FTECH 4415: Entrepreneurship with Plant and Business Management
LABORATORY EXERCISE NO. 2: MATERIAL SPECIFICATION AND PROCESS FLOW
2a. Material Specification
Specifications
Flavored Silken Tofu Skin Chips
Items
Raw
materials

Dried
Soybean
Physiochemical Characteristics
Weight (g)
Moisture (g/100g)
5000
8.29
Water activity
Total solids (g/100g)
Ash (%)
Minerals (g/kg)
P
Ca
K
Mg
Na
Cu
Fe
Zn
Mn
Protein (g/100g)
Lipoxygenase Activity
(units/solid)
Relative Lipoxygenase
Activity (% raw soy)
Fat (g/100g)
% Lipid fractions
Neutral Lipids (%)
Glycolipids (%)
91.71
4.82
5.380
1.948
17.318
2.063
0.445
0.010
0.206
0.044
0.031
32.54
Storage Requirement
Microbial characteristics
Total aflatoxin
(AFB1+AFB2+AFG1+AFG2)
(ppm, max)
10
Aflatoxin B1 only (ppm,
max)
5
Fumonisin (ppm, max)
2
 Store in a cool dry
place away from
any contaminants
27.68
100.00
18.64
91.00
2.66



Phospholipids (%)
Weight (g)
pH
EC (µS/cm)
Temperature (°C)
Turbidity (NTU)
Alkalinity (mg/L)
TDS (mg/L)
Water
SO4- (mg/L)
Cl- (mg/L)
Total hardness (mg/L)
Mg (mg/L)
Ca (mg/L)
Na (mg/L)
K (mg/L)
Weight (g)
Melting point (°C)
Relative density
(50°C/ water at 25°C)
Refraction index (n)
Moisture and
Vegetable Oil
impurities (%)
Iodine value
Saponification value
(mg KOH/g)
Unsaponifiable
matter (%)
Weight (g)
Moisture content (%)
Sour cream
and onion
Particle size (µm)
seasoning
6.97
50000
7±0.2
690
20±2
0.5
317
448
58
21
285
25
72
33
4
8000
34.2
0.90
Total Coliform Count
(MPN/100mL)
Fecal coliform Count
(MPN/100mL)
<102
<200
Enterococci (CFU/100mL)
40
E. coli (CFU/100mL)
500
Yeast and Mold Count
(CFU/mL) x104
 Store in a place
with temperature
15°C-27°C away
from any
contaminants
0
 Store in a cool
dry place away
from any
contaminants
1.46
0.1
55.83
208.2
Total Heterophilic Bacteria
(CFU/mL) x104
0
0.5
5000
Total mesophilic bacteria
13.66±0.15
(CFU/g)
<5.0
Enterobacteria (CFU/g)
1.33±0.23 Total coliforms (CFU/g)

8.8x10
0
<10
4
Store tightly
closed under
cool, dry
conditions in
an approved
Ash content (g/100g
DM)
pH
Titratable acidity
Weight (g)
Bulk density (100
tpas)
Insoluble index (mL)
E. Coli (CFU/g)
Coagulase-positive
staphylococci (CFU/g)
Sulfite-reducing bacteria
4.33±0.06 (CFU/g)
C. perfringens (CFU/g)
L. Monocytogenes (CFU/g)
35.33±0.58 Salmonella (CFU/25g)
Yeast and molds (CFU/g)
3000
Mesophilic Aerophiles
0.47-0.66
(CFU/g)

Skimmed
milk powder
Flavor
Scorched particles
Fat (%)

Sugar
Protein on SNF basis
(%)
Moisture (%)
Acidity (Lactic
acid)(%)
Weight (g)
Polarization (°Z, min)
Invert sugar content
(%m/m, max)
Conductivity ash
(%m/m, max)
0
<10
storage area.
Avoid
exposure to
light.
0
0
0
102
<103
≤1.00
Coliforms (CFU/g)
Color
<10
Pale cream
Clean
<10
Coagulase-positive
staphylococci (CFU/g)
Absent/1g
E. Coli (CFU/g)
Absent/1g
Salmonella (CFU/g)
Absent/1g
Disc A
 Store in a cool dry
place away from
any contaminants
≤1.5
≥34.00
Yeast and molds (CFU/g)
≤50
≤5.00
≤0.15
2000
99.8
0.04
0.04
Antibiotic
Negative
Total plate count,
mesophilic, (CFU/g, max)
10
Yeast and molds (CFU/g)
50
3
 Sugar should be
kept at the
maximum ambient
temperature of
3°C, and maximum
Moisture content,
max
60
Color (in ICUMA units
at 420nm, max)


