GENAU: The Complete System for Meat Factories: Stock Control, Yield Accuracy and Quality Management

By Eben & Kristi van Tonder, 19 November 2025

A Revolution in Stock Control, Yield Accuracy and Quality Management

GENAU is built on one principle. Data follows a structure in the factory. Every stock item must have an interface that links it to all relevant information, such as price, weight, batch number, production date and all details needed for control and traceability. We create these interfaces through numbers in a simple manual system that does not fail. This makes every pallet, crate and box visible in all stock locations, from freezers and chillers to deboning and processing rooms. It may sound slow and time-consuming, but it is not. Using this system, we can count stock faster than with barcode scanners, and it is far more robust

Production is controlled through a dedicated batch companion system that captures the essential events of every batch. All records move from paper into a group of AI modules that clean, sort, and prepare the data. The output is delivered in Excel workbooks. Excel is used because it is transparent, does not lock information behind menus and can be audited line by line.

In this paper, we discuss the broader requirements that make GENAU possible and the scientists who shaped our thinking. We present GENAU as far more than a tracking system. It is a holistic system of management that begins with structure on the factory floor and moves through to data without friction. Data becomes manageable only when people, space, equipment and information move within predictable patterns. Stock, yield, batch numbers, quality checks, and clean, usable data rely on this predictability. Without structure, numbers drift. Without disciplined capture points, data becomes meaningless. This is the first principle of GENAU. It anchors all activity in stable routines, controlled movement and clear numbering logic.

Structured data reflects the actual organisation of the factory. The physical world and the data world match each other. The information is channelled to AI platforms where it is cleaned and ordered. Reporting happens in Excel for a specific reason that we explain later. The system is far more than stock tracing. It is a complete framework for factory order, predictable flow and reliable information.

At the centre of this is OSASS, the order method that governs the physical environment in which GENAU operates. OSASS is explained here. It is the backbone of GENAU, the physical and behavioural discipline that makes structured data possible. The second part of the system is the world of analysis, where AI processes information with a speed and clarity unattainable by manual methods. Where OSASS is the backbone, this analytical layer is the muscles and the central nervous system, including the brain.

A major influence on this approach is W Edwards Deming, the American statistician whose work from the 1950s onwards helped rebuild Japan’s manufacturing base. He focused on variation, statistical control, predictable processes and learning through continuous measurement. He showed that most production failures arise from unstable systems rather than individual workers. GENAU applies these principles to the real conditions of meat factories in Africa and Europe by stabilising space, flow and data capture at source.

A second influence, introduced later in the article, is Claude Shannon, the American mathematician who founded information theory in 1948. His work on structure, channels, signal integrity, and noise reduction provides a framework for how data must move and how errors must be controlled. Deming shapes how GENAU builds stability in physical processes. Shannon shapes how GENAU structures information. Together, they explain why a system based on OSASS, numbering, registers, and real-time measurement produces a factory that behaves predictably and improves every day.

1. A unique number as the interface between data and the factory floor

Deming emphasised that data must be tied to a stable reference point to have meaning. GENAU links each set of data to a single unique number. This reference is assigned to every stock item in its smallest unit of measure: each crate of meat, each box of finished product, each bag of ingredients and each bundle of packaging.

Each number carries a defined set of data, including production day, weight, item number, species, cut, supplier, process history and cost. AI retrieves and combines this data instantly wherever it is needed. Operators work with one number rather than a scattered set of details. This stabilises movement, yield, shrinkage control and traceability. It makes data manageable.

2. Structure in every department

Deming showed that consistent output depends on consistent systems. If space, tools, machines, staff placement or flows shift unpredictably, measurement becomes unreliable. Every action and process is defined and not “evolved by accident.”

GENAU therefore establishes fixed zones, lines, stable crates and other stock positions, defined routes and predictable patterns of movement. Structure removes random variation and gives meaning to the data that follows.

3. Reporting that allows real analysis

Deming taught that knowledge comes from studying results over time. GENAU reports in Excel format because it allows data to remain active: trended, compared, graphed, validated and questioned. Static dashboards and PDFs freeze information and reduce investigation.

Excel supports real analysis of yields, movement, stock ageing, shrinkage and capacity behaviour. Output is presented over time – weeks, months or years. Never as a lone-standing data point, which is meaningless without context.

