Production Process
1. Soybeans Selection
Tofu is made from soymilk, an extractive of soybean. The soybeans used in our Tofu products are not genetically engineered or genetically modified organism ("non-GMO"), which is a rarity these days.
Products made from soybeans are rich in nutrients such as:
- Complete protein (containing all essential amino acids)
- Minerals (calcium, iron, manganese, and selenium)
- Unsaturated fatty acid, compared to animal protein
2. Soaking
The soybeans are soaked in a tank filled with clean, purified water for about 10 to 13 hours. This makes the extraction of protein from the beans easier.
3. Grinding
After a prescribed amount of water is added to the soybeans, they are ground to slurry (a thin mixture of an insoluble substance) in order to make the extraction of protein easy. The mashed soybeans are then ready to proceed to the next step.
To make protein extraction even easier, the ground soybeans are heated. This heating process eliminates soybean odor while pasteurizing the slurry and allowing for a better coagulation of proteins.
4. Filtration
The heated slurry is filtered through a fine screen to remove solid matters, such as soy pulp, which consists mainly of fiber (bean-curd refuse called Okara). This step allows the tofu to become smooth in texture.
5. Coagulation
The coagulation (or process of turning a fluid into a thickened mass) of the soybean milk into curd form is done by quickly mixing in calcium salt and other coagulants. This mixing allows the ions, such as calcium, to work to combine soybean protein with one another, resulting in the coagulation of soymilk into curd form.
6. Forming And Cutting
This curd-like Tofu is broken up and poured into a cloth-lined box. It is then pressed in order to eliminate excess water. This process finally results in Firm Tofu. Soft/Silken Tofu is made by coagulating slightly thicker soymilk without pressing to remove water.
When pressing Tofu, the pressure should be gradually increased in order to make the quality of the Tofu consistent. After pressing is finished, a large sheet of Tofu is automatically cut up into merchandise-size and packaged in containers.
7. Packaging And Labeling
Tofu is cut into small blocks and packaged in a container filled with clean water. The package is then sealed thermally with film imprinted with the product name, size, nutritional information, etc. Each product is also printed with an expiration date.
8. Pasteurizing
The packaged Tofu is pasteurized in a boil-cool pasteurizing machine. This continuously heats the Tofu, followed by immediately cooling it. By doing this, the product's fresh flavor is preserved for a long period of time.