AU626851B2

AU626851B2 - Process for producing shaped food

Info

Publication number: AU626851B2
Application number: AU33692/89A
Authority: AU
Inventors: Naomi Matsuo; Susumu Murata; Masako Sano
Original assignee: Kanebo Ltd
Current assignee: Kanebo Ltd
Priority date: 1989-04-05
Filing date: 1989-04-05
Publication date: 1992-08-13
Anticipated expiration: 2009-04-05
Also published as: AU3369289A; GB2238945B; WO1990011694A1; GB9025235D0; GB2238945A

Description

33692 89

PCT

OPI DATE 05/11/90 AOJP DATE 06/1z/90 APPLN. ID PCT NUMBER PCT/JP89/00367 (51) tgg 'Fp( 4 A23L 1/00, 1/212, 1/31 (11) S WO 90/11694 A23L 1/36, A23G 3/00, 3/30 Al A23P1/10 (43) 199 18 (18.10.1990) (21) lMtWSS-j- POT/JP89/00367 (22) lIl~58l 19894.F5B (05. 04. 89) (71) 0lBA 8JiV A (KANEBO, LTD. )CJP/JP] f131 -&KAlff Efi-BTTBl 7444- Tokyo, (JP) (72) %BJ3: fI i (MURATA, Susumu)CJP/JP3 t569 M.Sffi Ri;Ti 35- 1- 3 02 Osaka, (JP) t&al (MATSUO, Naomi )CJP/JPJ 7569 k rfli3~i -f Tr2-3 7-7 Osaka, (JP) f -ft-f (SANO, Masako)CJP/JP3 :534 KBmia: ERWl -5-4-905 Osaka, (JP) (74) IrA a± ifiEf (SAITOH, Yukihiko) T530 kJifZTkWfiEfMET82T]27-R 0 2 Osaka, (JP) (81) P'i AU, GB, JP BKmt®& (54)Title: PROCESS FOR PRODUCING SHAPED FOOD 5 4 aeo)4 f A 121 0 a M (57) Abstract A process for producing shaped food, which comprises binding processed fcod particles such as corn flakes or wheat flakes to each other with powdery a-starch or high-molecular substance containing an aqueous alcolhol and shaping the mixture into a long, platy form or the like. In the conventional process comprising wetting processed food particles, covering the wetted particles with powdery cereal containing a-starch and heat-drying the covered particles to impart a binding ability to the powder cereal to bind the processed food particles, there has been a problem that the cereal powders bind to each other to form a mass, which penetrates into a part of the shaped food to form spots or the like, thus deteriorating the appearance or taste of the food. In the process of the present invention, a sugar is adhered to the processed food particles before the particles are covered in a wet state with the powdery cereal containing a-starch. This process prevents the cereal powders from binding to each other so that the problem of the poor appearance or bad taste of the processed food due to the binding can be solved.

(57) k i l f t*I L MM U- Fl 8 7< -7 AT 7 ES MG Y& A- A U 7 1, 11 Fl I-I ML 1') BB7FR MR-',E MR1-')Y r GA >YrM BFII-f ty GB 4 1) 7, NL W- BG 1u~)7 GR NO BR 15-V& IT 31 SD CA +;'jpG SE CF 435A -t 1)Yf K SN 4, CGa>r KR*M SU v (111LI 1)1 311 TD D V '7LU &I 9, a 'u SPECIFIC AT I ON Title of the Invention A process for manufacturing olded food Technical Field This invention relates to a process for manufacturing molded food which is formed in a shape like a thin and long plate or stick by adhering granular or chipped processed food such as wheat flakes.

Prior Art Generally molded food molded with a binder such as corn syrup and the like in a shape of a rectangular paralellpiped by drying after steaming cereals such as millet has been so far familiar with as a confection or snack.