4. Deming’s Core Principles: The Foundations of GENAU

Deming’s work provides the conceptual base on which GENAU is built. His thinking can be summarised into five practical principles that shape how factories must be designed and managed if they are to produce predictable, high-quality output. Each principle directly informs GENAU’s structure, its logic and its method.

a. Variation is the enemy of quality

Deming taught that uncontrolled variation is the primary cause of defects, waste, delays and poor performance. In a meat factory, this appears as fluctuating yields, inconsistent trimming, unpredictable shrinkage, unstable weight declarations and stock drifting through the plant without a stable pattern. GENAU addresses this by stabilising space, numbering, flow and data capture so variation is reduced at its source. It targets the environment in which data collection takes place as much as the method of data collection.

On the Batch Companion side, which is the system used to manage QC, especially in processing and on the deboning modules where targeted block tests are applied, variables are controlled through tight processes, predefined SOPs and a real-time monitoring system that measures variation precisely and predicts outcomes. The strong QC component makes this one of the most capable and reliable systems in existence.

b. Systems must reduce variation to become stable

Deming argued that the system, not the worker, produces most outcomes. A factory only becomes stable when processes are fixed, flows are known, tools have defined positions, and each step has a consistent method. GENAU follows this directly: zones, crate logic, routes, registers and batch numbering systems remove randomness so the factory behaves the same way every day. As in the previous point, the application of the principle begins by addressing the environment and the processes that maintain order. Every day there is a meeting with every department, where the questions are asked: What are we doing better today than yesterday, and where have we advanced the system? We view every aspect of life in the factory as serving the processes. Because we work with people, we also follow the wisdom of Solomon that the wise make knowledge acceptable. We therefore design human-centred systems in consultation with management to hardwire outcomes.

c. Measurement must be continuous

Deming emphasised that understanding comes from studying results over time, not from occasional inspection. GENAU therefore measures movement, weights, yields and batch behaviour continuously. This allows the system to detect where shrinkage enters, where delays occur, where yield is gained and where the process is drifting. Continuous data is the basis for daily improvement. It reports in spreadsheets, in Excel. The absence of a dashboard is deliberate. Presenting results in spreadsheets gives the user full control over the data, allows direct interrogation of figures and trends, and supports management workbooks that track results over time.

d. Operators must understand the impact of their own work on the flow

Deming taught that people perform best when they understand the system they work in. GENAU includes clear SOPs, coaching and explanation so operators know why they do each action, how it affects yield and stock, and how their decisions influence downstream departments. When understanding increases, variation drops. It is a key feature that we explain to everybody how the entire system works, so that they can understand themselves in relation to the whole and the key part they play in achieving the shared objectives

e. Management must design processes that make correct work the default

Deming insisted that the system must support correct behaviour automatically. GENAU applies this by designing the environment so that the right action is the easiest: defined crate logic, numbering systems, movement paths, fixed capture points and stable workstations. When the system is well-designed, quality becomes a natural outcome rather than an effort. The entire batch companion and deboning model is based on this.

Taken together, these five principles form the intellectual foundation for GENAU. OSASS is the practical method through which these principles are expressed in daily work. It is the backbone of GENAU. Deming describes how a factory must think. OSASS describes how a factory must behave. OSASS is the physical environment in which GENAU operates and is an integral part of the system. The second part of the system is the world of advanced analysis, supported by human judgment and intuitive input, where AI processes data at a level of speed and structure that no manual method can match. Where OSASS is the backbone of GENAU, this analytical layer is its muscles and its central nervous system, including its brain.

5. OSASS: Deming’s principles expressed in factory practice

Deming’s work most strongly influenced the creation of OSASS. His focus on variation, stable systems, standard work and daily improvement shaped the way OSASS defines order, sanitation, arrangement, standardisation and self-discipline as the foundation for reliable factory behaviour. OSASS applies Deming’s principles directly to the physical environment so that every action, measurement and movement occurs within a stable, predictable system.

a. Order

Uncontrolled environments increase variation. Order stabilises the entire system.

b. Sanitation

Clean environments protect stable movement. Clutter forces operators to change paths, introducing variation.

c. Arrangement

Predictable results arise from predictable systems. Exact crate logic, tool placement and defined zones reduce variability.

d. Standardisation

Deming placed strong emphasis on standard work. Registers, numbering rules, SOPs and fixed procedures create repeatable behaviour.

e. Self-discipline

Sustained improvement requires daily adherence. Without discipline, variation returns.
OSASS converts Deming’s principles into daily factory practice.

