JP2004305149A - Method for producing food containing solid ingredient - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a food containing a solid ingredient and easily sterilizable without deteriorating the palatability and taste of the solid ingredient. <P>SOLUTION: The food containing a solid ingredient is produced by a step to fill a solid ingredient necessitating a long time for sterilization and the remaining solid ingredient in separate vessels, a step to separately sterilize the solid ingredient taking long time for sterilization and the remaining solid ingredient and filled in separate vessels by direct steam sterilization, a step to combine the sterilized solid ingredient taking long sterilization time with the remaining solid ingredient in a sterilized vessel in aseptic state, and optionally a step to add a sterilized seasoning liquid to the product in aseptic state. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【００３７】
表１中、殺菌値Ｆｏ値が１２分に達するまでに２分間より長い殺菌を必要とするものを長殺菌時間固形具材、２分間以下の殺菌で殺菌値Ｆｏ値が１２分に達するものを短時間殺菌固形具材と分類することができる。
【００３８】
実施例２
実施例１で使用した各固形具材について、一定時間殺菌温度１３５℃を保持した場合における固形具材の食感、風味の熱劣化度合いを調べた。
【００３９】
実施例１において、長殺菌時間固形具材中、殺菌値Ｆ_０値が１２分以上に達する時間が最も長いのは、「ジャガイモ（２０ｍｍのさいの目切り）」と「豆腐（２０ｍｍのさいの目切り）」の６分である。また、短時間殺菌固形具材中、殺菌値Ｆ_０値が１２分以上に達する時間が最も長いのは「イカ（１５ｍｍ巾のぶつ切り）」の２分であった。
【００４０】
このため、実施例２では、短時間殺菌固形具材が全て殺菌値Ｆ_０値が１２分以上に達した時間である２分、長殺菌時間固形具材が全て殺菌値Ｆ_０値が１２分以上に達した時間である６分、および６分よりさらに２分長い８分の殺菌時間後における固形具材の食感を、実施例１で求めた殺菌時間で殺菌した固形具材の食感、風味を対照として比較評価した。なお、直接蒸気殺菌の方法は実施例１と同様とした。
評価結果を表２に記載した。
【００４１】
【表２】

【００４２】
表２に示した結果より、２分間の殺菌後は、短殺菌時間固形具材および長殺菌時間固形具材のいずれも、対照と比較して、ほとんどが同様の食感、風味を保っている（「△」（許容範囲）となっている白菜およびごぼうは、特に歯ごたえが重要視されるため、やや食感、風味が劣化したとの結果が出たものと考えられる）。６分間の殺菌後、短殺菌時間固形具材はいずれ熱劣化が大きく、本来の食感を失っていた。このことから、短殺菌時間固形具材および長殺菌時間固形具材を同時に直接蒸気殺菌した場合は、短殺菌時間固形具材の食感、風味が損われることが明らかである。これに対して長殺菌時間固形具材は、６分間の殺菌後も、対照と比較して、鶏肉（２０ｍｍ角のぶつ切り）が許容範囲となった他は、同様の食感、風味を保っている。しかし、８分間の殺菌後、牛肉（２０ｍｍ角のぶつ切り）およびホタテ貝柱（直径３０ｍｍそのまま）の食感が（許容範囲ではあるが）熱劣化し、鶏肉（２０ｍｍ角のぶつ切り）と併せて、長殺菌時間固形具材中のすべての肉類、魚介類の食感、風味が熱劣化した。したがって、長殺菌時間固形具材について直接蒸気殺菌により第一次殺菌を行った後、短殺菌時間固形具材を加えて、先に殺菌した長殺菌時間固形具材と共に直接蒸気殺菌により第二次殺菌を行うという二段階の殺菌工程により直接蒸気殺菌を行う方法を用いた場合についても、特に肉類、魚介類について、やや固形具材の熱劣化があることが明らかになった。
【００４３】
実施例３
１．以下の方法で、シーフードカレーの常温保管可能な包装食品を製造した。固形具材としては、ジャガイモ、タマネギ、ニンジン、牛肉、イカを使用した。
ジャガイモ ２０ｍｍのさいの目切り ５００ｇ
ニンジン ２０ｍｍのさいの目切り ２００ｇ
タマネギ ３ｍｍ厚の薄切り １００ｇ
牛肉 ２０ｍｍ角のぶつ切り ２００ｇ
イカ １５ｍｍ巾のぶつ切り ２００ｇ
ホタテ貝柱 直径３ｃｍそのまま ３００ｇ
【００４４】
ジャガイモ、ニンジンおよびタマネギは熱耐性を高めるため、６０℃の０．０７％の乳酸カルシウム液に２時間浸漬したのち、水洗した。イカおよびホタテ貝柱は、アクを除去するため、沸騰水中で２分間ボイルした。また、調味液は市販のカレールーを湯で希釈したものを使用した。鍋に植物油をひき、牛肉表面の赤身がなくなるまで軽くいためた後、残りの固形具材を入れ、タマネギが褐色に変わるまで炒めた。その後、調味液１０００ｍｌを入れ、一度沸騰するまで煮込んだ後、約１０℃の冷蔵庫内で約１２時間保存し、その後、固形具材と調味液を分けた。
【００４５】
次に直径１０ｃｍ、深さ５ｃｍの円筒形で、底面に直径６ｍｍの穴をほぼ均等の間隔で１９個設けた上方開放型のポリプロピレン製の殺菌容器に、上記処理を行った固形具材を各５０ｇずつ入れ、固形具材の測定部分に殺菌値Ｆｏ値測定用のセンサーを差し込み、株式会社日阪製作所製の短時間調理殺菌試験機ＲＩＣ−１５Ｔに入れ、以下の手順により固形具材毎に直接蒸気殺菌を行った。
【００４６】
まず、各固形具材を入れた殺菌容器を短時間調理殺菌試験機の釜に入れて密閉した後、約２分間かけて、脱気した。その後、雰囲気温度を１３５℃に設定し、蒸気を殺菌装置の釜の中に導入した。雰囲気温度が１３５℃に達してから１５秒ごとに殺菌値Ｆｏ値を計測し、殺菌値Ｆｏ値が１２分を超えるまでの殺菌時間を求めた。
【００４７】
その結果、殺菌値Ｆｏ値が１２分を超えるまでの殺菌時間は、ジャガイモが６分、ニンジンが５分、タマネギが４５秒、牛肉が４分４５秒、イカが２分、ホタテ貝柱が３分１５秒であった。
【００４８】
この結果より、ジャガイモ、ニンジン、牛肉、ホタテ貝柱を長殺菌時間固形具材として、タマネギ、イカを短殺菌時間固形具材として分類した。
【００４９】
２．次に実際に食品として用いる固形具材を準備し、試験区毎に以下の処理を行った。
Ａ試験区：
長殺菌時間固形具材であるジャガイモ５０ｇ、ニンジンを２０ｇ、牛肉２０ｇ、ホタテ貝柱３０ｇを殺菌容器に充填し、株式会社日阪製作所製の短時間調理殺菌試験機ＲＩＣ−１５Ｔの釜に入れ、雰囲気温度１３５℃で６分間の直接蒸気殺菌を行った。その後、釜内の圧力を常圧に戻し、減圧して、２分間の真空冷却を行った。試験機の釜内の温度が４０℃以下になってから、固形具材が充填された殺菌容器を試験機より無菌的にクリーンベンチに取り出した。
【００５０】
次に短殺菌時間固形具材であるタマネギ１０ｇ、イカ２０ｇを、上記とは別の殺菌容器に充填し、短時間調理殺菌試験機ＲＩＣ−１５Ｔの釜に入れ、雰囲気温度１３５℃で２分間の直接蒸気殺菌を行った後、上記同様に減圧、真空冷却を行った後、固形具材が充填された殺菌容器を試験機より無菌的にクリーンベンチに取り出した。
【００５１】
直接蒸気殺菌が終了した長殺菌時間固形具材および短殺菌時間固形具材を、クリーンベンチ内で、あらかじめガス殺菌したＰＥＴ／ＡＬ／ＣＰＰの構成のラミネートパウチに組み合わせて充填した。次いで、予めチューブ式熱殺菌機により加熱殺菌した調味液１００ｍｌを無菌的に充填し、脱気した後、密封した。
【００５２】
Ｂ試験区：
