1/10

Soya chaap manufacturer, India Bound by protein, not maida. Hygienic and stick-free.

Soy and wheat protein hold our chaap together, and the plain rolls carry about 20 g of protein per 100 g. Our extruder makes one continuous sheet, and a line we built ourselves slices, rolls and glues it into chaap at our Rudrapur plant.

Maida-free
~20 g protein/100 g, plain rolls
Stick-free
No hand-wrapping
FSSC 22000

Soya Chaap Products - Frozen & Shelf-Stable

Range 1 of 2

Soya Chaap Range

Same HMMA chaap base. Pick the format your channel needs - badges on each SKU show which formats are available. Need keema, shreds, seekh or nuggets in soy protein?

See wet textured soy protein →

1.
Plain Soya Chaap
FrozenRetort
2.
Marinated Soya Chaap
FrozenRetort
3.
Canned Soya Chaap
Canned
4.
Soya Chaap Strips
FrozenRetort
5.
Soya Chaap Chunks
FrozenRetort

Range 2 of 2

Retort Chaap in a Pouch

Shelf-stable retort pouches - fully cooked, 24-month ambient shelf life, no cold chain needed. Ready to heat and eat or finish on the tava. Ideal for retail, D2C, HoReCa, and export.

1.
Chaap Rolls in Brine
Retort
Representative image
2.
Marinated Chaap (Retort Pouch)
Retort
Representative image

How it's made

From flour to frozen pack, in one plant

Eight steps, all from our line at Rudrapur. No step needs anyone to wrap or shape the chaap by hand.

Weighing feeders and extruder on Zippy's chaap line
Weighed in by feeders
Soy and wheat protein go into the extruder through weighing feeders, with water. No maida goes in, and nobody kneads a dough.
Continuous chaap protein sheet coming out of the cooling die
Extruded as one sheet
Heat and pressure line the protein up into fibres. It comes out of the extruder as one continuous sheet.
Protein sheet being sliced and rolled into chaap on Zippy's patented line
Rolled and glued by our own line
Our line slices the sheet, rolls it and glues it, so the roll holds its shape on its own. Patents #568286 and #597337.
Cut chaap rolls moving through the line in food-grade crates
Cut to size
Rolls are cut to length or into tikka pieces and move on by belt and crate. There is nothing to pull out.
Par-cooked chaap pieces on a stainless mesh belt
Par-cooked on a moving belt
Par-cooked formats go through on a continuous belt, so they reach your kitchen with colour already on them.
Racks of chaap going into the blast freezer
Into the blast freezer
Racks go straight into the blast freezer. Canned and retort chaap is sterilised in the pack instead.
Metal-checked before boxing
Frozen chaap passes a metal detector before it is boxed. It is a critical control point in our food-safety plan.
Tested and released by QA
Our QA team tests production samples in our in-house lab and signs off each day's batches.

What's different

Two ways to make chaap

Traditional chaap is a dough wrapped by hand around a stick. Ours is held together by protein instead of maida, and a machine rolls it from an extruded sheet. Here is what that changes.

Base

Soy dough, often with maida (refined wheat flour) as the binder

Soy and wheat protein, no maida; over half soya on a dry basis

Protein (as sold)

Depends on the recipe

About 20 g per 100 g in plain rolls

How it's shaped

Dough wrapped by hand around a wooden or bamboo stick

Protein extruded as a sheet, then sliced, rolled and glued by machine

What holds the shape

The stick, while it is steamed or boiled

The roll itself, glued on our line

What you weigh and pay for

Chaap plus the stick, sold by weight

No stick in the weight

In the kitchen

Pull the stick out, then cut

Straight to the board, or buy it already cut as tikka

In your kitchen

What lands in your kitchen

A plain roll about 30 to 35 mm across, or tikka cuts. Frozen for 18 months, or in retort pouch and can for 24 months without a freezer.