6. Fixed data capture points

Deming taught that data must be gathered in a consistent manner for variation to be understood. GENAU fixes the location, timing and method of each measurement. Batch numbers, crate movements, yields, weights and quality checks follow a fixed path. This produces consistent, comparable data.

7. Every action must serve the system and reduce entropy

Deming showed that systems must be designed so that correct work becomes the natural outcome. GENAU extends this idea: every action on the factory floor must be part of an intentional, structured process placed at a precise point to support a precise output. Nothing is random.
For each action, the operator and manager must be able to answer:

• Why do we do this
• Why do we do it here
• Why do we do it now
• What comes before and after
• What larger process does this action support

This produces a factory where steps build order rather than disorder. Each day, processes must strengthen, variation must fall, and entropy must decrease. This reflects Deming’s emphasis on continuous system improvement.

8. Managing complexity: the role of humans and the role of AI

Claude Shannon’s work on information theory provides the second structural pillar of GENAU. Shannon demonstrated that information flow depends on structure, stable channels and noise reduction. Humans are best at creating and maintaining this structure. They apply OSASS, guard data capture, organise space, define flows, design standard procedures and ensure the environment supports predictable work.
AI is best at managing the complexity humans cannot:

• sorting large volumes of data
• identifying hidden patterns and anomalies
• recognising variation across days and weeks
• combining crate data, yield data, registers and production records
• designing cutting and production programmes based on patterns
• consolidating customer orders into stable production planning

AI processes complexity at scale. Humans create the structure, clarity and stability that allow AI to work. Both roles must exist for GENAU to function.

9. The human experience: intuitive, natural and meaningful

GENAU is designed so that human work feels natural. Operators work in an orderly environment with clear flows and reliable routines. They handle crates, follow defined routes, record numbers and understand exactly why they perform each action.

AI manages complexity in the background so humans are not overwhelmed.

The experience must feel intuitive and aligned with personal and spiritual values:

• clarity instead of confusion
• purpose instead of randomness
• stability instead of noise
• progress visible every day

Work becomes satisfying when systems are stable and meaningful.

10. Continuous measurement

Deming showed that quality must be monitored during the process. GENAU tracks movement continuously, not only at shift-end. This reveals where yield is gained or lost, where shrinkage enters and where delays appear. Continuous measurement reflects the real behaviour of the factory.

11. Operators and the flow of work

Deming argued that workers perform best when they understand the system they work in. GENAU provides clear SOPs, explanations and coaching so operators understand how their actions influence yield, movement, stock stability and traceability.

Each department asks the same daily question: What did we improve today? Daily improvement strengthens structure and drives down variation.

12. Management by design, not reaction

A core Deming principle is that the system determines most outcomes. GENAU therefore focuses on designing layouts, numbering logic, routes, checklists and registers so that the correct action becomes the natural action. Reducing noise and unpredictability strengthens accuracy, throughput, yield and control.

13. From data to information

Deming taught that data becomes information only when variation is controlled. In GENAU, information emerges when:

• the environment is structured
• capture points are fixed
• reference numbers are stable
• actions fit a defined process
• variation is reduced through OSASS
• measurement is continuous
• patterns can be studied over time

When these conditions exist, yields stabilise, shrinkage becomes visible, stock becomes predictable, and movement becomes interpretable.

14. Profitability through stability

Deming demonstrated that reduced waste, predictable flow and better resource use increase profitability. GENAU enables this by giving managers stable data showing losses, inefficiencies, capacity gaps and stock patterns. Predictable systems produce predictable profit.

Conclusion

GENAU is a complete system for factory structure, stock control, yield accuracy and quality management. It applies Deming’s principles of variation control, statistical thinking, standard work and continuous improvement, supported by the physical discipline of OSASS. It then uses Shannon’s logic of information flow together with AI to manage complexity and give clarity to data. The result is a factory where movement is predictable, numbers are reliable, and improvement becomes part of daily work.