ジャガイモ５０ｇ、ニンジンを２０ｇ、牛肉２０ｇ、ホタテ貝柱３０ｇを殺菌容器に充填し、株式会社日阪製作所製の短時間調理殺菌試験機ＲＩＣ−１５Ｔの釜に入れ、雰囲気温度１３５℃で６分間の直接蒸気殺菌を行った後、同じ殺菌容器にさらにタマネギ１０ｇ、イカ２０ｇを充填し、先に殺菌したジャガイモ等と共にさらに２分間直接蒸気殺菌を行った。上記同様に減圧、真空冷却を行った後、固形具材が充填された殺菌容器を試験機より無菌的にクリーンベンチに取り出し、固形具材をあらかじめガス殺菌された上記構成のラミネートパウチに無菌的に充填した。次いで、上記同様に加熱殺菌した調味液１００ｍｌを無菌的に充填し、脱気した後、密封した。
【００５３】
Ｃ試験区：
ジャガイモ５０ｇ、ニンジンを２０ｇ、牛肉２０ｇ、ホタテ貝柱３０ｇ、タマネギ１０ｇおよびイカ２０ｇを全て同じ殺菌容器に加え、６分間の直接蒸気殺菌を行った。上記同様に減圧、真空冷却を行った後、固形具材が充填された殺菌容器を試験機より無菌的にクリーンベンチに取り出し、固形具材をあらかじめガス殺菌された上記構成のラミネートパウチに無菌的に充填した。次いで、上記同様に加熱殺菌した調味液１００ｍｌを無菌的に充填し、脱気した後、密封した。
【００５４】
Ｄ試験区：
ジャガイモ５０ｇ、ニンジンを２０ｇ、牛肉２０ｇ、ホタテ貝柱３０ｇと、タマネギ１０ｇ、イカ２０ｇとを、別々に上記構成のラミネートパウチに充填し、上記同様に加熱殺菌した調味液５０ｍｌをそれぞれのラミネートパウチに加えて脱気密封した。ジャガイモ等の長殺菌時間固形具材が充填されたラミネートパウチについて、ジャガイモの測定部分の殺菌値Ｆｏ値が１２分になるまで雰囲気温度１２０℃で、また、タマネギ等の短殺菌時間固形具材が充填されたラミネートパウチについて、イカの測定部分の殺菌値Ｆｏ値が１２分になるまで雰囲気温度１２０℃で、レトルト殺菌を行った。殺菌後、両者をクリーンベンチに取り出し、無菌的に別の滅菌済みラミネートパウチ内で組み合わせて充填、混合した。
【００５５】
Ｅ試験区：
ジャガイモ５０ｇ、ニンジンを２０ｇ、牛肉２０ｇ、ホタテ貝柱３０ｇと調味液５０ｍｌとを上記構成のラミネートパウチに充填して脱気密封し、ジャガイモの測定部分の殺菌値Ｆｏ値が１２分となるまで雰囲気温度１２０℃でレトルト殺菌を行った後、このラミネートパウチを開封し、タマネギ１０ｇ、イカ２０ｇと調味液５０ｍｌをさらに充填して脱気密封し、イカの測定部分の殺菌値Ｆｏ値が１２分となるまで雰囲気温度１２０℃で再度レトルト殺菌を行った。
【００５６】
Ｆ試験区：
ジャガイモ５０ｇ、ニンジンを２０ｇ、牛肉２０ｇ、ホタテ貝柱３０ｇ、タマネギ１０ｇ、イカ２０ｇと調味液１００ｍｌとを上記構成のラミネートパウチに充填し、ジャガイモの測定部分の殺菌値Ｆｏ値が１２分になるまでレトルト殺菌を行った。
【００５７】
３．結果
Ａ〜Ｆ試験区の各サンプルを、それぞれ２週間、３５℃で保管した結果、すべてのサンプルについて微生物の増殖は認められなかった。
【００５８】
Ａ〜Ｆ試験区の各サンプルを沸騰水中で５分間加熱した後、各固形具材の食感、風味について、実施例１で求めた殺菌時間で殺菌した場合の各固形具材の食感、風味を対照として比較評価した。
評価基準は下記の通りとした。
◎：対照と比較し、同等
○：対照と比較し、ほぼ同等
△：対照と比較し、差があるが許容範囲
×：対照と比較し、差があり、好ましくない
結果を表３に示す。
【００５９】
【表３】

【００６０】
表３に示した結果より、固形具材の食感、風味について、最も熱劣化が少ないのはＡ試験区であった。すなわち、長殺菌時間固形具材と短殺菌時間固形具材とを別々に直接蒸気殺菌を行うことで、商業的無菌を達成した後も固形具材本来の食感を維持させ、食感、風味の優れた、美味しい固形具材入り食品を提供できることがわかった。
【００６１】
実施例４
実際のすき焼きのメニューと同じように固形具材の組み合わせを設定し、殺菌方法の違いによる固形具材の食感、風味を検討した。
【００６２】
Ａ試験区：
全固形具材の中で、最も殺菌時間が長くかかる固形具材に合わせて殺菌時間を決定し、実施例３で用いた殺菌容器を用いて、実施例３と同様の方法で、すべての固形具材を同時に直接蒸気殺菌した。
【００６３】
Ｂ試験区：
殺菌時間が２分より長い長殺菌時間固形具材を選択して、そのうち最も殺菌時間が長くかかる固形具材に合わせて殺菌時間を決定し、実施例３で用いた殺菌容器を用いて、実施例３と同様の方法で直接蒸気殺菌を行った。次に２分以下で殺菌できる短殺菌時間固形具材を別の殺菌容器に充填して、最も殺菌時間のかかる固形具材の殺菌時間に合わせて直接蒸気殺菌を行った。直接蒸気殺菌が終了した後、長殺菌時間固形具材と短殺菌時間固形具材とを組み合わせて混合した。
【００６４】
結果：
Ａ試験区およびＢ試験区の固形具材の食感、風味を固形具材毎に評価した。

【００６５】
この結果、Ａ試験区では、豆腐、しらたき、しいたけ以外の固形具材の食感、風味は著しく劣化した。ねぎは著しく軟化し、牛肉はぼそぼそした食感となり、箸では掴めない状態に熱劣化した。Ｂ試験区では、固形具材はいずれもそれぞれ特有の食感、風味を保っていた。
【００６６】
実施例５
実施例４と同様の方法により、寄せ鍋を想定して、殺菌方法の違いによる固形具材の食感、風味を検討した。

【００６７】
この結果、Ａ試験区では、豆腐、たらの食感、風味は維持され、鶏肉の食感、風味はやや劣化した。また、イカは弾力を失い、白菜とごぼうは食感が著しく劣化した。一方、Ｂ試験区の豆腐および鶏肉の食感、風味はＡ試験区と同等であったが、イカは特有の食感を保っており、白菜、ごぼうはやや劣化しているものの、固形具材本来の特有の食感、風味を保っていた。
【００６８】
実施例４および５で製造した食品を１０パック作成し、２週間、３５℃で２週間保管したところ、いずれのパックにおいても微生物の増殖は認められなかった。
【００６９】
実施例６
図１に示すような内容器２０と、該内容器を収納する外容器３０から形成される一体型容器１０を用いて、本発明の方法により肉じゃがを製造した。内容器２０として、直径７０ｍｍ、深さ７５ｍｍの円筒形で底面に直径６ｍｍの穴をほぼ均等の間隔で１９個設けた、上方開放型のポリプロピレン性の容器を用いた。
【００７０】
肉じゃがは以下の固形具材を用いて作成した。
固形具材：
ジャガイモ ２０ｍｍ厚のさいの目切り ７０ｇ
ニンジン ２０ｍｍ角のさいの目切り ２０ｇ
タマネギ ３ｍｍ厚の薄切り ２０ｇ
牛肉 ２ｍｍ角の薄切り ２０ｇ
【００７１】
ニンジン、ジャガイモ、タマネギは熱耐性を高めるため、６０℃の０．０７％の乳酸カルシウム液に２時間浸漬した後、水洗いした。調味液は酒１５０ｍｌ、水１５０ｍｌ、砂糖４０ｇ、しょうゆ１５０ｍｌの割合で混合し、一度煮立てて作成した。鍋に植物油をひき、牛肉を軽く炒めた後、調味液１３０ｍｌを入れ、次いで残りの固形具材を入れた。一度沸騰するまで煮込んだ後、約１０℃の冷蔵庫内で約１２時間静置して、固形具材に調味液を浸漬させ、その後、固形具材と調味液を分けた。
【００７２】
実施例１と同様の方法により、各固形具材について、殺菌値Ｆｏ値が１２分を超えるまでの殺菌時間を求めた。その結果、殺菌値Ｆｏ値が１２分を超えるまでの殺菌時間は、ジャガイモが６分、ニンジンが５分、タマネギが４５秒、牛肉が３０秒であった。この結果より、ジャガイモおよびニンジンを長殺菌時間固形具材として、タマネギおよび牛肉を短殺菌時間固形具材として分類した。
【００７３】
上記耐熱処理を施したジャガイモおよびニンジンを、それぞれ上記の重量を計量して内容器２０に充填した。また、タマネギ、牛肉については、内容器２０と同形状でサイズがやや小さい、直径７０ｍｍ、深さ３５ｍｍの円筒形で底面に直径６ｍｍの穴をほぼ均等の間隔で１９個設けた上方開放型のポリプロピレン製内容器に充填した。
【００７４】
実施例５と同様に、株式会社日阪製作所製の短時間調理殺菌試験機ＲＩＣ−１５Ｔに内容器を入れて、順に直接蒸気殺菌を行った。ジャガイモおよびニンジンは、雰囲気温度１３５℃で６分間、タマネギおよび牛肉は、雰囲気温度１３５℃で４５秒間、直接蒸気殺菌を行った。直接蒸気殺菌が終了した長殺菌時間固形具材および短殺菌時間固形具材を、殺菌が終了した順にクリーンベンチ内に内容器ごと無菌的に取り出し、クリーンベンチ内で短殺菌時間固形具材を長殺菌時間固形具材が充填された内容器２０に無菌的に移し替えて組み合わせた。
【００７５】
次に、予めガス殺菌された直径７０．５ｍｍ、高さ７５．５ｍｍの上方開放型の円筒形で、開口部周辺に約１０ｍｍのフランジ（図１において符号３３で示す）をもつポリプロピレン製外容器に収納して一体型容器を形成した。次いで、予めチューブ式熱交換機により加熱殺菌した調味液３０ｍｌを無菌的に充填し、予めガス殺菌したナイロン／シリカ蒸着ポリエチレンテレフタラート／ポリエチレン製のフィルムで外容器の開口部を覆って外容器のフランジ部３３と熱溶着させ、密封した。