As typical examples of this molded food, there are confections called Awaokoshi in Japanese (millet confection), a granola bar and the like. There has been molded food which is formed by drying to puff (120 °C 30 min.) after molding under pressure by putting wheat flakes into a mold and then binding utilizing the puffing characteristics in wheat flakes. However, a product such as millet confection and a granola bar which is produced by adhering with a binder such as sugar or corn syrup as mentioned above causes a defect ll~sI ?s^J /T that since it is hard and fragile to be weak against an impact, when biting to eat, such a product crumbles parts around the bitten part to fall down. Furthermore, it causes a defect that taste of raw material itself does not remain because a large amount of a binder such as sugar or corn syrup is used to thereby add bad smell and sweet taste to the molded food.

The molded food which is formed by drying to puff (120 'C min.) after molding under pressure by putting wheat flakes into a mold is binded by utilizing puffing characteristics in wheat flakes in drying to puff, and since it is not used a binder at all, bindability between flake particles is bad. It causes a big problem that the particles around the bitten part fall off to dirty floor and the like when biting to eat.

To resolve the above-mentioned defects, the inventors found out that pregelatinized cereal(ce-starch) powder(a binder) becomes glutinous in the step of drying with heat, when granular or chipped processed food (hereinafter called particles of processed food") is binded in a good conditon with following steps comprising adding water to particles of processed food to make them in a wet condition, sprinkling the wet particles of processed food with pregelatinized cereal powder containing alcohol added water (alcohol aqueous solution), putting the sprinkled particles of processed food -a -2into a mold and drying it in this state. The above-mentioned improvement has been filed under a Japanese patent application No. 61-261237. With this effect the taste of raw material v can remain, and a binding condition of the particles of processed food each other is improved. Therefore, when eating, the circumstance is not smeared by falling off the particles around the bited part. Since pregelatianized cereal powder has no taste and smell, the taste of raw material itself remains. However, there is another problem that the obtained molded food has bad appearance and taste since it contains parts(spots) consisting of lumps(dama in Japanese) of pregelatinized cereal powder in the case that the molded food is actually mass-produced by applying this method. That is, when wet particles of processed food are sprinkled with pregelatinized cereal powder, said pregelatinized cereal powder treated with alcohol aqueous solution once adhered to the particles of processed food drops off from the particles of processed food with the progress of the mixing and the dropped pregelatinized cereal powder is binded each other to be in a lump-form. The lumps become a component of the composition. Therefore, the resolution of this problem is strongly desired.

Accordingly, it is an object of the invention to provide a process for producing molded food wherein molded food of which the taste of raw material itself remains and the binded 3r r rr 1 -4condition of the particles of processed food is good is produced without deteriorating the taste and appearance.

According to the present invention, the molded food which is free from bad taste and bad appearance based on the lumps of pregelatinized cereal powder, and is made the best use of the taste of its raw material can be obtained.

Disclosure of the Invention To accomplish the above-mentioned object, the present invention provides a process for producing molded food comprising: preparing pregelatinized cereal powder containing alcohol aqueous solution; making granular or chipped processed food in a wet condition by adding water; sprinkling said wet processed food with said pregelatinized cereal powder containing said alcohol aqueous solution; and 20 molding said sprinkled granular or chipped processed food by putting them into a mold and drying, wherein at Sleast one saccharide is adhered in a powdery or solution form with said particles of processed food prior to making them in a wet condition.

25 That is, the inventors made a series of research in order to improve said process for producing molded food Sdeveloped prior to the present invention. The object is to prevent pregelatinized cereal powder containing alcohol aqueous solution from parting from said particles 30 of processed food 920527,EEDAT.031,a:\33692kares,4 S/ 20527,EEDAT.031,a:\33692kan.res,4; i i and from becoming in a lump state by binding each other. As a result, the inventors found out that the pregelanized cereal powder does not part from the particles of processed food when saccharide is adhered in a powdery form or solution form to the particles of processed food before making the particles of processed food wet, and therefore, a phenomenon that the pregelatinized cereal powder each other becomes in a lump-form is not caused to give the molded food in a good condition and completed the present invention. By research of the inventor after that, it is also known clearly that almost the same binding effect is obtained in the case that powder of polymer material such as pullulan, agar-agar, dextrin, gummy matter, alginic acid, sodium alginic acid, carboxy methyl-cellulose, caramel, gelatine, egg white, gluten and the like are used alone or blended instead of said pregelatinized cereal powder containing alcohol aqueous solution. In this case, when saccharide is adhered in a powdery or solution form to the particles of processed food before making them wet, separation of powder of polymer material from said particles of processed food and becoming in a lump state by binding said powder of polymer material each other are prevented to give a molded food in a good condition.

