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SOY PROCESSING TECHNOLOGIES

1. COMPARATIVE ANALYSIS OF TECHNOLOGIES AND EQUIPMENT FOR SOY PROCESSING

2. THE URGENCY OF THE PROBLEM

3. GOALS AND OBJECTIVES

4. TEKMASH® TECHNOLOGY

5. TEK-SM UNIT DESCRIPTION

6. CALCULATION OF TOTAL SAVINGS AFTER THE NEW TECHNOLOGY INTRODUCTION

7. THE EVALUATION OF PROFITABILITY BENEFITS AFTER THE INTRODUCTION OF TEKMASH® TECHNOLOGY IN A CATTLE FARM.

8. TECHNOLOGICAL BENEFITS

It is well known that soy processing technologies are subdivided into dry and wet ones depending on the utilized processes. Soy milk, soy mayonnaise, and soy paste obtained from whole soy beans are among the products manufactured by wet technologies (sometimes soy beans undergo pre-processing). Soy milk is traditionally manufactured on the so called soy cows. This equipment enables wet soy beans crushing, thermal processing at the temperature of 203...230F (95...110) utilizing steam generator. The technological process is completed with a retention interval for the destruction and inactivation of harmful compounds. Soy mayonnaise is obtained from condensed soy milk; soy paste is an educed sediment obtained from soy milk after its sedimentation containing primarily carbohydrates and a small percentage of residual proteins and fats. (Specifications of one of the "soy cows" manufactured in Ukraine are listed in Table 1, chapter 6.1).

The soy cake production processes after soy beans were treated in high-speed mills or in extruders for soy oil production are referred to as the "dry" technologies. Soy flour can also be obtained by milk condensing and evaporation. Dry soy products (flour and cake) manufactured by the Ukrainian enterprise EKO LLC are 1.5-2 times cheaper than similar products of foreign manufacturers. The indisputable advantage of soy products manufactured by "dry" technologies is their long shelf life and simple handling for animal feeding.

The soy milk production equipment market is quite diverse both by capacity and by origin of the equipment. For example, the capacity of equipment manufactured by Krasnodar companies, widely spread in Russia is between 4.76 and 1058 gallons/hour (18-4000 liters/hour) with electricity consumption rate between 10 and 300 kW respectively. A few design adjustments introduced by Tronka-Agrotekh LLC, Kiev, Ukraine in their USK soy cows reduced electricity consumption almost by one third.

The volume of soy cake import has shrunk in the last several years despite the fact that the product is widely used in cattle and pig farms in Ukraine. This is explained by extremely high price of the imported product and increase of domestic manufacturers activity.

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1. COMPARATIVE ANALYSIS OF TECHNOLOGIES
AND EQUIPMENT FOR SOY PROCESSING

The analysis of technologies and specifications of the currently available equipment for balanced fodder mix production in real-life farm operation in Ukraine provides grounds for a conclusion about the imperfection of soy beans processing equipment and technologies. Thus, for the production of soy milk with 7% dry matter content it is necessary to heat 93% of water almost to the boiling point and then cool it to the feeding temperature. This leads to big energy losses and rising equipment prices.

In our opinion, application of "dry technologies is not very profitable in animal husbandry. Besides the high prices for soy flour and soy cake, the low effectiveness of soy cake fodder application is also worth noting. Indeed, it is well known that soy beans are the treasury of unique protein complexes, easily digestible fats, amino acids, microelements. The soy beans shelf life without loss of their unique qualities depends on the beans shell integrity (the soy grade is determined by the percentage of damaged and broken beans). If the shell is broken, the active substances cause quick fats oxidization and vitamin complexes decomposition.
Because of this very reason, the dry soy processing technology for soy cake production cannot be viewed as effective one, because the speed of oxidization processes by far exceeds the speed of balanced fodder mix production. Besides, this method does not provide a way of inactivation of such harmful substances as urease and trypsin inhibitor, which causes diseases and deaths of animals.

The results of analyses conducted by Palladin Biological Research Center at the Institute of Biochemistry of the National Academy of Science of Ukraine show, that vitamin ingredients of the soy paste produced by TEKMASH hydrodynamic processing technology remains intact, i.e. identical to that of soy beans before processing!

