Prime Texture Manufacturing Method- A new type of soy meat with a meat-like texture and the savoriness of oil
Development of protein rather than soy oil
Fuji Oil started out in 1950 as a manufacturer of oils, but all the other oil manufacturers in Japan were long established companies that had been around since before WWII. As a late starter, we also had difficulty obtaining the raw materials for oils and fats to press oil from. As such, we focused on defatted soybeans which the oil had been pressed out of. Defatted soybeans are rich in protein that contains a lot of essential amino acids. So Fuji Oil changed the concept it worked under away from oil and focused on the development of defatted soybeans, switching course to research into defatted soybeans. 1969 saw the birth of “Fujinik” textured soy protein (an ingredient for soy meat). The management at the time were sure that plant-based protein would become essential one day, and it was their desire to be of use to society when that day came.
In actual fact, as well as pressing oil from palm and other raw materials for oils and fats, Fuji Oil also undertook analysis and research into amino acids in the meal left after the oil was pressed. This research led to research into defatted soybeans, and resulted in the subsequent use of soy protein in food products.
*Defatted soybeans
The leftover material after soybeans have been pressed. The more that oil is pressed out the higher the proportion of protein, so the protein contained in defatted soybeans is around 50%.
"Fujinic" released in 1969
Defatted soybeans
Manufacturing of textured soy protein (an ingredient for soy meat)
Textured soy protein is manufactured by adding water to defatted soybeans and kneading them in a machine called an extruder at high temperature and high pressure, and then blowing the material out at normal temperature and pressure to expand it before drying it. Expanding the material makes it porous, and gives it a fibrous feeling and texture.
The product is available with the colors
chicken, beef, and pork.
The texture and form also vary for each product.
We currently manufacture roughly 70 varieties of textured soy protein, with the colors chicken, beef, and pork, and in the forms of mince, sliced meat, and chunks. On the other hand, Fuji Oil believed that there was still room for improvement in terms of the texture and flavor of textured soy protein. And so our researchers have worked on a daily basis to create a new manufacturing method.
The amount of oil normally found in textured soy protein is usually a few percent or lower, so it faced the issues of always having a dry feeling compared to real meat and not melting in the mouth very well. This said, it was not as if these issues could be addressed by simply adding oils and fats during the manufacturing process, as adding oils and fats actually made difficult to recreate a meat-like fibrous texture and resulted in a weaker texture.
The key lies in the combination of processing technologies for oils and fats and protein
As well as soybean ingredient research, Fuji Oil has for many years been undertaking research and development into hard butters for chocolate and other plant-based oils and fats. On the basis of the knowledge we had gained from research into oils and fats, we reexamined the soy meat ingredient manufacturing process from scratch. And by applying processing technologies for oils and fats and protein, we successfully managed to manufacture a new type of soy meat that replicates the fibrousness, texture, juiciness, and other aspects of meat. While leveraging the deliciousness of soybeans, we have also managed to achieve a meat-like fibrousness, texture, and melt-in-the-mouth qualities.
*A patent application has been filed for this manufacturing method under the name “Prime Texture Manufacturing Method”.
The new soy meat ingredients produced using this new manufacturing method (Prime Texture Manufacturing Method) are comprised of two types: dried and frozen. The new soy meat ingredients include roughly between 5% and 10% plant-based oils and fats. The frozen type can be cut to any size desired, and can be cooked without any further preparation.
Dried type (after rehydration)
Dried type（cooking example）
Frozen type
Frozen type（cooking example）
In recent years, soy meat has been gaining attention as a sustainable food product from the perspective of environmental impact and issues faced by society such as the issue of population. There are great hopes that consumption of delicious and easy-to-cook soy meat will become widespread, and that it will become accepted as an even more familiar form of food.