i-d _el= _tj t Y C111 I i i -r rrrman~v* 5a Therefore according to a further embodiment of the present invention there is provided a process for producing molded food comprising: providing a powdery polymer selected from pullulan, agar-agar, dextrin, gummy matter, alginic acid, sodium alginic acid, carboxyl methyl-cellulose, caramel, egg white and gluten; making granular or chipped processed food in a wet condition by adding water; sprinkling said wet processed food with said powdery polymer; and molding said sprinkled granular or chipped processed food by putting them into a mold and drying, wherein at least one saccharide is adhered in a powdery or solution form with said particles of processed food prior to making them in a wet condition.

In the present invention, as a binder, pregelatinized cereal powder containing alcohol aqueous solution and powdery 1 920527,EEDAT.031,a:\33692kan.res,5 -6 polymer material are used. As said pregelatinazed cereal powder, there are gelatinized materials of the iollowings, nonglutinous rice powder, glutinous rice powder, waxy corn starch, potato starch, wheat starch, corn starch and tapioca starch. These may be used alone or blended. As a powdery polymer material, there are poly-saccharaide such as pullulan, agar-agar, dextrin, gummy matter, alginic acid, sodium alginic acid, carboxy methyl-cellulose, caramel and the like and protein powder such as gelatine, egg white, gluten and the like. As said gummy matter there are gum arabic, locust bean gum and the like. These may be also used alone or blended.

The particle size of these binder is normally used at 10 mesh pass in the light of their bindability. Normally these are used !in the range of 5~20 parts by weight per 100 parts by weight of particles of processed food in the light of a balance between their bindability and their taste. 85 vol of ethyl alcohol is preferably used as alcohol aqueous solution contained in said pregelatinized cereal powder. In this case, the water content of alcohol aqueous solution influences to a bindability of pregelatianized cereal powder. The water S, content in the range of 2~40 vol is preferable. As particles of processed food which are a main component of the molded food according to the present invention, there are corn flakes, wheat flakes, instant noodle chips, nuts, dried vegetables, dried processed vegetables, dried fruits, dried processed fruits, dried meat, dried processed meat, dried C f rfishes, dried processed fishes and confections and the like.

As said confections, there are candies, puffed confections such as popcorn, Achewing gum, baked confections, bean confections, processed chocolate such as chocolate chips, and they are used alone or blended. In the present invention, a large amount of one kind selected from above-mentioned particles of processed food is used as a main component and a small amount of another kind as a sub-component is added and dispersed therein. As saccharide which is adhered to the particles of processed food before making them wet, there are sugar (white superior sugar, granulated sugar), powdered corn syrup, glucose, fructose, and maltose, and they are used alone or blended. These saccharides are normally used in a powdery form, but it may be used in a solution form by adding water. From a view of preventing a binder of prcgelatinized cereal powder from becoming in a lump state, sugar is preferably used as saccharide. But if a large amount of these saccharides is used, the taste of the particles of .\o'rrYc\\lj processed food themselves is deteriorated. Therefore,Ait is set in the range of 2 ~40 parts by weight (in the case of liquid form saccharide such as corn syrup, it is set on the basis of solid part) per 100 parts by weight of particles of processed food.

In the present invention, the molded food is, for example, produced using above-mentioned materials as follows.

4,1 M -7o Iu rM- 9~.