【００７６】
対照としてジャガイモ、ニンジン、タマネギ、牛肉を内容器２０に充填して、すべての固形具材について同時に雰囲気温度１３５℃で６分間の直接蒸気殺菌を行った後、上記と同様に密封したものを製造した。
【００７７】
両者を２週間、３５℃で保管した結果、いずれの場合においても微生物の増殖は認められなかった。
【００７８】
本発明により製造した肉じゃがは、各固形具材の熱劣化がなく、良好な食感、風味を保っていたが、すべての固形具材を同時に直接蒸気殺菌した対照の肉じゃがは、ジャガイモ、ニンジンについてはほぼ同等の食感、風味を保っていたものの、牛肉は箸で掴もうとするとボロボロに崩れ、タマネギは煮溶けた状態になり、食感、風味とも著しく劣化していた。
【００７９】
実施例７
図２に示す底面および側面に孔を設けた内容器５０と、該内容器を２個並列に収納する外容器６０から形成される一体型容器４０を用いて、本発明の方法により釜飯の素を製造した。
【００８０】
内容器５０として、縦９５ｍｍ、横８０ｍｍ、深さ２５ｍｍの直方体で底面および側面それぞれに直径３ｍｍの穴をほぼ均等の間隔で底面には８１個、側面には２７個設けた上方開放型のポリプロピレン性の容器を用いた。
【００８１】
釜飯の素は以下の固形具材を用いて作成した。
固形具材：
にんじん ２０ｍｍ角のぶつ切り ４０ｇ
鶏肉 ２０ｍｍ角のぶつ切り ３０ｇ
ごぼう ２ｍｍ厚の細切り １５ｇ
しいたけ ２ｍｍ幅のスライス １０ｇ
こんにゃく ５ｍｍ厚の短冊切り １５ｇ
【００８２】
にんじんは熱耐性を高めるため、６０℃の０．０７％の乳酸カルシウム液に２時間浸漬した後、水洗いした。鶏肉は表面の赤身が消えるまでボイル処理を行った。また、調味液（醤油２５％、砂糖１０％、みりん３％、塩６％、グルタミン酸ナトリウム３％、水５３％）は７６ｇを一製品相当の充填量とした。
【００８３】
実施例１と同様の方法で、各固形具材について、殺菌値Ｆｏ値が１２分を超える殺菌時間を求めた結果、にんじんが５分１５秒、鶏肉が４分３０秒、ごぼうが１分、しいたけが１分３０秒、こんにゃくが３分であった。この結果より、にんじん、鶏肉およびこんにゃくを長殺菌時間固形具材として、ごぼうおよびしいたけを短殺菌時間固形具材として分類した。
【００８４】
上記耐熱処理を施したにんじん、鶏肉およびこんにゃくを上記の重量だけ計量して内容器５０に充填した。次にごぼうおよびしいたけを重量だけ計量して別の内容器５０に充填した。
【００８５】
実施例６と同様に、株式会社日阪製作所製の短時間調理殺菌試験機ＲＩＣ−１５Ｔに内容器ごと入れた。にんじん、鶏肉およびこんにゃくは雰囲気温度１３５℃で５分間１５秒、ごぼうおよびしいたけは雰囲気温度１３５℃で１分３０秒間直接蒸気殺菌を行った。直接蒸気殺菌終了後、長殺菌時間固形具材が入った内容器および短殺菌時間固形具材が入った内容器をクリーンベンチに無菌的に取り出した。
【００８６】
次に、予めガス殺菌された縦９５．５ｍｍ、横１６１ｍｍ、高さ２５．５ｍｍの直方体の形状をした、上方開放型で、開口部周辺に約１０ｍｍのフランジ（図２において符号６３で示す）をもつポリプロピレン製外容器６０に、２つの内容器５０を並列に収納し、内容器５０のフランジと外容器６０のフランジとを係合させて一体型容器４０を形成した。次いで、予めチューブ式熱交換機により加熱殺菌した調味液３８ｇずつを各内容器５０に無菌的に充填し、予めガス殺菌したナイロン／シリカ蒸着ポリエチレンテレフタラート／ポリエチレン製のフィルムで外容器６０の開口部を覆って外容器６０のフランジ部６３と熱溶着させ、密封した。
【００８７】
対照として、すべての固形具材を縦９５ｍｍ、横１６０ｍｍ、高さ２５ｍｍの直方体で底面および側面それぞれに直径３ｍｍの穴をほぼ均等の間隔で底面に１６２個、長側面に５４個、短側面に２７個設けた上方開放型のポリプロピレン性の容器に充填して、雰囲気温度１３５℃で５分１５秒間の直接蒸気殺菌を行った後、上記と同様の外容器を用いて一体型容器を形成し、上記同様のフィルムで密封したものを作成した。
【００８８】
両者を２週間、３５℃で保管した結果、いずれの場合においても微生物の増殖は認められなかった。
【００８９】
生米２合を水洗いし、通常の水加減（４００ｍｌ）の加水をし、上記の実験から得られたサンプルについて、フィルムを剥がして、内容器に充填された固形具材および調味液から成る中身を全部同時に家庭用炊飯器に入れて炊飯した。炊飯終了後、各固形具材の食感、風味を比較した。
【００９０】
本発明により製造した釜飯の素は、固形具材の熱劣化が少なく、炊飯終了後も良好な食感、風味を保っていた。しかし、全ての固形具材を同時に直接蒸気殺菌した対照の釜飯の素は、にんじん、鶏肉およびこんにゃくについては良好な食感を保っていたが、しいたけおよびごぼうについては、食感、風味が著しく劣化した。
【００９１】
【発明の効果】
本発明の製造方法により製造した固形具材入り食品は、熱劣化により固形具材の食感、風味が損なわれることなく、長期保存においても、商業的無菌を保つことができる。
また、本発明の製造方法は、容易であり、大掛かりな設備等が必要ないため、コストが安い。
【図面の簡単な説明】
【図１】図１は、一体型容器の斜視図である。
【図２】図２は、内容器を２つ並列に収納できる一体型容器の斜視図である。
【符号の説明】
１０・・・一体型容器
２０・・・内容器
２１・・・内容器側面
２２・・・内容器底面
２３・・・内容器フランジ
２４・・・孔
３０・・・外容器
３１・・・外容器側面
３２・・・外容器底面
３３・・・外容器フランジ
４０・・・一体型容器
５０・・・内容器
５１・・・内容器側面
５２・・・内容器底面
５３・・・内容器フランジ
５４・・・孔
６０・・・外容器
６１・・・外容器側面
６２・・・外容器底面
６３・・・外容器フランジ[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for producing a food containing solid ingredients, and more particularly to a method for producing a food containing different kinds and sizes of solid ingredients such as curry, sukiyaki, fried pot, meat potato, and pot rice.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, various kinds of retort foods, such as meat bowls that can be easily cooked by heating in a microwave oven or an oven, Chinese rice bowl, beef bowl, and pasta sauce, have been produced. These foods are usually filled in a container such as a retort pouch and then sterilized by retort (pressurized and heated). Since film packaging such as retort pouches can easily block microorganisms completely, retort-sterilized foods can usually be stored at room temperature. As described above, retort foods have been rapidly spreading in recent years because they are easy to cook and can be stored for a long period of time.In recent years, retort foods have been included in foods in accordance with consumer preferences for higher quality. Diversification, upsizing, and upgrading of solid ingredients are progressing.
