Techno-Economic Feasibility of Producing High-Protein Tofu from Chickpeas: Process Design and Nutrient Recovery

This study presents a comprehensive assessment of tofu production from whole chickpeas as a plant-based protein alternative for sustainable food systems and humanitarian use. A novel process comprising soaking, wet milling, starch sedimentation, thermal coagulation, and optional drying yielded tofu with 56.2% protein (dry basis). Byproducts, including starch and okara, were also recovered and characterized. Nutrient recovery analysis, relative to seed nutrient content, showed that tofu retained most of the protein (59.1%) and fat (43.2%), okara accounted for the majority of fiber (34.5%) with residual protein (13.5%) and fat (16.7%), while the starch fraction primarily contained net carbohydrates (21.6%). Techno-economic modeling showed that fresh tofu can be produced with minimal inputs and an estimated thermal requirement of 0.798 kWh/kg, while tofu powder required 4.109 kWh/kg; both represent idealized values assuming no heat loss or system inefficiency. Theoretical energy minima were estimated under idealized assumptions, and broader environmental and food security implications are discussed as perspectives. Unlike soy, chickpeas carry a low allergenic risk, which may enhance suitability for population-wide feeding interventions. Broader implications for sustainable development goals (hunger, health, climate action) and humanitarian applications are discussed as perspectives. Chickpea tofu may represent a viable shelf-stable protein platform for local and emergency food systems.