The Complete Work on our GENAU System


References

Deming, W. E. Out of the Crisis. MIT Press, 1986.
Deming, W. E. The New Economics for Industry, Government, Education. MIT Press, 1993.
Deming, W. E. Statistical Method from the Viewpoint of Quality Control. Dover Publications, 2000 (original lectures delivered in 1939).
JUSE (Japanese Union of Scientists and Engineers). The Improvement Journey: Early Records of Quality Control in Postwar Japan. JUSE Press, various editions.
Shewhart, W. A. Economic Control of Quality of Manufactured Product. D. Van Nostrand, 1931.
Shannon, C. E. A Mathematical Theory of Communication. Bell System Technical Journal, 27 (1948): 379–423 and 623–656.
Shannon, C. E. and Weaver, W. The Mathematical Theory of Communication. University of Illinois Press, 1949.
Ishikawa, K. Guide to Quality Control. Asian Productivity Organization, 1976.
Juran, J. M. Juran on Planning for Quality. Free Press, 1988.
Ohno, T. Toyota Production System: Beyond Large-Scale Production. Productivity Press, 1988.
Norman, D. A. The Design of Everyday Things. MIT Press, 2013 (revised edition).
Montgomery, D. C. Introduction to Statistical Quality Control. Wiley, 8th edition, 2019.
Provost, L. P. and Murray, S. K. The Health Care Data Guide: Learning from Data for Improvement. Jossey-Bass, 2011.

Soya: Review of some health concerns and applications in the meat industry

Introduction

Vagadia et al. (2015) state that soya “contains a variety of bioactive anti-nutritional compounds including protease trypsin inhibitors, phytic acid, and isoflavones that exhibit undesirable physiological effects and impede their nutritional quality. Inactivation of these trypsin inhibitors, along with deleterious enzymes, microbes, bioactive components and increasing the protein quality by improving its texture, colour, flavour, functionality and digestibility are the most important factors to be considered in the crucial stage in the manufacturing of soy products.”  Are there reasons to be concerned and what can we learn about its history and possible applications in the meat industry?

Historically Valued Plant

Before we break down the concerns raised by Vagadia et al. (2015), it is instructive to know that soya has been consumed in many countries since before recorded history.  A rich tradition developed around its use in medicine from antiquity.    Duke (1991) showed that a search of his “Medicinal Plants of the World” database (Sept. 1981) indicated that soybeans are or have been used medicinally in China to treat the following symptoms/diseases or for the following medicinal properties (listed alphabetically; Most information from: Li Shih-Chen. 1973. Chinese Medicinal Herbs. San Francisco: Georgetown Press):

“Abortion, ague, alcoholism, anodyne, antidote for aconite or centipede or croton, antivinous, anus, apertif, ascites, ataxia, blindness, bone, bugbite, burn, carminative, chestcold, chill, circulation, cold, complexion, decongestant, diaphoretic, diuretic, dogbite, dysentery, dyspnea, eczema, edema, enuresis, feet, fever, halitosis, headache, hematuria, impotence, intoxication, kidney, labor, laxative, leprosy, malaria, marasmus, marrow, melancholy, metrorrhagia, nausea, nervine, ophthalmia, pile, pregnancy, preventive (abortion) puerperium, refrigerant, resolvent, rheumatism, scald, sedative, skin, smallpox, snakebite, sore, splenitis, splinter, stomach, tinea, venereal, vertigo, vision.”

Uses in other parts of the world include cancer, and cyanogenetic, shampoo (USA), diabetes (Turkey), soap (Asia), stomach problems (India).

Not only was it recognized as a superfood in many parts of the world, but it was celebrated for its medicinal value.  Looking at the factors of concern raised by many, we begin by looking at the most well-known concern factor of its role as a trypsin inhibitor.

Trypsin Inhibitors

The German physiologist Wilhelm Kühne (1837-1900) discovered trypsin in 1876. It is an enzyme that cleaves peptide bonds in proteins (serine protease) and is therefore essential in digestion.   It is found in the digestive system of many vertebrates, where it hydrolyzes proteins. (Kühne, 1877)  Trypsin is formed in the small intestine when its proenzyme form, the trypsinogen, produced by the pancreas, is activated. (Engelking, 2015)  A trypsin inhibitor (TI) is then something (a protein) that reduces the biological activity of trypsin and as such have a negative effect on nutrition by impairing the digestion of food.