Zippy soya chaap rolls, whole and sliced, on a dark plate — Plain rolls, maida-free

Zippy soya chaap rolls on a serving board — Straight to the board

Sliced seared soya chaap on a platter — Seared and sliced

yield in our cook test: 97%
to cook: 1 min
oil taken up in our cook test: 7%
frozen shelf life: 18 months

Our own R&D measurements on our chaap. Ask for the method with your samples.

Field note

Why we took the stick out

How the line came about, and what kitchens actually do with chaap.

Read the field note →

Cut it the way you normally would and see. We'll send frozen samples with the spec.

Request samples

Hygiene

Hygiene you can check

We'd rather show you than ask you to trust us. These are the controls a buyer's auditor asks about.

Shaped by machine
Our extruder and our own rolling line form the chaap. Nobody wraps or shapes it by hand.
No stick, no wood in processing
Our chaap has no stick, and our QA team keeps wood out of the processing area altogether.
Cleaning logged every shift
Equipment cleaning and sanitising is logged shift by shift in our QA app.
Lab results on the spec sheet
Our canned chaap's nutrition and microbiology lab results are published on its spec sheet, under Specs below.

Loading trays for the blast freezer
Rudrapur plant floor

FSSC 22000 certified. Audited every year by Intertek.

Intertek India is a NABCB-accredited certification body (accreditation FS 010).

Covers: Frozen ready-to-cook foods: textured soya protein, soya chaap, marinated chaap, soy mince, kebabs, and coated and uncoated products

Reg. 0212626 · valid until 07 May 2028 · FSSAI licence 12623999000092

View certificate (PDF) →Check the FSSC 22000 register →

Know more

Formats, specifications, cost per kg and the questions buyers ask us most.

Zippy Edibles makes soya chaap on its twin-screw high-moisture extrusion line at Rudrapur, Uttarakhand. Our chaap is 100% maida-free, and the base is more than half soya on a dry basis. Available frozen (18-month shelf life) or shelf-stable in canned and retort pouch formats (24-month ambient shelf life). Contract manufacturing (co-packing) and private label services for QSR chains, retail brands, D2C companies, and export markets.

Why Choose Zippy as Your Soya Chaap Manufacturer

Twin-Screw HMMA Line

Twin-screw high-moisture extrusion line at Rudrapur, built around a German extruder. A continuous process with in-house QC.

Zero Maida, Soy-Led Base

Our proprietary formulation uses no refined flour. The base is more than half soya on a dry basis.

Frozen + Shelf-Stable Options

Choose frozen for domestic supply or retort/canned for export. 24-month ambient shelf life eliminates cold chain dependency.

Proven at Scale

Supplying a national QSR chain and frozen-food brands, on 10 MT/day extrusion capacity.

The Economics of Maida-Free Chaap

Our own numbers, in our cook test

Metric	Zippy TexPro Chaap (in our cook test)
Yield After Searing	97%
Cook Time	1 minute
Oil Absorption	7%
Oil Cost	Rs 10/kg

Figures from our cook test on the seared product.

Brands we supply

Jubilant FoodWorks

Wow Momo

Blue Tribe

Ananda

Son of Swaad

Sadak Chaap

Available Formats

Same product, multiple formats. Pick the one your channel needs.

Frozen

Shelf Life

18 months at -18C

Packaging

Vacuum bag, 1-5 kg standard

Retort Pouch

Shelf Life

24 months ambient

Packaging

Retort pouch, custom sizes

10 MT/day retort capacity, no cold chain required

Canned

Shelf Life

24 months ambient

Packaging

Can, 800 g (500 g drained)

Soya Chaap Manufacturing Specifications

HMMA Extruder	twin-screw HMMA extruder (Germany)
Extrusion Capacity	10 MT/day
Retort Capacity	10 MT/day, ambient-stable pouches and cans
Marination	Vacuum tumbler + industrial ovens
Automation	Machine-formed chaap line
Soy Content	>50% soya on dry basis (maida-free)
Shelf-Stable Formats	Retort pouch and canned (24-month shelf life)
Cold Storage	250 MT frozen storage capacity
Freezing	IQF spiral freezer + trolley blast freezer
MOQ	1 MT pilot; full truck for regular frozen supply
Lead Time	2 weeks standard, 3-4 weeks custom
Certifications	FSSC 22000, FSSAI Licensed

Canned Soya Chaap - full data sheet

ZE-SC-CAN-800G · v1.1 · October 2026. Ingredients, lab-tested nutrition, packaging and micro standards - published openly.

