yeast Extract depending on the intensity of the meat flavour in your broth. Suggested reduction: 50-100%.
• Clarify broth if necessary (strain out solids) before use to avoid residue on the chunks.
• Proceed with the hydration & flavour infusion as normal.

Benefits:

• Enhances authentic meat flavour.
• May reduce the need for expensive flavor additives.

3. Hydration & Flavor Infusion

• Load dry TVP chunks into a hydration tank or vacuum tumbler.
• Add the hot flavour broth (or meat broth alternative).
• Soak or tumble for 30-45 minutes at 75-85°C.
• Agitate or rotate every 10-15 minutes for uniform absorption.
• Target weight increase: 80-100%.

4. Drying for Dehydration

• Spread hydrated chunks evenly on drying trays.
• Dry at 60-70°C until moisture content reaches 8-10%.
• This step is crucial to avoid oil splatter during frying/roasting and to enhance crunch.

5. Oil Coating (Optional)

• Lightly coat the dried chunks with 2-5% oil (soy oil, chicken fat, or beef fat).
• Toss thoroughly to ensure even distribution.
• This step enhances flavour delivery and crispness.

6. Roasting / Frying (Primary Crunch Step)

• Roasting:
  • Roast in a hot air oven at 140-160°C for 20-30 minutes.
  • Stir periodically to ensure uniform roasting.
• Frying (Alternate Method):
  • Deep-fry in oil at 150-160°C until golden brown and crispy.
  • Drain excess oil immediately after frying.

7. Final Seasoning

• While chunks are still warm (but not hot), apply dry seasoning blends. Example flavours:
  • BBQ spice
  • Smoked beef rub
  • Chicken marinade powder
  • Salt and vinegar
• Use a drum mixer or seasoning tumbler for even application.

8. Cooling & Packaging

• Cool roasted or fried chunks to room temperature (<30°C).
• Pack in moisture- and oxygen-barrier bags (vacuum-packed or nitrogen-flushed).
• Suggested pack sizes: 50g, 100g, 500g bulk bags.

Final Product Specifications

• Moisture Content: <5%
• Texture: Extra crispy, crunchy
• Flavour: Intense umami, meat-like (beef/chicken/pork depending on flavouring)
• Shelf Life: 6-12 months in dry storage below 25°C

Estimated Costing per 10 kg Batch (in South African Rands)

Ingredient	Qty (kg or L)	Cost per kg/L (R)	Total Cost (R)
TVP Chunks	10.00 kg	18.00	180.00
Yeast Extract	0.10 kg	85.00	8.50
HVP	0.10 kg	70.00	7.00
Salt	0.15 kg	10.00	1.50
Sugar	0.05 kg	12.00	0.60
Onion Powder	0.02 kg	60.00	1.20
Garlic Powder	0.02 kg	65.00	1.30
Black Pepper	0.01 kg	180.00	1.80
Smoked Paprika (optional)	0.02 kg	90.00	1.80
Soy Oil / Fat	0.20 kg	30.00	6.00
Phosphate Blend (optional)	0.05 kg	60.00	3.00
I+G (optional)	0.01 kg	450.00	4.50
Water	10.00 L	0.50	5.00
Seasoning for Final Coating	0.20 kg	150.00	30.00
Energy & Drying Costs	per batch		50.00

| Total Estimated Cost per 10 kg Batch | | | R 301.20 |

Cost per kg (finished product): R 30.12