Iodized salt
Citric acid
Sulfur Dioxide
(mg/kg, max)
Water insoluble
matter (mg/kg, max)
Copper (mg/kg, max)
Weight (g)
color
Particle size (mm)
NaCl %
Moisture content (%)
Water insoluble
matter (%)
Calcium (%)
Copper (%)
Magnesium (%)
Sulfate (%)
Total Alkalinity (%)
Iodine (mg/kg)
Lead (mg/kg)
Arsenic (mg/kg)
Cadmium (mg/kg)
Mercury (mg/kg)
Weight (g)
Assay (%)
Water (%, max)
Residue on ignition
(%, max)
relative air
humidity of 70 %
0.1
10
60
2
3000
white
1mm
96.0
4
E. coli (MPN/g)
Absent
Salmonella (/25g)
absent

Total plate count (CFU/g)
Iodized salt must
be stored under
dry, ventilated,
and hygienic
conditions.
The bags of
iodized salt shall
be stored only in
covered rooms
or go-downs to
protect from
excessive
humidity and
direct sunlight.
<10
1
0.5
2.0
0.5
0.5
0.5
30-60
1
0.5
0.5
1
500
99.5-100.5
0.5
0.5

Total fungal count (CFU/g)
<10
Total staphylococci count
(CFU/g)
-
Total coliform count
(CFU/g)

N/A
-
Anhydrous
Citric Acid is
slightly
hygroscopic
and should be
Oxalate/olxalic acid
(%, max)
0.036
Sulfate (%), max)
0.015
Arsenic (ppm)
1
Heavy metals (ppm)
5
Lead (ppm)
Tridodecylamine
(ppm)
0.5
Color and clarity
stored under
low
temperature
and low
humidity
conditions in
airtight
containers to
prevent
caking.
0.1
Passes the
USP test
Specification
Quantity
Base Material
Packaging
materials

Food-graded
laminated
bag
Size
Thickness
Capacity
Type of pouch
Pouch pattern
Pouch finish
Pouch lamination
Closure type
Packaging type
500 pieces
Kraft/ Cast Polypropylene/ Vacuum Metalized
Polyethylene
110x185+35mm
132 microns
500g
Standup pouch
Printed laminated pouch
Glossy
Multi-layer lamination
Heat sealed
bag
Storage
 Bags should be well
maintained to avoid
any movement
2b. Sample Process Flow
Person Responsible
 Quality control
analyst
 Production Staff
Process Involved
Star
t
Dried soybeans
Water
Vegetable oil
Sugar
Salt
Sour cream and onion powder
Citric acid
Receiving of
materials
 Production staff
Are the materials
free from any
damage or
contamination?
Equipment involved
Yes
Washing and soaking
 Production staff
1. Dry beans tank
2. Soybean transferring
machine
Form no. 1:
raw material
receiving log
3. Soybean soaking and
washing machine
Form no. 2:
operator log
book
4. Grinding and
separating machine
Form no. 2:
operator log
book
5. Okara transportation
machine
Form no. 2:
operator log
book
Add water
No
Grinding and separating
Rejection of materials
 Production staff
 Production staff
 QC analyst
 Production staff
Filtering (soymilk+okara)
Is the
temperatur
e at 100°C?
Yes
Molding
Form no. 3:
operator log
visual control
of bubbles and
temperature
Form no. 2:
operator log
book
Form no. 2:
operator log
book
Form no. 4:
operator log
pH and
calibration
10. Hydraulic press
Peeling
Form no. 2:
operator log
book
11. Dried tofu clothespeeling machine
Form no. 2:
operator log
book
12. Hydraulic pump
station
Form no. 2:
operator log
book
13. Electric drier
Form no. 2:
operator log
book
Cooking
6. Soymilk cooking
machine
No
Plate cool exchanger
Repeat heat treatment
7. Plate cool exchanger
machine
 Production staff
Coagulating
 Production staff
 Production staff
 Production staff
Is the
pH at
<5?
Yes
pH control <5
Add citric acid
Discard batch if pH >5
after 24 hours
Is the quality
of tofu skin
up to the
standards?
Yes
No
Tofu skin
Drying
Discard batch
 Production staff
 QC analyst
 Production staff
9. Thin tofu sheet
pouring machine
No
 QC analyst
 Production staff
8. Soymilk coagulating
and seasoning
equipment
Pouring
 QC analyst
Yes
Is the
temperatur
e at 165185°C?
Deep frying
Add vegetable oil
Extra fat/oil
removal
No
Repeat heat
treatment
14. Deep fryer
Chips salting and
flavoring addition
 Production staff
15. Drying rack
Does it
conform to
the require
specifications
?
Yes
Final product packing
and storage
Sugar
Salt
Sour cream and
onion powder
Form no. 3:
operator log
visual control
of bubbles and
temperature
Form no. 2:
operator log
book
16. bowl
Form no. 2:
operator log
book
17. storage cabinet
Form no. 5:
finished
product
specification
log record
No
 Production staff
 QA officer/ QC
analyst
Documents
End
Discard
batch