2. THE URGENCY OF THE PROBLEM

The conducted analysis of the available soy processing technologies provides grounds for a conclusion that there is no integral development concept of soy additives production technologies development, which should meet the following requirements:

  • animals feeding technology optimization;
  • cost reduction, i.e. increasing farming profit margins;
  • minimization of energy resources consumption;
  • environment protection.

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3. GOALS AND OBJECTIVES

1. Fodders should be prepared right before the animals are fed.
2. The fodder feeding temperature must be between 68° and 86°F (20°-30°C).
3. The energy consumption rate for the production of fodders based on soy, peas and other components must be the lowest possible.
4. Equipment capacity must be the lowest feasible.
5. Equipment and technology must ensure effective production of the following fodder types: soy-grain, soy-corn, peas-grain, etc.
6. Technology must ensure effective incorporation of vitamin, medicinal and other additives.
7. Reliability and safety of equipment operation.
8. Environment friendliness of equipment and technology.

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4. TEKMASH® TECHNOLOGY

TEKMASH technology is implemented through TEK-SM hydrodynamic units and is based on:
1. The production of concentrated soy additives in the form of creamy and pasty products.
2. Soy paste thinning with cold water to achieve the necessary soy milk consistency immediately after preparation reducing the temperature to 68°...86°F (20°...30°C).
3. One of the available equipment options satisfies the requirement of full equipment autonomy with the installation of a diesel engine.
4. Safety and reliability of the technology is defined by absence of heating elements. The equipment does not have a steam generator and does not require an approval from the State Committee on Labor Protection and Supervision.
5. TEKMASH technology is waste-free. Environment pollution is out of the question.

The technology ensures:

  • minimization of energy resources expenditures owing to the combination of heating, grinding, mixing processes as well as incorporation of necessary additives in one production cycle;
  • minimization of equipment capacity owing to its high efficiency (at least 90%);
  • elimination of heat exchange equipment.

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5. TEK-SM UNIT DESCRIPTION

TEK-SM unit operation is based on liquid heating caused by hydromechanic phenomena, namely, cavitation and turbulent friction. The equipment comprises an electric or diesel driven pump, a reservoir where the ingredients are loaded (raw materials, water, additives) and a special nozzle where the mixture ingredients are crushed and heated. The necessary technological temperature is maintained and controlled by automatic sensors. The equipment is protected by patents in Ukraine, Russia as well as international patent applications.

The revolutionary approach to heating soy suspension allows:

  • to prevent formation of carcinogenic substances found in thermal-oxidized product caused by sticking and burning on heating surfaces;
  • to ensure even heating throughout the entire volume of the processed mixture, thus eliminating vitamin destruction caused by overheating part of the product;
  • to simplify the equipment design, which in turn reduces the operation and maintenance costs.

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6. CALCULATION OF TOTAL SAVINGS AFTER THE NEW TECHNOLOGY INTRODUCTION

6.1. Comparison with the conventional wet soy milk production technology.

Comparison chart of soy milk production equipment (UKS-1000 manufactured by Tronka-Agrotekh, Kiev, Ukraine and TEK-4SM designed and manufactured by TEKMASH Institute R&D Enterprise, Kherson).

Technical specifications
USK-1000
TEK-4SM
Notes
1. Capacity
gallons/hour
ltrs./hour
milk
264.6
1,000
paste
84.7
320
Dry matter content: in milk - 7%, in paste - 28%
2. Soy beans consumption,
lbs./hour
kg/hour
154
70
197.12
89.6
 
3. Wattage, kW
6
45
 
4. Steam consumption per 1 mt
of end product,
lbs.
kg
440
200
-
 
5. Operators
2
2
 
6. Full technological cycle: operation/pause, min.
60
45 / 15
 
7. Water consumption,
gallons/hour
ltr/hour
608.5
2,300
79.4
300
Additional 264.6 gallons or 1,000 ltrs of water is necessary to thin the soy paste to milk consistency
8. Equipment weight,
lbs.
kg
2,640
1,200
1,760
800
 
9. Cost of equipment, USD
30,656
9,630
Prices effective on August 1, 2004

Benchmark data for economic efficiency calculation:

  • Shift duration 8 hours, the number of full technological cycles - 7, the duration of production preparation cycle 1 hour. The number of shifts per day 1.
  • Accelerated depreciation rate 20%, the number of work days per year 365.
  • Cost:
    • Raw material (soy)
      - U$ 111.11 if grown at the farm;
      - U$ 185.19 - if bought from a supplier.
    • Electricity U$ 0.05115 per 1 kWhour (with VAT).
    • Land lease: U$ 111.11 per month per 333.33 sq. foot
  • Estimated transportation expenses: U$ 185.19/month.
  • Wages fund: U$ 166.67 per month, including all applicable taxes.
  • Overhead cost (32%): U$ 53.7/month.
  • Operation expenses (not including the cost of water and electricity):
    185.19+166.67+53.7+111.11 = U$ 516.67 per month or U$ 17.22 per day.
  • Depreciation cost per day:
    - U$ 16.8 (USK-1000)
    - U$ 3.24 (TEK-4SM).
  • For the production of 1 mt of soy milk, USK-1000 unit consumes 440 lbs (200 kgs) of steam at the pressure of 1.4 MPa, which corresponds to the energy consumption of 174 kWhour. The total energy consumption rate of USK-1000 is 180 kWhour per cycle or U$ 9.20 per hour (U$ 64.26 per shift).
    TEK-4SM unit consumes 34 kWhour per cycle, which corresponds to U$ 1.74 per hour or U$ 12.19 per shift.
  • Water expenditures at the rate of U$ 0.24 per 1m3 make for U$ 3.89 and U$ 2.15 per day respectively.
  • The total operation expenses per day, including items 8, 9 and 10 amount to:
    - U$ 17.22+64.26+16.8+3.89 = 102.17 (USK-1000);
    - U$ 17.22+12.19+3.24+2.15 = 34.8 (TEK-4SM).
  • Based on the equipment specifications being compared, the capacity per shift is:
    - USK-1000: 15,400 lbs of soy milk (7,000 kg); 1,078 lbs (490 kg) of soy beans is necessary;
    - TEK-4SM: 4,928 lbs of soy paste (2,240 kg); 1,379.84 lbs (627.2 kg) of soy is necessary.
    Soy milk with 7% dry matter content can be prepared without additional energy consumption by thinning the soy paste with cold water at 1:3 ratio. The total mass of milk prepared by this technology is 19,712 lbs (8,960 kg). The milk temperature will be between 77° and 86° F (25°...30°), which meets the technological requirements of animal feeding.
  • The net cost of 1 mt of soy milk is:
    - USK-1000: U$ 102.17:7 = U$14.6 per 1 metric ton;
    - TEK-4SM: 34.8:8.9 = U$3.91 per 1 metric ton.
    This way, the cost of soy milk manufactured on TEK-4SM unit is 3.7 times lower than the cost of the product manufactured on USK-1000.
  • Processing 1 mt of soy beans costs:
    - USK-1000: U$ 102.17:0,49 = U$ 208.52;
    - TEK-4SM: 34.8:0,6272 = U$ 55.56.
  • To be conservative, suppose USK-1000 produces 7 metric tons of milk per day. 7 mt x 365 = 2555 mt.
    The production cost will be 2555 x U$ 14.6 = U$ 37,303
    Production of the same annual amount of milk on TEK-4SM unit will cost 2555 x 3.91 = U$9,990
    This way, the total savings will amount to U$ 27,313
  • For a more complete understanding of the processing cost, regardless of the equipment type, let us compare it to the soy beans cost. Suppose, the cost of soy beans growth is U$ 111.11 per 1 mt. Then the full production cost of 1 mt of soy milk is :
    - USK-1000: U$ 14.6 + 111.11 x 0.07 = U$ 22.38;
    - TEK-4SM: U$ 3.91 + 111.11 x 0.07 = U$ 11.69.
    To make our further analysis simpler, let us substitute kilos to liters, since the relative density of soy milk with 7% dry matter content is close to the relative density of water. Then the cost of 1 ltr of soy milk will be:
    - manufactured on USK-1000: U$ 0.0224;
    - manufactured on TEK-4SM: U$ 0.0117 .
    To simplify further analysis, let's round them off to a bigger number:
    - USK1000: U$ 0.023.
    - TEK-4SM: U$ 0.012.

