Manufacture of Tofu at domestic level

Dr.A.P.Gandhi Principal Scientist (Biochemistry) Soybean Processing and Utilization Center Central Institute of Agricultural Engineering Bhopal-462038 (MP). The tofu is prepared at domestic level in two stages. First the soymilk is made and secondly it is coagulated to form tofu, which are then pressed. The processing of soybeans is required to inactivate the ANF, to minimize the un acceptable beany flavor and improve the digestibility of the protein. The following steps are followed for making tofu: Cleaning: The beans are cleaned thoroughly. The debris/stubbles/broken/stones are removed and dehulled. Soaking: The splits are soaked in water with 0.1%(w/v) sodium bicarbonate at room temperature at a ratio of one to three (w/v). The length of soaking depends on the season. Winter 20-22 hours Spring 12-14 hours Autumn 10-11 hours Summer 6-7 hours The variation is due to the different room temperatures and water temperatures prevailing in these seasons. The soaking removes most of the bitter substances. Mashing: Sufficient water is poured on to the soaked splits to cover them and then ground to a mash in a ratio of one to six (w/v). During mashing hot water may be used. Heating: The mash is cooked in an open vessel or under pressure. It may take 20-30 minutes. Filtration: The mash is filtered after the heat treatment in to a large cotton/muslin bag, which is pressed by hand. The pulp (okara) is mainly fiber and crude protein. It is usually used for animal /aqua/poultry/swine feed. Occasionally used for humans. The liquid is the soymilk. Heating and coagulation: The soymilk is boiled. A small amount of coagulant is added into a wooden or metal container and the milk is added after bringing it to the required temperature for coagulation. Finally the remainder of the coagulant is added and the mixture left for 15-30 minutes to coagulate. Draining: Normally cheesecloth is used to line a wooden/metallic container in to which the coagulated milk is poured. The remainder of the cloth is folded on top and a wooden lid is fitted. Different weights are used to yield pressure for making variety of tofus. For soft tofu the pressure may be 2-4g/cm2 for five minutes then increased to 5-10g/cm2 for 10-15 minutes or until the whey stops draining out. For firmer tofu the pressure required is 20-100g/cm2 for 20-30 minutes. Finally the tofus are cooled in chilled water for 60-90 minutes and refrigerated or sold fresh. The procedure is very simple to follow and can be followed by the average family with the available utensils/gadgets/equipment. About 2 kg of firm tofu may be obtained from one kg of beans processed. The chemical composition of tofu per 100g is shown as under:

Protein 5-9g Fat 2-4g Carbohydrates 2-4g Water 80-90g Fiber 0.2g Energy 0.32MJ Calcium 1.0mg Iron 1.7mg Phosphorus 1.0mg Vitamin B1 0.05mg Vitamin B2 0.04mg Nicotinic acid o.5mg Packaging: The tofu may be directly put in to the customers container or into thin polythene bags. The tofu must be stored under water to prevent it drying out. To improve its shelf life it may be packed in different ways: In plastic bags for 7-14 days if refrigerated. Heat-sealed in water filled plastic trays. Vacuum packed for 3-5 weeks. Sold in bulk at 4oC. The water must be changed daily. Packed in jars, heated for one hour in boiling water and given an airtight seal, it has a shelf life to six months. Equipment Required: sieves, stone mill/mixie, soaking tank, container for boiling, cheesecloth bags, wooden boxes for pressing, hand operated press etc. Coagulating agents: The coagulation step is very important and requires care. If the curd has crumbly texture, it is likely to have been caused by adding too much coagulant too fast and at too high temperature, causing the curds to form too quickly. In sufficient coagulant will give a low yield. Nigari Type: It is produced during the salt manufacture from the seawater and contains magnesium sulphate, magnesium chloride and calcium chloride. It is used at 3% by weight of dry beans at 78-85oC. Sulphates: Calcium sulphate or gypsum and magnesium sulphate or Epson salt are used at 2.2% of dry beans at 70-75oC.It gives smoothest texture tofu. Acids: 21% Citrus juice, lactic acid or 16%vinegar is used. At 80-90oC. Lactone: Glucono delta lactone (GDL) is mixed with soymilk at 0.6% and heated at 8590oC for 30-50 minutes. An increased yield and a low amount of okara may be obtained by including a two stagegrinding step. For example 5kg of beans are soaked in 15kg of water with further 15kg of water added during the first grinding stage and 7.5kg during the second stage. The machine should be washed with 5-6kg of water to avoid wastage. After boiling the milk

for 2-3 minute, no cold water is added but when the temperature falls to 80-90oC the coagulant is added. Flavored tofus: Fruit flavored tofus: It is achieved by adding different fruit juices, which are acidic. They will coagulate the milk and also add the typical fruit flavors. The pH of the fruit juices may be adjusted to 2.3-2.9 and 14-35 ml are added to 10 liters of soymilk. Spiced tofus: Different spices like hot chilli powder is added in hot water and mixed with the soymilk before adding the coagulant. Milk blended tofus: Acetic acid is added to cows milk to separate the milk proteins, which are then added to soybean milk. The proportion of acetic acid to milk is 0.02:100 and the ratio of milk proteins to soymilk is 3:7. Coffee tofus: 0.5-10% soluble coffee and sugar are added to the soymilk at 40oC, which is coagulated then with GDL. The product is packed and heat processed in 300ml pots by heating in water at 90oC for 50 minutes.