View specification Download PDF

Soya Chaap Manufacturing FAQ

How is Zippy soya chaap made?+

Zippy uses HMMA (High-Moisture Meat Analog) extrusion on a German twin-screw extruder. The protein comes out as one fibrous sheet, and our own line rolls it into chaap with no maida and no stick. The base is more than half soya on a dry basis, and the continuous process runs at industrial volumes.

What is HMMA extrusion and why does it matter for soya chaap manufacturing?+

HMMA stands for High-Moisture Meat Analog - an extrusion process that gives plant protein a fibrous, meat-like texture. Dry extrusion (TVP, soya chunks) runs at low moisture, and the product is sold dry and soaked before cooking. HMMA runs at high moisture, so the protein comes out as a layered, fibrous sheet that is already hydrated and ready to cook. Zippy makes its chaap on a twin-screw high-moisture extrusion line at Rudrapur, built around a German extruder.

Do you manufacture shelf-stable soya chaap for export markets?+

Yes. We offer both retort pouch and canned formats with 24-month ambient shelf life - no cold chain required. This makes export logistics simpler and cheaper. Current export markets include UAE, South Africa, Canada, Australia, the West Indies and Nepal, among others. Our FSSC 22000 certification meets international food safety requirements.

What is the MOQ and lead time for soya chaap contract manufacturing?+

1 MT pilot; full truck for regular frozen supply. Frozen moves by reefer, and a half-empty vehicle costs the same as a full one. If your volume is under that we can often club your order onto a truck already running to your city, so tell us your delivery city. Lead time is 2 weeks standard, 3-4 weeks for custom formulations.

Does Zippy offer private label soya chaap manufacturing?+

Yes. We have a pilot extruder for developing custom formulations. We can adjust texture, protein content, shape, flavor profile, and packaging format. Current custom products include items developed for a national QSR chain and D2C brands.

Is soya chaap healthy?+

Zippy's HMMA-extruded soya chaap uses no maida, and the base is more than half soya on a dry basis. It is also a source of dietary fibre, contains no artificial preservatives, and is suitable for vegetarian and vegan diets.

What is maida-free soya chaap and why does it matter?+

Maida-free soya chaap is bound with vital wheat gluten and soy protein instead of maida (refined wheat flour). Zippy's chaap contains no maida, and the base is more than half soya on a dry basis. It suits buyers who want a soy-led ingredient list and a fibrous bite that comes from the protein itself.

Who manufactures soya chaap for brands in India?+

Zippy Edibles makes soya chaap for brands as a contract and private-label manufacturer. We supply a national QSR chain, frozen-food brands and retail private labels (see the Clients section on this page for named customers). We offer private label manufacturing with custom formulations, packaging and branding. Our FSSC 22000 certified facility in Rudrapur, Uttarakhand has 10 MT/day HMMA extrusion capacity.

What cooking yield does Zippy HMMA chaap give?+

In our cook test, Zippy chaap gave 97% yield after searing, cooked in about 1 minute and took up about 7% oil. There is no stick to remove and no maida binder. For HoReCa and QSR operators that means more usable product per kg purchased.

How does soya chaap compare to chicken in protein content?+

Zippy's plain HMMA soya chaap rolls carry about 20g of protein per 100g (17g in canned chaap, which is packed in brine); raw chicken breast has around 25g per 100g. Our chaap needs no cold chain in shelf-stable formats, has a 24-month shelf life in retort/canned formats, and is 100% plant-based - which opens up vegetarian and export markets where chicken is excluded.