At first, powdery sugar is added to the particles of processed food such as corn flakes, wheat flakes and the like and mixed to make it adhere enough thereto. On the other hand, alcohol aqueous solution such as ethyl alcohol is added to pregelatinized cereal powder such as kambaiko in Japanese (powder of gelatinized glutinous rice) and mixed to give pregelatinized cereal powder containing alcohol aqueous solution. Next the particles of processed food adhered with powdery sugar are mixed with pouring water to make in a wet condition. Thus the required state where said pregelatinized cereal powder is adhered to whole of the particles of processed food uniformly and it is hard for the particles to part is prepared. Then said pregelatinized cereal powder is added to the wet particles of processed food and mixed sufficiently to sprinkle the particles of processed food with said pregelatinized cereal powder. The reason why alcohol aqueous solution is contained into the pregelatinized cereal powder is because the kambaiko absorbs water rapidly to be in a glutinous state when only water is added to the kambaiko.

The kambaiko does not bind in such a state. On the contrary, when alcohol aqueous solution is used, becoming in a glutinous state of the kambaiko rapidly is prevented by the action of alcohol and the binding action is given. To describe in detail, since water is contained in alcohol aqueous solution, when the alcohol aqueous solution is soaked into the kambaiko, -8-

F:

alcoh.ol and water are soaked into the kambaiko. As a result, the glutinous state of kambaiko is not caused by water contained in the alcohol aqueous solution while alcohol exists, but caused by water left after evaporating alcohol.

Therefore, such kambaiko containing alcohol aqueous solution is mixed with said particles of processed food in a wet condition, the mixture is molded and then dried to thereby evaporate alcohol in alcohol aqueous solution and leave water in the kambaiko. Consequently the kambaiko becomes in a glutinous state, so that said particles of processed food are binded well. In this case, the glutinous state of kambaiko is not caused at the step of molding but caused at the step of drying. In the step, the kambaiko is mixed with said particles of processed food in a wet condition uniformly, and a binding action is given in the state. Therefore, a fine binding effect is obtained with a small amount of kambaiko.

Generally said molding is done by a molding machine. At this time, it is preferable that the molding is done by compress on molding and said particles of processed food themselves are adhered closely with pregelatinized cereal powder containing alcohol aqueous solution. Drying after molding is done in a state that said particles of processed food are in a mold or they are taken out of a mold. In this case, drying by hot air is normally done, but when the particles of processed food which are melted and deformed by

I

7 1 -c, 1 ~j ;i i heat are used, ventilation drying or natural drying is applied.

In thus obtained molded food, the taste of its raw material remains since pregelatinized cereal powder without strange taste and smell is used as a binder. When eating, the particles of processed food are not crumbled since they are binded tightly each other by a binding action which said pregelatinized cereal powder provides. Furthermore, in manufacturing the above mentioned molded food, the operation of adhering particles of processed food with powdery sugar is conducted prior to making the particles of processed food in a wet condition. Said pregelatinized cereal powder which once adhered to the particles of processed food in sprinkling process does not part from the particles. Therefore a phenomenon the parted pregelatinized cereal powder is binded each other to be in a lump form with the progress of mixing with sprinkling does not occur. Therefore, the appearance and taste of the product does not deteriorate.

In the above manufacturing process, powdered pregelatinized cereals involved the alcohol aqueous solution is used as a binder. The powdered polymer material mentioned above may be used instead of this since the same effect is obtained. In this case, since the above powdered polymer material does not become in a glutinous state like powdered pregelatinized cereals, it does not require alcohol aqueous 0- 'I 1 0

I

solution. Flakes and the like are used as the particles of processed food in the above process. But the use of instant noodle chips as the main material is effective. That is, in this case, the pregelatinized cereal powder as a binder fastly dissolves and noodle chips separate in a moment with mere pouring boiling water to the molded food. Thereby, the above noodle chips can be eaten in a condition that they are puffed and softened with hot water similarly to ordinary instant noodle.

As mentioned above, in this invention as a form of granular or chipped form of processed food, a line form like instant noodle chips is included. And pregelatinized cereal powder used as the binder includes not only the material which is obtained by pregelatinizing powdered cereals such as gluti-"ous rice powder or nonglutinous rice powder but also special pregelatinized cereal powder prepared by adding to mixture of water and alcohol to a pregelatinized material and drying.