[0003]
Here, the retort sterilization is to fill a container such as a pouch or a tray with a solid ingredient and a seasoning liquid, and after degassing and sealing, pressurize and heat sterilize the container at 121.1 ° C. for 4 minutes or more. It is a method of achieving commercial sterility of foodstuffs filled in containers.
[0004]
However, in this method, since the sterilization of both the solid ingredient and the seasoning liquid is performed simultaneously by indirect pressurization and heating from the outside of the container, the time required for sterilization becomes longer, and thermal degradation of the solid ingredient occurs. I will. For this reason, the finished food contains solid ingredients with impaired texture and flavor. In particular, when sterilizing foods containing a plurality of solid ingredients, it is necessary to set the sterilization time according to the solid ingredients that take the longest time to sterilize. Becomes excessively long and thermal degradation occurs. In addition, the container odor is transferred to the food due to long-time sterilization, which causes the flavor of the food to deteriorate.
[0005]
On the other hand, Patent Literature 1 discloses a method in which a solid ingredient is filled in an upward-opening type container and steam-sterilized directly, and then the container is aseptically filled with a separately sterilized seasoning liquid and hermetically sealed. I do. Direct steam sterilization is a sterilization method in which high-temperature steam is directly applied to a solid component to perform sterilization, has good heat conduction, and can achieve commercial sterility in a short time.
[0006]
However, even in this method, when sterilizing a food containing a plurality of solid ingredients, similar to conventional retort sterilization, it is necessary to set the sterilization time according to the solid ingredients that take the longest time to sterilize, Thermal degradation of the solid component material that does not take much time for sterilization occurs. In direct steam sterilization, sterilization is performed using a higher temperature than in retort sterilization. Therefore, when the sterilization time is longer, the thermal deterioration of the solid component is more severe than in retort sterilization.
[0007]
On the other hand, Patent Literature 2 discloses that a plurality of solid ingredients are sterilized in advance for each solid ingredient according to the size and properties of the solid ingredients, and then each solid ingredient is combined. Provided is a method for producing a cooked food which is filled in a retort pouch or a container and sterilized with a low heat load. By using this method, it is possible to prevent the solid ingredients from collapsing and heat denaturing, but it is necessary to sterilize each solid ingredient, and it is necessary to aseptically perform the operation of combining each solid ingredient. Therefore, the operation is difficult, a large-scale device is required, and the cost increases.
[0008]
In order to solve these problems, the present applicant classifies the solid ingredients contained in the solid ingredient-containing food into solid ingredients that require a long time to sterilize and solid ingredients that require a long time to sterilize. After the primary sterilization of the ingredients by direct steam sterilization, the remaining solid ingredients are added, and the second sterilization is performed by direct steam sterilization together with the solid ingredients that have been previously sterilized and take a long time to sterilize. A method of achieving commercial sterility of a food containing solid ingredients by a sterilization step is disclosed (Japanese Patent Application No. 2003-054065).
[0009]
However, in this method, the solid ingredients that take a long time to sterilize are subjected to secondary sterilization in addition to the primary sterilization that can ensure commercial sterility, so that the texture and the thermal degradation of flavor are reduced. There was room for improvement in this respect.
[0010]
[Patent Document 1]
JP-A-9-84567
[Patent Document 2]
JP-A-8-242828
[0011]
[Problems to be solved by the invention]
An object of the present invention is to provide a method for producing a food containing a solid ingredient which can be easily sterilized without impairing the texture and flavor of the solid ingredient.
[0012]
[Means for Solving the Problems]
The present invention includes the following inventions.
(1) A step of filling a solid container which takes a long time to sterilize and the remaining solid components in separate containers among the solid components included in the food containing the solid components, wherein the sterilization is performed in the separate container. A step of directly steam sterilizing each of the solid ingredient and the remaining solid ingredient which takes a long time, and the solid ingredient and the remaining solid ingredient which are directly steam-sterilized and which take a long time to sterilize are sterilized under aseptic conditions. A method for producing a solid ingredient-containing food, comprising a step of filling and combining in a container and, if necessary, a step of adding a sterilized seasoning liquid under aseptic conditions.
(2) The solid ingredient which takes a long time to sterilize is more than 2 minutes to obtain a sterilization value Fo value of 12 minutes or more when the sterilization atmosphere is at a temperature of 135 ° C. in a portion where the temperature of the solid ingredient hardly rises. The method according to (1), which is an ingredient requiring long sterilization.
(3) Among the solid ingredients included in the food containing the solid ingredients, the solid ingredients that take a long time to sterilize and the remaining solid ingredients are provided with holes on the bottom surface or on a part or the whole of the bottom surface and the side surfaces. A step of filling each of the inner containers, a step of directly steam-sterilizing each of the solid components and the remaining solid components that take a long time to sterilize the different containers, and the sterilization directly steam-sterilized. Both the solid ingredients and the remaining solid ingredients that take a long time to transfer to another inner container under aseptic conditions and combined, or the direct sterilization of the solid ingredients and the remaining solid ingredients that take a long time to sterilize One of the ingredients is transferred to the inner container filled with the other solid ingredient under aseptic conditions and combined, and then both the solid ingredient and the remaining solid ingredient that take a long time to sterilize are used. The filled inner container is stored in a sterilized outer container under aseptic conditions, or the sterilized directly sterilized solid container or the separate inner container filled with the remaining solid components is time-consuming. Is stored under sterile conditions in the same sterilized outer container to form an integrated container. If necessary, a sterilized seasoning solution is added to the inner container and / or the outer container under aseptic conditions. And a step of sealing a part or the whole of the integrated container under aseptic conditions.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described in detail according to the order of steps.
[0014]
Filling the solid ingredients in the food containing the solid ingredients in a separate container with the solid ingredients that take a long time to sterilize and the remaining solid ingredients, respectively.
Among the solid ingredients included in the food containing the solid ingredients, a solid ingredient that takes a long time to sterilize is selected. One or more kinds of solid ingredients may be selected. First, the sterilization time of each solid ingredient is measured. Here, the “sterilization time” is the time required from the time when the ambient temperature reaches 135 ° C. to the time when the sterilization value in the portion where the temperature of the solid component hardly rises reaches the Fo value = 12 minutes. Say. The `` part where the temperature of the solid ingredient is hardest to rise '' is usually the part farthest from the surface of the solid ingredient, for example, the central part if the solid ingredient is spherical, and the diagonal line if it is rectangular. It is an intersection part. Hereinafter, in the present specification, the “portion where the temperature of the solid component is hardest to rise” is referred to as a “measurement portion”. The sterilization time is measured by inserting the sensor of the sterilization value Fo value measuring device into the measuring part of each solid ingredient and measuring the time until the sterilization value Fo value reaches 12 minutes at an ambient temperature of 135 ° C. by direct steam sterilization. It can be performed by measuring. As the measuring device, for example, a sterilization value Fo value measuring device attached to a short-time cooking sterilization tester RIC-15T manufactured by Hisaka Manufacturing Co., Ltd. can be used. When measuring the sterilization value Fo value of a thin solid component, it is preferable to use a sensor having a shape that can be inserted into the thin solid component, for example, a CHNS SCHS1-OK having a diameter of 0.5 mm. Thermocouple type sensor can be used.
[0015]
The present inventor has studied various solid ingredients such as vegetables, meat, fish, and the like. As a result, in the measurement part of the solid ingredients, the sterilization value Fo value reached 12 minutes within a certain period of time, It has been found that the disinfection value Fo value takes a long time and is divided into those that reach 12 minutes. The inventor of the present invention has also found that a good result can be obtained by classifying the solid ingredients at the predetermined time of 2 minutes and at the boundary of 2 minutes.
[0016]
Here, the solid ingredients that take a long time to sterilize in the case of 2 minutes are referred to as “long sterilization time solid ingredients”, and the remaining solid ingredients are referred to as “short sterilization time solid ingredients”. Further explanation will be given.
[0017]
When manufacturing a food containing a solid ingredient, it is assumed that the food contains four solid ingredients A, B, C, and D. In this case, the sterilization time required until the sterilization value Fo reaches 12 minutes is measured by direct steam sterilization for each solid ingredient. Next, when the obtained results are A: 7 minutes, B: 4 minutes, C: 1 minute, and D: 45 seconds, A and B, which take longer than 2 minutes for sterilization at 2 minutes, Long sterilization time solid ingredients, C and D with a sterilization time of less than 2 minutes can be classified as short sterilization time solid ingredients.
[0018]
Although not limited, when the solid ingredients are diced into a substantially cubic shape, if the length of one piece of the substantially cube is 20 mm or more, they often belong to the long sterilization time solid ingredients, and also substantially When the length of one piece of the cube is 5 mm or less, it often belongs to a solid material having a short sterilization time.