The concern about soya’s trypsin inhibitors is of no real concern to us.  It turns out that trypsin in humans is more resistant to inhibition than is the trypsin of other mammalian species. “The effect on human trypsin of soybean trypsin inhibition in soy protein does not appear to be a potential hazard to man. Therefore, the elimination of STI does not seem to be necessary for humans.”  (Flavin DF, 1982)

“In animal diets, however, pancreatic toxicity must be considered whenever soybean protein is utilized. Soybeans should be treated to increase their nutritional benefits and decrease any animal health risks. This will ensure healthy control subjects in laboratory situations and avoid misinterpretation of pathologic data.

The treatment suggested is heat since heat will destroy most of the soybean trypsin inhibitors. Additional supplementation is required following heat treatment for amino acids such as methionine, valine, and threonine; for choline; and for the minerals zinc and calcium.  Excessive heat must be avoided since it will decrease the nutritional value of soybean protein and increase lysinoalanine, a nephrotoxic substance.

Finally, the use of STI as a promotor in the study of potential pancreatic carcinogens may prove beneficial for cancer research and might be considered in the future.” (Flavin DF, 1982)

Phytic acid

Phytic acid also is suspect due to its inhibitory effect related to nutrition.  Anderson (2018) states “It is a unique natural substance found in plant seeds. It has received considerable attention due to its effects on mineral absorption. Phytic acid impairs the absorption of iron, zinc, and calcium and may promote mineral deficiencies”  (Arnarson, 2018)

As is the case with the trypsin inhibition, the story is a bit more complicated than that because phytic acid also has a number of health benefits.

Anderson writes that “phytic acid, or phytate, is found in plant seeds. It serves as the main storage form of phosphorus in the seeds. When seeds sprout, phytate is degraded and the phosphorus released to be used by the young plant. Phytic acid is also known as inositol hexaphosphate, or IP6. It’s often used commercially as a preservative due to its antioxidant properties.

Phytic acid is only found in plant-derived foods. All edible seeds, grains, legumes and nuts contain it in varying quantities, and small amounts are also found in roots and tubers. The following table shows the amount contained in a few high-phytate foods, as a percentage of dry weight:

Phytic Acid in food

As you can see, the phytic acid content is highly variable. For example, the amount contained in almonds can vary up to 20-fold.

Phytic acid impairs absorption of iron and zinc, and to a lesser extent calcium.  This applies to a single meal, not overall nutrient absorption throughout the day.  In other words, phytic acid reduces mineral absorption during the meal but doesn’t have any effect on subsequent meals.  For example, snacking on nuts between meals could reduce the amount of iron, zinc and calcium you absorb from these nuts but not from the meal you eat a few hours later.

However, when you eat high-phytate foods with most of your meals, mineral deficiencies may develop over time.  This is rarely a concern for those who follow well-balanced diets but may be a significant problem during periods of malnutrition and in developing countries where the main food source is grains or legumes.

Avoiding all foods that contain phytic acid is a bad idea because many of them are healthy and nutritious.  Also, in many developing countries, food is scarce and people need to rely on grains and legumes as their main dietary staples.

Phytic acid is a good example of a nutrient that is both good and bad, depending on the circumstances.  For most people, it’s a healthy plant compound. Not only is phytic acid an antioxidant, but it may also be protective against kidney stones and cancer.  Scientists have even suggested that phytic acid may be part of the reason why whole grains have been linked with a reduced risk of colon cancer.

Phytic acid is not a health concern for those who follow a balanced diet.  However, those at risk of an iron or zinc deficiency should diversify their diets and not include high-phytate foods in all meals.  This may be especially important for those with an iron deficiency, as well as vegetarians and vegans.

There are two types of iron in foods: heme iron and non-heme iron.  Heme-iron is found in animal foods, such as meat, whereas non-heme iron comes from plants.

Non-heme iron from plant-derived foods is poorly absorbed, while the absorption of heme-iron is efficient. Non-heme iron is also highly affected by phytic acid, whereas heme-iron is not.  In addition, zinc is well absorbed from meat, even in the presence of phytic acid.