That is, since the water permeability of this special pregelatinized cereal powder is controlled by a treatment of the mixture of water and alcohol, rapid expanding by absorbing water does not occur at the time of adding water.

Therefore, it is hard for this special pregelatinized cereal powder to bind each other and become in a lump form at the time of wet. It has good affinity to the particles of

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l processed food. Further, in the above manufacturing process the molding process comprises filling the material to the mold and removing, but it may be conducted by a roller pressure method. In this case, the press roller of the machine used is a mold. And as to the method for drying, a freeze dry method, a microwave method and the like besides the hot air drying may be selected appropriately.

As mentioned above, when molded food is manufactured with the present invention, a phenomenon which gelatinized cereal powder having alcohol aqueous solution or powdered polymer material used as a binder binds each other in manufacturing process to become in a lump form and the lumps are contained in the molded food to form spots does not occur. Therefore, the molded food of which the appearance is good and the taste is not deteriorated by the lumps of the binder, pregelatinized cereal powder can be manufactured. The above pregelatinized cereal powder and powdered polymer material are almost tasteless and odorless, and further the amount of saccharide which is coated to the particles of processed food for preventing the binder from becoming in a lump form is small, therefore the taste of particles of processed food can remain.

Brief Description of the Drawing Fig. 1 is an explanative drawing shown a manufacturing T -12- NT j 9/ i ii condition of an example in the present invention; Fig. 2 is a perspective view of the molded food which is manufactured in the above process.

Preferable Embodiments Next, the present invention is explained based on Examples.

[Example 1 100 parts by weight (pbw) of wheat flakes, 10 pbw of dried corn, 5 pbw of dried wakame (seaweed) and 10 pbw of dried carrot are mixed, and then to this mixture 10 pbw of the powdery sugar (white superior sugar) is added and mixed.

Next, 10 pbw of water is added to this mixture and mixed.

Otherwise, by adding 15 pbw of 85% ethyl alcohol solution to pbw of kambaiko and mixing them, kambaiko containing the alcohol aqueous solution is prepared. Next this kambaiko is mixed with the above mixture (wet condition by adding the water), as shown in Fig. 1, the mixture (10) is filled in a molding machine and is compression-molded. Next, this is dried by hot air in a mold (90"C, 15min.), and then is removed from the mold to manufacture a molded food shown in Fig. 2. This molded food has no lump of kambaiko and it looks well and the taste thereof is good. The taste obtained in the condition that the binder is dissolved and flakes are separated each other by adding the milk to the molded food is -13- 3 L i ii also good.

Example 2 pbw of dried small fish (sardine, flatfish and the like), 200 pbw of crisp, 50 pbw of almond, 1 pbw of vitamine powder B, C, D etc.) and 10 pbw of dried wakame are mixed, and 30 pbw of powdered corn syrup is added and mixed. Next, pbw of water is added to this mixture and mixed.

Otherwise, kambaiko containing alcohol aqueous solution is prepared by adding 15 pbw of 85% ethyl alcohol to 30 pbw of kambaiko. This kambaiko is added to the above mixture and well mixed, and then the mixture is filled into a mold and dried by hot air at 90°c (15 min.) in that state, and removed.

Thus the molded food which has the effect same as enrichment is manufactured. This molded food has good taste and is soft and pleasant to the tongue without any lumps of kambaiko.

Example 3 pbw of powdered granular sugar is added to 300 pbw of popcorn and mixed, further 30 pbw of water is added thereto and mixed. Otherwise, kambaiko containing water is prepared by adding 15 pbw of 85 vol ethyl alcohol to 30 pbw of kambaiko. This kambaiko is added to the above mixture and mixed, and then the mixture is filled into the mold and dried by hot air at 90°C (15 min.) in that state, and removed from -14- 1?L the mold.

Thereby, the molded food which is binded popcorn with a binder, kambaiko is obtained. This molded food has no lump of kambaiko and the taste of popcorn used therein remains to make the molded food with a good taste. And as well as the molded food shown in Example 2, taste of the binder and roughness to the tongue by the binder are not felt at all.