[0019]
The sterilization temperature and sterilization time when manufacturing actual foods vary depending on the type and amount of the solid ingredients, the seasoning method, and the like. When the actual sterilization temperature is set to a temperature different from 135 ° C., for example, 145 Even if the temperature is set to 130 ° C. or 130 ° C., the classification of the solid ingredients can be performed based on the sterilization time at an ambient temperature of 135 ° C.
[0020]
Before sterilization, or to season the solid ingredients with the seasoning liquid, or when performing a process to prevent thermal degradation of the solid ingredients, using the solid ingredients after performing the seasoning and processing, It is desirable to classify solid ingredients.
[0021]
After selecting the solid ingredients for a long sterilization time in this way, next, solid ingredients for actually producing food are prepared and filled in a container. As the container, a cup-shaped container usually used for direct steam sterilization can be used. In addition, when the solid ingredients are directly steam sterilized, and then aseptically transfer the sterilized solid ingredients to a product container that actually fills the solid ingredient-containing food, as a container for performing direct steam sterilization, A stainless steel or ceramic container exclusively used for steam sterilization can be used. In the case where the solid ingredient is directly filled into the product container of the food containing the solid ingredient and sterilized from the beginning, a highly heat-resistant resin container can be used. Also, at the time of sterilization, if moisture generated by steam, moisture from solid ingredients, gravy, etc. accumulates in the container or adheres to the solid ingredients, the temperature rise of the measurement part is significantly delayed, and the sterilization time is reduced. May be longer. For this reason, it is preferable to provide a hole in the bottom surface of the container, or a part or the whole of the bottom surface and the side surface, so that moisture, meat juice, and the like can be discharged. The diameter, shape, number, and the like of the holes can be appropriately selected according to the type and size of the solid ingredients, the amount of water and gravy, and the like.
[0022]
The filling of the solid ingredient can be performed by an apparatus used in the prior art, and need not be performed aseptically. The filling amount can be appropriately determined according to the amount of the solid ingredient-containing food, the amount of the solid ingredient, the amount of the seasoning liquid, and the like, but the filling amount of the long sterilization time solid ingredient and the short sterilization time solid ingredient is determined. Since each product is equivalent to one product, there is no need to transfer the product to a product container after sterilization. Therefore, the risk of microbial contamination is reduced, the work is reduced, and the cost of product production can be reduced.
[0023]
Sterilization of the solid ingredients for long sterilization time and the solid ingredients for short sterilization time can be performed in order using one direct steam sterilizer. In this case, the solid component that has been previously sterilized is placed in a sterile environment such as a clean bench until the subsequent sterilization process is completed. In addition, the direct steam sterilization using two direct steam sterilizers for long sterilization time sterilization of solid ingredients and short sterilization time of solid ingredients simultaneously reduces the working time and further sterilization. It is possible to shorten the time for placing the solid component material in the clean bench. This can reduce the possibility of contamination by microorganisms.
[0024]
A step of directly steam sterilizing each of the solid ingredients that take a long time to sterilize and the remaining solid ingredients filled in separate containers.
After filling the solid ingredients that take a long time to sterilize in separate containers, these solid ingredients are directly sterilized by steam sterilization. Here, "direct steam sterilization" refers to a sterilization method in which steam is directly heated and sterilized by bringing steam into direct contact with a solid component. In order to perform heat sterilization to achieve commercial sterility of solid ingredients by direct steam sterilization, a sterilization temperature of 130C to 145C is usually required. The time required for the sterilization value Fo value to reach 12 minutes varies depending on the type and size of the solid ingredient, the sterilization temperature, and the like, but the sterilization time is determined according to the solid ingredient that requires the longest time for sterilization. Although the direct steam sterilization is not limited, for example, it can be performed using a short-time cooking sterilization tester RIC-15T manufactured by Hisaka Seisakusho Co., Ltd.
[0025]
Filling sterilized containers under sterile conditions with the steam-killed solid ingredients and the remaining solid ingredients that take a long time and combining them
The solid ingredients which take a long time to sterilize by direct steam sterilization and the remaining solid ingredients are filled in a sterilized container under a sterile environment such as a clean bench. For the filling, one of the solid ingredient that takes a long time to sterilize and the remaining solid ingredient may be placed on the other solid ingredient, or may be arranged side by side. Further, both may be mixed. Regardless of the filling method, it is preferable that the filling is performed so that the shape of the solid ingredient material does not collapse and a good appearance is maintained.
[0026]
Adding sterilized seasoning under sterile conditions as needed
After the step of combining the solid ingredients, the food containing the solid ingredients is completed by aseptically filling the solid ingredients with a sterilized seasoning liquid as needed. The filling of the seasoning liquid can be performed by a conventionally used device.
[0027]
When steam sterilization is performed directly using a special container, after sterilization, the solid ingredients are sterilized into product containers such as cup-shaped food containers containing solid ingredients and bag-shaped containers made of soft packaging material. After the transfer, the seasoning liquid can be filled aseptically.
[0028]
When the completed food containing solid ingredients is filled into the product container from the beginning and the sterilization step is performed, the food can be packaged by aseptically sealing the opening of the container. Especially when oxidation is a problem, for example, when there is a large space between the filled solid ingredients or seasoning liquid and the seal of the container opening for food containing solid ingredients, fish, meat, etc., fats and oils When filling a solid ingredient containing a large amount, for example, when manufacturing food such as "shrimp mayonnaise sauce", oxidation can be prevented by filling the container with nitrogen and then sealing. The product container is not particularly limited, but requires heat resistance, pressure resistance, impact resistance and the like according to the product and the cooking method, such as microwave cooking.
[0029]
Use of integrated container
In carrying out the production method of the present invention, an integrated container comprising an inner container and an outer container for accommodating the inner container can be used.
[0030]
For example, when a solid ingredient is filled into the inner container 20 of the integrated container 10 including the inner container 20 and the outer container 30 that stores the inner container 20 as shown in FIG. Both the long sterilization time solid ingredient and the short sterilization time solid ingredient, which have been directly steam sterilized, are transferred to another inner container 20 under aseptic conditions and combined, and the inner container 20 is stored in the outer container 30 as it is, and an integrated container 10 can be formed. After filling the inner container 20 with the long sterilization time solid ingredient and the short sterilization time solid ingredient, and performing steam sterilization directly, either one of the long sterilization time solid ingredient or the short sterilization time solid ingredient is sterilized. The inner container 20 may be stored in the outer container 30 after being transferred to and combined with the inner container 20 filled with the other solid ingredient material below. The storage can be performed, for example, by engaging the flange 23 of the inner container 20 with the flange 33 of the outer container 30. In addition, a hole 24 for discharging water, meat juice, or the like of the solid ingredient material can be provided on the side surface 21 or the bottom surface 22 of the inner container 20, or a part or the whole of the side surface 21 and the bottom surface 22. After the inner container 20 is housed in the outer container 30 to form the integrated container 10, a seasoning solution heat-sterilized as needed is aseptically filled and the opening of the outer container 30 is sealed by a simple method. Foods containing solid ingredients can be manufactured.
[0031]
Further, as shown in FIG. 2, an integrated container 40 including an inner container 50 and an outer container 60 capable of storing two inner containers 50 in parallel may be used. In the case of using the integrated container 40, both the long sterilization time solid ingredient and the short sterilization time solid ingredient are filled in separate inner containers 50 and steam sterilized directly. It is stored in the same sterilized outer container 60 under aseptic conditions, and the heat-sterilized seasoning liquid is aseptically filled and the opening of the outer container 60 is sealed. In addition, a hole 54 for discharging moisture, meat juice, or the like of the solid ingredient material can be provided on the side surface 51 or the bottom surface 52 of the inner container 50, or a part or the whole of the side surface 51 and the bottom surface 52. The storage can be performed, for example, by engaging the flange 53 of the inner container 50 with the flange 63 of the outer container 60. Such an integrated container 40 can separate the long sterilization time solid ingredient and the short sterilization time solid ingredient until the consumer eats the food. Sterilization time It is convenient when the solid ingredients have different seasonings.
[0032]
【Example】
Example 1
The sterilization time was examined for various solid ingredients.
Various solid ingredients were cut into various sizes, steam sterilized directly at an ambient temperature of 135 ° C., and the time required for the sterilization value Fo value in the measurement portion of the solid ingredients to reach 12 minutes was measured. .
[0033]
Vegetables were cut into the shapes shown in Table 1, immersed in a 0.07% calcium lactate aqueous solution at 60 ° C. for 2 hours, and then washed with water in order to increase heat resistance.
