Zippy Edibles
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Soya Chaap

Zippy Edibles' state-of-the-art facility in Rudrapur, Uttarakhand commissioned in 2023, sets a new standard for soya chaap. Our pioneering No maida Soya Chaap is crafted using an advanced high moisture extrusion process, offering a juicy and tender culinary experience. Enjoy high protein, quick cooking, and unmatched consistency in every bite. Now available in shelf stable cans and retort pack as well.

Our Offerings

Shelf Stable

  • 1.

    Canned Soya Chaap

    Canned Soya Chaap

  • 2.

    Plain Soya Chaap (Retort Pouch)

    Plain Soya Chaap (Retort Pouch)

  • 3.

    Marinated Chaap Soya Chaap (Retort Pouch)

    Marinated Chaap Soya Chaap (Retort Pouch)

Frozen

  • 1.

    Plain Soya Chaap

    Plain Soya Chaap

  • 2.

    Marinated Soya Chaap

    Marinated Soya Chaap

  • 3.

    Soya Chaap Strips

    Soya Chaap Strips

  • 4.

    Soya Chaap Chunks

    Soya Chaap Chunks

How It's Made

1

Soy Protein Preparation

High-quality defatted soy flour is precision-mixed with water and natural ingredients. No maida or refined flour is used - our formulation uses 50%+ soy protein flour on a dry basis, the highest in the Indian industry.

2

HMMA Extrusion

The mixture enters our Coperion ZSK 54 twin-screw extruder from Germany. High moisture, high shear, and controlled temperature create a fibrous, meat-like texture - fundamentally different from traditional chaap made by hand-wrapping soy around sticks.

3

Downstream Forming

Our proprietary downstream line (designed and built in-house) shapes the extrudate into rolls, strips, chunks, or custom forms. The hollow-core design replaces the traditional wooden stick, allowing better marinade penetration.

4

Marination & Flavoring

Products are marinated using vacuum tumblers for deep, even flavor absorption. Multiple flavor profiles available including tandoori, achari, malai, and custom formulations for QSR chains.

5

Freezing or Retort Packaging

Frozen products go through spiral and blast freezers with ammonia refrigeration for rapid, uniform freezing. Shelf-stable products are packed in retort pouches or cans with 24-month shelf life - no cold chain needed.

Technical Specifications

HMMA ExtruderCoperion ZSK 54 twin-screw (Germany)
Extrusion Capacity10 MT/day
Frozen RTC Capacity15 MT/day
MarinationVacuum tumbler + industrial ovens
AutomationFully automated, hands-free chaap line
Soy Protein Content>50% soy protein flour on dry basis (maida-free)
Shelf-Stable FormatsRetort pouch and canned (24-month shelf life)
Cold Storage300 MT frozen storage capacity
FreezingSpiral & blast freezers, ammonia refrigeration
MOQ1 MT standard, pilot trials available
Lead Time1-2 weeks standard, 3-4 weeks custom
CertificationsFSSC 22000, FSSAI Licensed

Why Choose Zippy for Soya Chaap

India's Most Advanced Technology

Operating one of India's most advanced HMMA extrusion lines (Coperion ZSK 54 from Germany). Industrial-grade consistency that QSR chains demand.

Zero Maida, Maximum Protein

Our proprietary formulation uses no refined flour. Over 50% soy protein flour on dry basis - the highest in the Indian soya chaap market.

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 leading QSR chains, major retail brands, and D2C brands. Batch-to-batch consistency at 10+ MT/day.

Zippy vs Traditional Chaap

See the difference that HMMA extrusion technology makes

Zippy HMMA Chaap vs Traditional Manual Chaap - side by side comparison showing fibrous texture, 100% yield, and clean label advantages

The Economics of TexPro Chaap

HoReCa Cost Advantage - Why kitchens are switching

MetricZippy TexPro ChaapFresh ChaapFrozen Branded
Yield After Frying97%57%61%
Frying Time1 minute5 minutes5 minutes
Oil Absorption7%20%20%
Oil CostRs 10/kgRs 28/kgRs 28/kg

60% more yield and Rs 18/kg oil savings with Zippy TexPro Chaap on fried product

Frequently Asked Questions

How is Zippy's soya chaap different from traditional chaap?+
Traditional soya chaap is made by hand-wrapping soy dough around wooden sticks - a manual, inconsistent process that relies on maida (refined flour) as a binder. Zippy uses HMMA (High-Moisture Meat Analog) extrusion with a Coperion ZSK 54 twin-screw extruder. This creates a naturally fibrous, meat-like texture with zero maida and over 50% soy protein flour on dry basis. The result is more consistent, higher in protein, and scalable for industrial volumes.
What is HMMA extrusion and why does it matter?+
HMMA stands for High-Moisture Meat Analog - an advanced extrusion process that creates realistic meat-like textures from plant proteins. Unlike dry extrusion (TVP/soy chunks), HMMA produces a layered, fibrous structure similar to real meat. Zippy operates one of India's most advanced HMMA extrusion lines, using a Coperion ZSK 54 from Germany. This technology is what leading QSR chains require for consistent quality at scale.
Can Zippy supply shelf-stable soya chaap for export?+
Yes. We offer both retort pouch and canned formats with 24-month ambient shelf life - no cold chain required. This makes export logistics significantly simpler and cheaper. Current export markets include South Africa, UAE, and Egypt. Our FSSC 22000 certification meets international food safety requirements.
What is the MOQ and lead time for soya chaap orders?+
Standard products: 1 MT minimum order, 1-2 week lead time. Custom formulations (flavors, shapes, private label): 5 MT minimum, 3-4 week lead time. Pilot trials are available for smaller quantities to validate the product before committing to full orders.
Can you develop custom soya chaap products for our brand?+
Yes. We have a dedicated R&D kitchen and pilot extruder for developing custom formulations. We can adjust texture, protein content, shape, flavor profile, and packaging format. Current custom products include items developed specifically for leading QSR chains and major retail brands. Development timeline is typically 4-8 weeks.

Ready to Get Started?

Whether you need bulk supply, custom formulations, or private label packaging, we can help. Pilot trials available.

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