If puffed rice or Chinese noodle chips added some taste instead of popcorn is used, the same molded food which is binded popcorn with the binder is obtained.

Comparison Adding powdered sugar to particles of the processed food prior to making them wet is not conducted. Except this, with the same process as in Example 1 the molded food is manufactured. In this food, some lumps of kambaiko are dotted, and white spots are found partially. It looks no good and the taste thereof is deteriorated by the lumps.

Example 4 300 pbw of crisp, 50 pbw of almond nuts, 20 pbw of peanuts are mixed and further 35 p.bw of powdered sugar (white superior sugar) is mixed. Next, 50 pbw of water is added to this mixture and mixed well to make it wet. After this, the same process as in Example 1 are conducted and the same molded 1 food is manufactured. In this molded food, no lump of kambaiko is found, and the taste of almond remains enough and the taste is soft and pleasant to the tongue.

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Claims

1. A process for producing molded food comprising: preparing pregelatinized cereal powder containing alcohol aqueous solution; making granular or chipped processed food in a wet condition by adding water; sprinkling said wet processed food with said aqueous solution; and molding said sprinkled granular or chipped processed food by putting them into a mold and drying, wherein at least one saccharide is adhered in a powdery or solution form with said particles of processed food prior to making them in a wet condition.

2. A process for producing molded food comprising: providing a powdery polymer selected from pullulan, agar-agar, dextrin, gummy matter, alginic acid, sodium alginic acid, carboxyl methyl-cellulose, caramel, egg white and gluten; making granular or chipped processed food in a wet condition by adding water; sprinkling said wet processed food with said powdery S. 25 polymer; and molding said sprinkled granular or chipped processed food by putting them into a mold and drying, wherein at *least one saccharide is adhered in a powdery or solution form with said particles of processed food prior to S• 30 making them in a wet condition.

3. A process for producing a molded food according to claim 1 or claim 2, wherein said granular or chipped processed food is at least one kind of granular or chipped processed food selected from a group comprising corn flakes, wheat flakes, instant noodle chips, nuts, dried vegetables, dried processed vegetables, dried 920527,EEDAT.031,a:\33692kan.res,17 1 T Nt 'To 18 fruits, dried processed fruits, dried meat, dried processed meat, dried fishes, dried processed fishes, and confections.

4. A process for producing molded food according to claim 3, wherein the confection is at least one kind of confection selected from candy, puffed confection, chewing gum, baked confection, bean confection and processed chocolate.

A process for producing molded food according to claim 1, wherein the pregelatinized cereal powder is at least one kind of pregelatinized cereal powder selected from gelatinized material of followings, glutinous rice powder, nonglutinous rice powder, waxy corn starch, potato starch, wheat starch, corn starch and tapioca starch.

6. A process for producing molded food according to any one of claims 1 to 5, wherein the drying in drying step is done by any of a hot air drying process or a microwave :drying process.

7. A process as claimed in claim 1 or claim 2 25 substantially as hereinbefore described with reference to any one of the examples other than the comparative examples. DATED this 27th day of May, 1992. KANEBO, LTD. e. By Its Patent Attorneys DAVIES COLLISON CAVE 920527,EEDAT.031,a:\33692kanres,18 SWTO Abstract The present invention relates to a process for producing a molded food which particles of processed food such as corn flakes, wheat flakes are binded with pregelatinized cereal powder containing alcohol aqueous solution or powdery polymer material to mold them in a shape such as thin and long plate and the like. In the case that particles of processed food are made in a wet condition, said wet particles are sprinkled with pregelatinized cereal powder, and dried with heating to mold the particles of processed food by making the pregelatinized cereal powder as a binder, the appearance and taste are deteriorated since pregelatinized cereal powder itself is binded each other to be in a lump state and the lumps a.re contained in the molded food to become spots. In this invention, particles of processed food are adhered with saccharide previously, then they are made in a wet condition and sprinkled with pregelatinized cereal powder. Thus binding of pregelatinized cereal powder itself each other is not caused and the problem that deterioration of appearance and taste is caused by the lumps is solved. 1 9 -i