[0034]
A cylindrical container having a diameter of 10 cm and a depth of 5 cm and having an upward opening was used as a container for filling the solid ingredients. At the bottom of the container, 19 holes having a diameter of 6 mm were uniformly provided. The experiment was performed for each solid component. About 50 g of each solid ingredient was filled in a container, and steam sterilization was directly performed by the following procedure using a short-time cooking sterilization tester RIC-15T manufactured by Hisaka Seisakusho.
[0035]
First, a solid cooking material in which a sensor of a sterilization value Fo value measuring device attached to a quick cooking sterilization tester RIC-15T manufactured by HISAKA CORPORATION was inserted into a measurement part was put into a container. After setting in a kettle and sealing, it was degassed for about 2 minutes. Thereafter, the atmosphere temperature was set to 135 ° C., and steam was introduced into the kettle of the sterilizer. After the ambient temperature reached 135 ° C., the sterilization value was measured every 15 seconds, and the sterilization time when the sterilization value Fo value exceeded 12 minutes was determined. Table 1 shows the results.
[0036]
[Table 1]

[0037]
In Table 1, those that require sterilization longer than 2 minutes before the sterilization value Fo value reaches 12 minutes are those that have a long sterilization time of 2 minutes or less and sterilization value Fo value reaches 12 minutes by sterilization for 2 minutes or less. It can be classified as short-time sterilized solid ingredients.
[0038]
Example 2
With respect to each solid ingredient used in Example 1, the texture and the degree of thermal deterioration of the flavor of the solid ingredient when the sterilization temperature was maintained at 135 ° C. for a certain time were examined.
[0039]
In Example 1, the sterilization value F in the solid ingredients for a long sterilization time₀The longest time for the value to reach 12 minutes or more is “potatoes (20 mm dice)” and “tofu (20 mm dices)” for 6 minutes. In addition, sterilization value F₀The longest time for the value to reach 12 minutes or more was "squid (15 mm width chopped)" for 2 minutes.
[0040]
For this reason, in Example 2, all of the short-time sterilization solid ingredients were sterilized value F₀2 minutes which is the time when the value reached 12 minutes or more, the long sterilization time solid ingredients all sterilization value F₀The solid ingredients sterilized by the sterilization time obtained in Example 1 were used to evaluate the texture of the solid ingredient after 6 minutes, at which the value reached 12 minutes or more, and after an 8 minute sterilization time, which was 2 minutes longer than 6 minutes. The texture and flavor of the wood were compared and evaluated as controls. The method of direct steam sterilization was the same as in Example 1.
The evaluation results are shown in Table 2.
[0041]
[Table 2]

[0042]
According to the results shown in Table 2, after sterilization for 2 minutes, almost all of the short-time sterilization time solid ingredients and the long-time sterilization time solid ingredients maintain the same texture and flavor as compared with the control. (As for the Chinese cabbage and burdock which are "△" (acceptable range), since the texture is regarded as particularly important, it is considered that the result is that the texture and flavor slightly deteriorated.) After the sterilization for 6 minutes, the solid ingredients for a short sterilization time eventually had a large thermal deterioration and lost their original texture. From this fact, it is clear that the texture and flavor of the short-time sterilizing solid material are impaired when the short-time sterilizing time solid component and the long-time sterilizing time solid component are directly steam-sterilized simultaneously. On the other hand, the long-sterilization time solid ingredients maintain the same texture and flavor except that chicken (20 mm square chopped) was within the allowable range after the sterilization for 6 minutes compared to the control. I have. However, after sterilization for 8 minutes, the texture of beef (20 mm square chopped) and scallop (30 mm diameter as it is) thermally deteriorated (although it was within an allowable range), and together with chicken (20 mm square chopped), Sterilization time The texture and flavor of all the meat and seafood in the solid ingredients deteriorated by heat. Therefore, after performing the first sterilization by direct steam sterilization on the long sterilization time solid ingredients, the short sterilization time solid ingredients are added, and the second sterilization is performed by direct steam sterilization together with the previously sterilized long sterilization time solid ingredients. In the case of using the method of performing direct steam sterilization by a two-stage sterilization process of sterilization, it has become clear that there is a slight thermal deterioration of solid ingredients, particularly for meat and seafood.
[0043]
Example 3
1. The following method was used to produce seafood curry packaged food that can be stored at room temperature. Potatoes, onions, carrots, beef and squid were used as solid ingredients.
Potato 20mm dice 500g
Carrot 20mm dice 200g
Onion 3mm thick slice 100g
Beef 20mm square chopped 200g
Squid 15g width chopped 200g
Scallop scallop 3cm in diameter 300g
[0044]
Potatoes, carrots and onions were immersed in a 0.07% calcium lactate solution at 60 ° C. for 2 hours and then washed with water in order to enhance heat resistance. The squid and scallop scallop were boiled in boiling water for 2 minutes to remove the acne. As the seasoning liquid, a commercially available curry roux diluted with hot water was used. Vegetable oil was poured into a pan, lightly cooked until the leanness of the beef disappeared, and then the remaining solid ingredients were put in and fried until the onion turned brown. Thereafter, 1000 ml of the seasoning liquid was added, and the mixture was boiled once to a boil, and then stored in a refrigerator at about 10 ° C. for about 12 hours. Thereafter, the solid ingredient and the seasoning liquid were separated.
[0045]
Next, each of the solid ingredients subjected to the above treatment was placed in a polypropylene sterilization container having a diameter of 10 cm and a depth of 5 cm, and provided with 19 holes each having a diameter of 6 mm on the bottom surface at substantially equal intervals. 50 g each, put a sensor for measuring the sterilization value Fo value into the measuring part of the solid ingredients, put in a short cooking sterilization tester RIC-15T manufactured by Hisaka Manufacturing Co., Ltd., according to the following procedure for each solid ingredient Direct steam sterilization was performed.
[0046]
First, the sterilization container containing the respective solid ingredients was put in a kettle of a short-time cooking sterilization tester, sealed, and then degassed for about 2 minutes. Thereafter, the atmosphere temperature was set to 135 ° C., and steam was introduced into the kettle of the sterilizer. The sterilization value Fo value was measured every 15 seconds after the ambient temperature reached 135 ° C., and the sterilization time until the sterilization value Fo value exceeded 12 minutes was determined.
[0047]
As a result, the sterilization time until the sterilization value Fo value exceeds 12 minutes is 6 minutes for potato, 5 minutes for carrot, 45 seconds for onion, 4 minutes and 45 seconds for beef, 2 minutes for squid, and 3 minutes for scallop. 15 seconds.
[0048]
From these results, potatoes, carrots, beef and scallops were classified as solid ingredients for long sterilization time, and onions and squids were classified as solid ingredients for short sterilization time.
[0049]
2. Next, solid ingredients actually used as food were prepared, and the following treatment was performed for each test section.
Test area A:
Fill the sterilization container with 50 g of potatoes, 20 g of carrots, 20 g of beef, and 30 g of scallop scallop, which are long-time sterilization time solid ingredients, and put them in a pot of a short-time cooking sterilization tester RIC-15T manufactured by Hisaka Seisakusho Co., Ltd. Direct steam sterilization was performed at a temperature of 135 ° C. for 6 minutes. Thereafter, the pressure in the kettle was returned to normal pressure, the pressure was reduced, and vacuum cooling was performed for 2 minutes. After the temperature in the pot of the testing machine became 40 ° C. or less, the sterilization container filled with the solid ingredients was aseptically removed from the testing machine to a clean bench.
[0050]
Next, 10 g of onion and squid 20 g, which are solid ingredients for short-time sterilization, are filled in a sterilization container different from the above, placed in a kettle of a short-time cooking / sterilization tester RIC-15T, and heated at an ambient temperature of 135 ° C. for 2 minutes. After performing direct steam sterilization, after performing pressure reduction and vacuum cooling in the same manner as described above, the sterilization container filled with the solid components was aseptically removed from the test machine to a clean bench.
[0051]
The long sterilization time solid component and the short sterilization time solid component which had been subjected to direct steam sterilization were filled in a clean bench in combination with a laminate pouch having a structure of PET / AL / CPP which had been gas sterilized in advance. Next, 100 ml of the seasoning liquid previously sterilized by heating with a tube-type heat sterilizer was aseptically filled, degassed, and sealed.
[0052]
Test B:
50 g of potato, 20 g of carrot, 20 g of beef and 30 g of scallop scallop are filled in a sterilization container and put into a pot of a short-time cooking sterilization tester RIC-15T manufactured by Hisaka Seisakusho Co., Ltd. for 6 minutes at an ambient temperature of 135 ° C for 6 minutes. After steam sterilization, the same sterilization container was further filled with 10 g of onion and 20 g of squid, and steam sterilized directly with potatoes and the like previously sterilized for another 2 minutes. After performing pressure reduction and vacuum cooling in the same manner as described above, the sterilization container filled with the solid ingredients is aseptically removed from the tester to a clean bench, and the solid ingredients are aseptically sterilized into a laminate pouch having the above-described configuration and gas sterilization in advance. Filled. Next, 100 ml of the seasoning liquid heat-sterilized in the same manner as above was filled aseptically, degassed, and then sealed.