Therefore, mineral deficiencies caused by phytic acid are rarely a concern among meat-eaters.  However, phytic acid can be a significant problem when diets are largely composed of high-phytate foods while at the same time low in meat or other animal-derived products.  This is of particular concern in many developing nations where whole grain cereals and legumes are a large part of the diet.”  (Arnarson, 2018)

Isoflavones

Isoflavones are a class of phytoestrogens — plant-derived compounds with estrogenic activity. Soybeans and soy products are the richest sources of isoflavones in the human diet.  (oregonstate.edu)

“Since many breast cancers need estrogen to grow, it would stand to reason that soy could increase breast cancer risk. However, this isn’t the case in most studies.

In a review of 35 studies on soy isoflavone intake and breast cancer incidence, higher soy intake reduced breast cancer risk in both pre- and postmenopausal Asian women.  For women in Western countries, one study showed soy intake had no effect on the risk of developing breast cancer.

This difference may be due to the different types of soy eaten in the Asian compared to the Western diet. Soy is typically consumed whole or fermented in Asian diets, whereas in Western countries, soy is mostly processed or in supplement form.

In an animal study, rats fed fermented soy milk were 20% less likely to develop breast cancer than rats not receiving this type of food. Rats fed soy isoflavones were 10–13% less likely to develop breast cancer.  Therefore, fermented soy may have a more protective effect against breast cancer compared to soy supplements.  Additionally, soy has been linked to a longer lifespan after breast cancer diagnosis.

In a review of five long-term studies, women who ate soy after diagnosis were 21% less likely to have a recurrence of cancer and 15% less likely to die than women who avoided soy.”  (Groves, 2018)

From the above notes, it may appear that it is perfectly safe for humans to consume raw soya.  There is however one very good reason to cook soya well before it is consumed.

Lectin Effects

“Soybeans contain lectins, glycoproteins that bind to carbohydrates in cells. This can damage the cells or lead to cell death in the gastrointestinal tract. Lectins may bind to the intestinal walls, damaging the cells and affecting nutrient absorption as well as causing short-term gastrointestinal side effects. Unlike most proteins, lectins aren’t broken down by enzymes in the intestine, so the body can’t use them. Lectins can affect the normal balance of bacteria in the intestine and the immune system in the digestive tract.” (Perkins, 2018)

Dr. Mark Messina discussed the issue with Lectin in soya in a brilliant article entitled “Is Soybean Lectin an Issue?”  He writes, “Given all the attention they’re receiving, you might think these proteins are newly discovered, perhaps because of a sudden advance in technology. Given all the concerns being raised about them, you might be thinking of avoiding foods that contain them. If you do, you can pretty much say goodbye to a long list of healthy foods such as legumes (including soy and peanuts), eggplant, peppers, potatoes, tomatoes, and avocados. Despite the hoopla, studies show there is little reason for concern.

Lectins are anything but new to the scientific community. They are a class of protein that occurs widely in nature and have been known to exist in plants for more than a century. Much of the lectin research has focused on legume lectins but these carbohydrate-binding proteins are widely distributed throughout the plant kingdom. The lectin in soybeans was discovered in the 1950s.

In plants, lectins appear to function as nitrogen storage compounds, but also have a defensive role, protecting the plant against pests and predators. They are capable of specific recognition of and binding to carbohydrate ligands. The term lectin (legere = Latin verb for to select) was coined by Boyd circa 1950 to emphasize the ability of some hemagglutinins (lectins) to discriminate blood cells within the ABO blood group system.5-The term lectin is preferred over that of hemagglutinin and is broadly employed to denote “all plant proteins possessing at least one non-catalytic domain, which binds reversibly to a specific mono- or oligosaccharide.”

Orally ingested plant lectins remaining at least partially undigested in the gut may bind to a wide variety of cell membranes and glycoconjugates of the intestinal and colonic mucosa leading to various deleterious effects on the mucosa itself as well as on the intestinal bacterial flora and other inner organs. The severity of these adverse effects may depend upon the gut region to which the lectin binds. Several cases of lectin poisoning due to the consumption of raw or improperly processed kidney beans have been reported.

The lectin content of soybeans varies considerably among varieties, as much as fivefold. However, from a nutritional perspective, it is the amount in properly processed soyfoods that is most relevant. Although there has been a lot of debate about whether even active soybean lectin is harmful,  a true pioneer in this field, Irvin E. Liener, concluded that soybean lectin isn’t a concern because it is readily inactivated by pepsin and the hydrolases of the brush border membrane of the intestine. But, others think soybean lectin does survive passage through the small intestine.