6.2 Comparison with the "dry" soy milk production technology

This technology implies production of soy milk from soy flour. Let us consider the technology applied by ECO LLC, Kiev, Ukraine. According to promotional materials of this company, the average price of dry soy flour is around U$666.67 per 1 mt.
1. The production of 1 mt of soy milk with 7% dry matter content costs U$ 46.67.
2. To reach the feeding temperature the soy flour needs to be mixed with water and heated to 68°...86°F (20°...30°C). This will take 25 kWhour, which together with the water cost will add up to U$ 1.85.
3. Considering the cost of labor, lease, etc., the cost of 1 mt of soy milk will be not less than U$ 51.85 or U$ 0.052 per liter.
This means, that the soy milk prepared from soy flour is more than 4 times more expensive than the soy milk produced by TEKMASH® technology.

6.3 Calculation of equipment pay-back period.

1. Let us suppose (as we did earlier) that some 7 mt of soy milk are produced in one day.
2. This way, the savings per 1 mt of produced soy milk after the change of the "dry technology to the wet one will be:
U$ 51.85 U$ 12.96 = U$ 38.89 or U$ 272.23 per day.
3. If the original equipment cost is U$ 5933.3, then its pay-back period will be U$ 5933.3 : U$ 272.23 = 22 days.

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7. THE EVALUATION OF PROFITABILITY BENEFITS AFTER THE INTRODUCTION OF TEKMASH® TECHNOLOGY IN A CATTLE FARM

According to the report of Mechta agricultural company - one of the best farms in Ukraine, 109.79 gallons (415 ltr.) of soy milk are used for calves feeding within 6 months period, and the total fodder mass is 4015 lbs or 1825 kg.

The calculation based on the farms data shows that the fodder cost is U$ 67.96 or around U$ 0.017 per pound (U$ 0.037 per kg). That is if the 109.79 gallons of soy milk is produced from soy flour at the cost of U$ 0.024 per 1 lbs (U$ 0.052 per 1 kg).

The total savings after the new technology introduction with the soy milk cost at U$ 0.013 per 1 kg will be 415 x (0.052 0.013) = U$ 16.18, which equals to 23.8%

As it becomes clear from multiple publications, the fodder cost equals to around 60% of the total cost of raising livestock. This means that the new technology introduction allows to reduce the total livestock raising costs by 14.7%. Likewise, the profit margins will rise accordingly, i.e. the profitability will increase from 18.7% to 33.4%.

Therefore, we can draw a conclusion that only owing to the change of soy milk production technology the farm profitability can increase more than by one half!

If we make a detailed calculation for the case when a farm uses "soy cow equipment for the soy milk production, the total fodder cost will be U$ 56.02.
Therefore, after the new technology introduction the fodder cost will be reduced by:

415 x (0.024 - 0.013) = U$ 4.57
The profitability will rise by 5% (from 18,7% to 23,7%), or in 1.27 times!

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8. TECHNOLOGICAL BENEFITS

To prove the effectiveness of the offered technology in terms of nutritive components preservation, independent researches of soy paste produced by TEKMASH technology were carried out in Palladin Biological Research Center at the Institute of Biochemistry of the National Academy of Science of Ukraine.

The soy paste was compared with the ground soy beans. To avoid the loss of nutritive components the beans were ground immediately preceding each test. Based on the research results the following conclusion can be drawn:

1. The vitamin complex contained in the paste is several times richer than the one in the soy flour.
2. Fats (or fat acids, to be more precise) keep their qualitative balance (unsaturated - saturated acids) after the processing. This specifically relates to unsaturated linoleic and linolenic acids (which make for around 60% of all fats), important for the digestion process. It is worth pointing out that during the dry processing technology and long-term storage the content of these essential compounds decreases significantly.
3. Amino acids composition (i.e. proteins in first approximation) is hardly modified at all in comparison with dry soy beans, which is explained by absence of heating surfaces causing thermal destruction of proteins.

Therefore, the research confirms the high effectiveness of the offered soy processing technology in terms of the nutritive value of the end product TEKMASH soy paste.

 

 

 


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