[0053]
Test plot C:
50 g of potatoes, 20 g of carrots, 20 g of beef, 30 g of scallops, 10 g of onions, and 20 g of squid were all added to the same sterilization container, and subjected to direct steam sterilization for 6 minutes. After performing pressure reduction and vacuum cooling in the same manner as described above, the sterilization container filled with the solid ingredients is aseptically removed from the tester to a clean bench, and the solid ingredients are aseptically sterilized into a laminate pouch having the above-described configuration and gas sterilization in advance. Filled. Next, 100 ml of the seasoning liquid heat-sterilized in the same manner as above was filled aseptically, degassed, and then sealed.
[0054]
Test area D:
50 g of potato, 20 g of carrot, 20 g of beef, 30 g of scallops, 10 g of onion, and 20 g of squid were separately filled in the laminated pouch having the above constitution, and 50 ml of the seasoning solution heat-sterilized in the same manner as above was added to each laminated pouch. And hermetically sealed. For a laminated pouch filled with a long sterilization time solid ingredient such as potato, the sterilization value Fo value of the measurement part of the potato is 120 ° C. until the sterilization value Fo value becomes 12 minutes, and a short sterilization time solid ingredient such as onion is used. The filled laminate pouch was subjected to retort sterilization at an ambient temperature of 120 ° C. until the sterilization value Fo of the measurement portion of the squid became 12 minutes. After sterilization, both were taken out to a clean bench, aseptically combined and filled and mixed in another sterilized laminate pouch.
[0055]
E test area:
50 g of potatoes, 20 g of carrots, 20 g of beef, 30 g of scallops and 30 ml of seasoning liquid are filled in a laminated pouch having the above-mentioned structure, sealed by degassing and sealed, and the ambient temperature is maintained until the sterilization value Fo value of the measurement portion of the potato becomes 12 minutes. After performing the retort sterilization at 120 ° C., the laminate pouch is opened, 10 g of onion, 20 g of squid and 50 ml of seasoning liquid are further filled and sealed by degassing, and the sterilization value Fo value of the measurement portion of the squid is 12 minutes. The retort sterilization was performed again at an ambient temperature of 120 ° C.
[0056]
Test zone F:
50 g of potato, 20 g of carrot, 20 g of beef, 20 g of scallop, 30 g of onion, 10 g of onion, 20 g of squid and 100 ml of seasoning liquid are filled in the laminated pouch having the above constitution, and the retort is performed until the sterilization value Fo value of the measurement portion of the potato becomes 12 minutes. Sterilization was performed.
[0057]
3. result
As a result of storing each of the samples in the A to F test groups at 35 ° C. for 2 weeks, no growth of microorganisms was observed in any of the samples.
[0058]
After heating each sample of A to F test sections in boiling water for 5 minutes, the texture of each solid ingredient, the taste, the texture of each solid ingredient when sterilized for the sterilization time obtained in Example 1, The flavor was compared and evaluated as a control.
The evaluation criteria were as follows.
：: Compared with control, equivalent
：: almost equivalent to control
△: Compared with control
×: There is a difference compared with the control, which is not preferable
Table 3 shows the results.
[0059]
[Table 3]

[0060]
According to the results shown in Table 3, the test section A exhibited the least thermal deterioration in the texture and flavor of the solid ingredients. That is, by directly performing steam sterilization on the solid ingredients for long sterilization time and the solid ingredients for short sterilization time separately, the original texture of the solid ingredients is maintained even after achieving commercial sterility, and the texture and flavor are maintained. It has been found that it is possible to provide a food containing solid ingredients excellent in the above.
[0061]
Example 4
The combination of solid ingredients was set in the same way as the actual sukiyaki menu, and the texture and flavor of the solid ingredients due to the different sterilization methods were examined.
[0062]
Test area A:
Among all the solid ingredients, the sterilization time is determined according to the solid ingredient that takes the longest sterilization time, and all the solid ingredients are sterilized using the sterilization container used in Example 3 in the same manner as in Example 3. The ingredients were simultaneously steam sterilized directly.
[0063]
Test B:
A sterilization time longer than 2 minutes is selected by selecting a solid material having a long sterilization time, and a sterilization time is determined according to the solid material that requires the longest sterilization time, and the sterilization time is determined using the sterilization container used in Example 3. Steam sterilization was performed directly in the same manner as in Example 3. Next, a solid material having a short sterilization time which can be sterilized in 2 minutes or less was filled in another sterilization container, and steam sterilization was directly performed according to the sterilization time of the solid material requiring the longest sterilization time. After the direct steam sterilization was finished, the long sterilization time solid ingredients and the short sterilization time solid ingredients were combined and mixed.
[0064]
result:
The texture and flavor of the solid ingredients in the A test section and the B test section were evaluated for each solid ingredient.

[0065]
As a result, in the A test plot, the texture and flavor of the solid ingredients other than tofu, shirataki and shiitake deteriorated remarkably. The green onions softened remarkably, and the beef had a rough texture and was thermally degraded so that it could not be grasped with chopsticks. In the test section B, each of the solid ingredients maintained its unique texture and flavor.
[0066]
Example 5
In the same manner as in Example 4, assuming a fryer, the texture and flavor of the solid ingredients were examined by different sterilization methods.

[0067]
As a result, in the test plot A, the texture and flavor of the tofu and taro were maintained, and the texture and flavor of the chicken were slightly deteriorated. In addition, squid lost elasticity, and the texture of Chinese cabbage and burdock deteriorated remarkably. On the other hand, the texture and flavor of the tofu and chicken in Test B were the same as those in Test A, but squid maintained its unique texture, and although Chinese cabbage and burdock were slightly deteriorated, solid ingredients were used. The original peculiar texture and flavor were kept.
[0068]
When 10 packs of the foods produced in Examples 4 and 5 were prepared and stored for 2 weeks at 35 ° C. for 2 weeks, no growth of microorganisms was observed in any of the packs.
[0069]
Example 6
A meat potato was manufactured by the method of the present invention using an integrated container 10 formed of an inner container 20 as shown in FIG. 1 and an outer container 30 for storing the inner container. As the inner container 20, a polypropylene container having a top shape of 19 mm and a depth of 75 mm and having 19 holes with a diameter of 6 mm on the bottom surface at substantially equal intervals was used.
[0070]
Meat potatoes were prepared using the following solid ingredients.
Solid ingredients:
Potato 20mm thick dice 70g
Carrot 20g square dice 20g
Onion 3mm thick slice 20g
Beef 2mm square slice 20g
[0071]
Carrots, potatoes and onions were immersed in a 0.07% calcium lactate solution at 60 ° C. for 2 hours and then washed with water in order to enhance heat resistance. The seasoning solution was prepared by mixing 150 ml of sake, 150 ml of water, 40 g of sugar, and 150 ml of soy sauce, and boiling once. Vegetable oil was poured into a pan, and the beef was lightly fried. Then, 130 ml of the seasoning liquid was added, followed by the remaining solid ingredients. After being boiled to boiling once, the mixture was allowed to stand in a refrigerator at about 10 ° C. for about 12 hours, and the seasoning liquid was immersed in the solid ingredients, and then the solid ingredients and the seasoning liquid were separated.
[0072]
In the same manner as in Example 1, the sterilization time until the sterilization value Fo value exceeded 12 minutes was determined for each solid ingredient. As a result, the sterilization time until the sterilization value Fo value exceeded 12 minutes was 6 minutes for potato, 5 minutes for carrot, 45 seconds for onion, and 30 seconds for beef. From these results, potatoes and carrots were classified as solid ingredients for long sterilization time, and onions and beef were classified as solid ingredients for short sterilization time.
[0073]
The potatoes and carrots subjected to the heat treatment were weighed and filled in the inner container 20 respectively. The onion and beef are of the same shape as the inner container 20 and have a slightly smaller size, a cylindrical shape having a diameter of 70 mm and a depth of 35 mm, and 19 holes with a diameter of 6 mm provided on the bottom surface at substantially equal intervals. Filled in a polypropylene inner container.
[0074]
In the same manner as in Example 5, the inner container was put in a short-time cooking sterilization tester RIC-15T manufactured by Hisaka Seisakusho Co., Ltd., and steam sterilization was performed directly in order. The potatoes and carrots were directly steam sterilized at 135 ° C. ambient temperature for 6 minutes, and the onions and beef were directly steam sterilized at 135 ° C. ambient temperature for 45 seconds. The long sterilization time solid components and the short sterilization time solid components that have been directly steam sterilized are aseptically removed together with the inner container into the clean bench in the order in which the sterilization has been completed, and the short sterilization time solid components are lengthened in the clean bench. Sterilization time Aseptically transferred to the inner container 20 filled with the solid ingredients and combined.