Not surprisingly, autoclaving legumes including soybeans completely inactivates lectins. However, foods aren’t typically autoclaved. The most practical, effective, and commonly used method to abolish lectin activity is aqueous heat treatment. Under conditions where the seeds are first fully soaked in water and then heated in water at or close to 100°C, the lectin activity in fully hydrated soybeans, kidney beans, faba beans, and lupin seeds is completely eliminated.  Thompson et al. noted that cooking beans to the point where they might be considered edible are more than sufficient to destroy virtually all of the hemagglutinating activity of lectins. More recently, Shi and colleagues23 found that soaking and cooking soybeans destroyed more than 99.6% of the lectin content, which agrees with earlier work by Paredes-Lopez and Harry.

Finally, evidence from clinical trials in no way suggests that the possible residual lectin content of soyfoods is a cause for concern. Adverse effects typically associated with lectin toxicity don’t show up in the hundreds of clinical trials involving a range of soy products that have been published. Not surprisingly, the U.S. Food and Drug Administration recently concluded that soy protein is safe.”  (Messina, 2018)

Saponins in Soybeans

Saponins in soya are responsible for the bitter taste, foam-forming, and activities that rupture or destroy red blood cells.  Its presence in soya is probably an evolutionary development to protect it against, for example, Callosobruchus chinensis L., a common species of beetle.  Its protecting properties can be seen for example by the fact that [certain strains of] the first instar larvae, after burrowing beneath the seed coat, subsequently die without moulting. (Applebaum, 1965)

There are five known soya saponins: Soya sapogenols A, B, C, D, and E.  Saponins cannot be inactivated by cooking because cooking doesn’t break down this toxin like it does lectins.”  (Perkins, 2018)  “Triterpenoid saponins in the mature soybean are divided into two groups; group A soy saponins have undesirable astringent taste, and group B soy saponins have health-promoting properties. Group A soy saponins are found only in soybean hypocotyls, while group B soy saponins are widely distributed in legume seeds in both hypocotyls (germ) and cotyledons. Saponin concentrations in soybean seed are ranged from 0.5 to 6.5%.”  (Hassan, 2013)

Bondi and Birk (1966) investigated soybean saponins as related to the processing of petroleum etherextracted meal for feed and to the preparation of soy foods.  They found that “soybean saponins are harmless when ingested by chicks, rats and mice even in a roughly threefold concentration of that in a 50% soybean meal supplemented diet.” They are decomposed by the caecal microflora of these 3 species. Their non-specific inhibition of certain digestive enzymes and cholinesterase is counteracted by proteins which are present in any natural environment of these saponins. The haemolytic activity of soybean saponins on red blood cells is fully inhibited by plasma and its constituents –
which naturally accompany red cells in blood. Soybean saponins and sapogenins are not absorbed into the blood-stream (Note: Or perhaps not observed in the bloodstream). It may, therefore, be concluded that haemolysis – one of the most significant in vitro [in glass/test tubes] properties of soybean saponins and others–bears no ‘obligation’ for
detrimental activity in vivo [in living organisms].”  (Bondi, et al, 1966)

Birk, et al, 1980, found that “saponins are glycosides that occur in a wide variety of plants. They are generally characterized by their bitter taste, foaming in aqueous solutions, and their ability to hemolyze [break down] red blood cells. The saponins are
highly toxic to cold-blooded animals, their toxicity being related to their activity in lowering surface tension. They are commonly isolated by extraction of the plant material with hot water or ethanol.”  (Birk, 1980)  Leaching the saponins out of the soybeans, removing the bitter taste.  (Perkins, 2018)

Applications and History

Reviewing the history of the development of soya industry in Israel, brought up some interesting perspective on its application in food.

“Hayes Ashdod was one of Israel’s first company to make foods from soybeans and Israel’s first manufacturer of modern soy protein products. In 1963 the company launched its first product, a soy protein concentrate named Haypro. This product was also the first commercial soy protein concentrate manufactured outside the United States. The main applications for Haypro were as a meat extender.”  (Chajuss, 2005)

“In 1966 Hayes Ashdod Ltd. introduced texturized soya protein concentrates under the brand names Hayprotex and Contex. Hayprotex was designed for use mainly as a minced
meat extender, while Contex was designed mainly for vegetarian analogs.”  (Chajuss, 2005)

“Concerning early textured soy protein concentrates: Hayes Ashdod introduced Hayprotex and Contex in 1966, and a company we are well familiar with for making nitrite curing of meat commercially available around the world through their legendary Prague Powder, the Griffith Laboratories from Chicago introduced GL-219 and GL-9921 in 1974, and Central Soya introduced Response in 1975.”  (Chajuss, 2005)

“In 1969 Hayes started to produce Primepro, a more functional and soluble soy protein concentrate, by further treatment of the aqueous alcohol extracted soy protein concentrate (Haypro), for use as substitutes for soy protein isolates and for caseinates in various food systems, especially in the meat processing industries.”  (Chajuss, 2005)

Further reading

A tremendous resource on research on soya is HISTORY OF SOYBEANS AND SOYFOODS IN THE MIDDLE EAST

Conclusion

Soya is a tremendous food and protein source.  The health concerns are addressed at the manufacturing stage.  Application of isolates, concentrates and TVP are multiple.  Even today, after being available on the market for so many years, all its various applications in foods have not been exhausted.  We are limited only by our imagination and interesting work remains to integrate its use into modern meat processing plants.

Reference

Applebaum, S.W.; Gestetner, B.; Birk, Y. 1965.  Physiological aspects of host specificity in the Bruchidae–IV.  Developmental incompatibility of soybeans for Callosobruchus. J. of Insect Physiology 11(5):611-16. May.

Arnarson, A.  2018. Phytic Acid 101: Everything You Need to Know.

Birk, Yehudith; Peri, Irena. 1980. Saponins. In: I.E. Liener, ed. 1980. Toxic Constituents of Plant Foodstuffs. 2nd ed. New York: Academic Press. xiv + 502 p. See p. 161-182. Chap. 6.

Bondi, A.; Birk, A. 1966. Investigation of soybean saponins as related to the processing of petroleum ether-extracted meal for feed and to the preparation of soy foods, to provide information basic to improving the nutritional value of soybean protein products. Rehovot, Israel: Hebrew University. 80 + xvii p. USDA P.L. 480. Project no. UR-A10-(40)-18. Grant no. FG-IS-112. Report period 1 March 1961 to 28 Feb. 1966. Undated. 28 cm.

Chajuss, D.. 2005. Brief biography and history of his work with soy in the USA and Israel. Part II (Interview). SoyaScan Notes. Feb. 19. Followed by numerous e-mails. Conducted by William Shurtleff of Soyfoods Center.

Duke, J. A. 1991. Research on biologically active phytochemicals in soybeans (Interview). SoyaScan Notes. Oct. Conducted by William Shurtleff of Soyfoods Center.

Engelking, Larry R. (2015-01-01). Textbook of Veterinary Physiological Chemistry (Third Edition). Boston: Academic Press. pp. 39–44. ISBN 9780123919090.

Flavin DF. The effects of soybean trypsin inhibitors on the pancreas of animals and man: a review. Review article. Vet Hum Toxicol. 1982. 1982 Feb;24(1):25-8.

Groves, M..  2018.  Is Soy Good or Bad for Your Health?

Hassan, S. M..  2013.  Soybean, Nutrition, and Health.  Intech  http://dx.doi.org/10.5772/54545

Kühne, W. 1877. “Über das Trypsin (Enzym des Pankreas)”, Verhandlungen des naturhistorisch-medicinischen Vereins zu Heidelberg, new series, vol. 1, no. 3, pages 194-198

Messina, M.  2018.  Is Soybean Lectin an Issue?  The Soy Nutrition Institute
The latest findings in soy health research, https://thesoynutritioninstitute.com

Perkins, S.  2018. What Happens if You Eat Raw Soybeans?

Vagadia, B. H., Vanga, S. K., Raghavan, V. 2015.  Inactivation methods of soybean trypsin inhibitor – A review. Received 14 December 2015, Revised 21 January 2017, Accepted 19 February 2017, Available online 27 February 2017. Elsevier. Trends in Food Science & Technology, Volume 64, June 2017, Pages 115-125

https://lpi.oregonstate.edu/mic/dietary-factors/phytochemicals/soy-isoflavones

Image Credit: https://semillasdealegria.com/products/soya?variant=29970856133