[0075]
Next, an outer polypropylene container having a gas-sterilized 70.5 mm diameter, 75.5 mm height, open-topped cylindrical shape, and having a flange (indicated by reference numeral 33 in FIG. 1) of about 10 mm around the opening. To form an integrated container. Then, the opening of the outer container is covered with a film made of nylon / silica vapor-deposited polyethylene terephthalate / polyethylene which has been sterile-filled with 30 ml of the seasoning liquid which has been previously heat-sterilized by a tube heat exchanger, and which has been previously gas-sterilized. It was heat-welded to the part 33 and sealed.
[0076]
As a control, potatoes, carrots, onions, and beef were filled into the inner container 20, and all solid ingredients were simultaneously subjected to direct steam sterilization at an ambient temperature of 135 ° C for 6 minutes, and then sealed as described above to produce did.
[0077]
As a result of storing both at 35 ° C. for 2 weeks, no microorganism growth was observed in any case.
[0078]
The meat and potatoes manufactured according to the present invention did not undergo thermal deterioration of each solid ingredient and had a good texture and flavor, but the control meat and potatoes, which were steam-sterilized simultaneously with all the solid ingredients, were potato and carrot. Although the beef had almost the same texture and flavor, the beef broke down when trying to grab it with chopsticks, and the onion was boiled and melted, and both the texture and flavor were significantly deteriorated.
[0079]
Example 7
By using the inner container 50 formed with the inner container 50 provided with holes on the bottom and side surfaces shown in FIG. Was manufactured.
[0080]
Top-open polypropylene with a rectangular parallelepiped having a length of 95 mm, a width of 80 mm and a depth of 25 mm as the inner container 50, having 81 holes on the bottom surface and 27 holes on the side surfaces at approximately equal intervals on the bottom surface and side surfaces, respectively. Sex containers were used.
[0081]
The pot rice was prepared using the following solid ingredients.
Solid ingredients:
Carrot 20mm square chopped 40g
Chicken 20mm square chopped 30g
Burdock 2mm thick shredded 15g
Shiitake mushroom 2mm wide slice 10g
Konjac 5mm thick strip 15g
[0082]
Carrots were immersed in a 0.07% calcium lactate solution at 60 ° C. for 2 hours and then washed with water in order to enhance heat resistance. Chicken was boiled until the red meat on the surface disappeared. In addition, 76 g of the seasoning liquid (soy sauce 25%, sugar 10%, mirin 3%, salt 6%, sodium glutamate 3%, water 53%) was used as a filling amount equivalent to one product.
[0083]
In the same manner as in Example 1, the sterilization value Fo value of each solid ingredient was determined to be a sterilization time exceeding 12 minutes. As a result, carrots were 5 minutes and 15 seconds, chicken were 4 minutes and 30 seconds, burdock was 1 minute, Shiitake was 1 minute and 30 seconds, and konjac was 3 minutes. Based on the results, carrots, chicken and konjac were classified as solid ingredients for long sterilization time, and burdock and shiitake were classified as solid ingredients for short sterilization time.
[0084]
The carrot, chicken and konjac that had been subjected to the above heat treatment were weighed by the above-mentioned weight and filled into the inner container 50. Next, the burdock and shiitake mushroom were weighed and filled into another inner container 50.
[0085]
Similarly to Example 6, the inner container was put into a short-time cooking sterilization tester RIC-15T manufactured by Hisaka Seisakusho Co., Ltd. Carrot, chicken and konjac were directly steam sterilized at an ambient temperature of 135 ° C. for 5 minutes and 15 seconds, and burdock and shiitake were directly steam sterilized at an ambient temperature of 135 ° C. for 1 minute and 30 seconds. After the end of the direct steam sterilization, the inner container containing the solid material for a long sterilization time and the inner container containing the solid material for a short sterilization time were aseptically removed to a clean bench.
[0086]
Next, it is a gas-sterilized rectangular parallelepiped shape having a length of 95.5 mm (length), 161 mm (width), and 25.5 mm (height), and is an open-top type with a flange of about 10 mm around the opening (indicated by reference numeral 63 in FIG. 2). The two inner containers 50 were housed in parallel in the outer container 60 made of polypropylene, and the integral container 40 was formed by engaging the flange of the inner container 50 with the flange of the outer container 60. Next, each inner container 50 is aseptically filled with 38 g each of the seasoning liquid heat-sterilized by a tube-type heat exchanger in advance, and the opening of the outer container 60 is filled with a gas-sterilized nylon / silica-deposited polyethylene terephthalate / polyethylene film. , And heat-welded to the flange portion 63 of the outer container 60 to seal it.
[0087]
As a control, all the solid ingredients were 95 mm in length, 160 mm in width, and 25 mm in height, and the bottom and side surfaces were each provided with 162 holes of 3 mm in diameter on the bottom surface and at approximately equal intervals on the bottom surface, 54 on the long side surface, and 54 on the short side surface. After filling into 27 open-top polypropylene containers and performing direct steam sterilization at 135 ° C. for 5 minutes and 15 seconds, an integrated container was formed using the same outer container as above. And sealed with a film similar to the above.
[0088]
As a result of storing both at 35 ° C. for 2 weeks, no microorganism growth was observed in any case.
[0089]
2 g of unpolished rice is washed with water, water is added with normal water (400 ml), the film obtained from the above experiment is peeled off, and the contents are made up of solid ingredients and seasoning liquid filled in an inner container. Were put into a domestic rice cooker at the same time and cooked. After cooking, the texture and flavor of each solid ingredient were compared.
[0090]
In the case of the rice cooked according to the present invention, the solid ingredients were less thermally degraded and maintained a good texture and flavor even after the completion of rice cooking. However, the control rice cooked with all solid ingredients simultaneously steam-sterilized had a good texture for carrots, chicken and konjac, but the texture and flavor of shiitake and burdock were significantly degraded. did.
[0091]
【The invention's effect】
The food containing the solid ingredient produced by the production method of the present invention can maintain commercial sterility even during long-term storage without impairing the texture and flavor of the solid ingredient due to thermal deterioration.
In addition, the manufacturing method of the present invention is easy and does not require large-scale equipment, so that the cost is low.
[Brief description of the drawings]
FIG. 1 is a perspective view of an integrated container.
FIG. 2 is a perspective view of an integrated container capable of storing two inner containers in parallel.
[Explanation of symbols]
10 ・ ・ ・ Integral container
20 ... inner container
21 ... inner container side
22 ・ ・ ・ Bottom of inner container
23 ・ ・ ・ Inner container flange
24 ... hole
30 ・ ・ ・ Outer container
31 ・ ・ ・ Outer container side
32 ・ ・ ・ Bottom of outer container
33 ・ ・ ・ Outer container flange
40 ・ ・ ・ Integral container
50 ... inner container
51 ・ ・ ・ Side of inner container
52 ・ ・ ・ Bottom of inner container
53 ・ ・ ・ Inner container flange
54 ... hole
60 ・ ・ ・ Outer container
61 ・ ・ ・ Side of outer container
62 ・ ・ ・ Bottom of outer container
63 ・ ・ ・ Outer container flange

Claims (3)

Among the solid ingredients contained in the solid ingredient-containing food, a step of filling the solid ingredients and the remaining solid ingredients that take a long time to sterilize in separate containers,
A step of directly steam sterilizing each of the solid ingredients and the remaining solid ingredients that take a long time for the sterilization filled in the separate container,
Filling the sterilized container with aseptically assembling the solid ingredients that take a long time to sterilize directly steam sterilized and the remaining solid ingredients, and adding a sterilized seasoning liquid under aseptic if necessary Process,
A method for producing a food containing solid ingredients, comprising: The solid ingredient which takes a long time to sterilize, in a portion where the temperature of the solid ingredient is hardest to rise, sterilization longer than 2 minutes to obtain a sterilization value Fo value 12 minutes or more when the sterilization atmosphere is at a temperature of 135 ° C. The method according to claim 1, which is a necessary ingredient. Of the solid ingredients included in the solid ingredient-containing food, the solid ingredients that take a long time to sterilize and the remaining solid ingredients are separated from each other by providing holes on the bottom surface, or on a part or the whole of the bottom surface and side surfaces. A process of filling the inner container,
The step of directly steam sterilizing each of the solid ingredients and the remaining solid ingredients that take a long time to sterilize the different inner containers,
Both the solid ingredients that take time to sterilize directly steam sterilized and the remaining solid ingredients are transferred to another inner container under aseptic conditions and combined, or the solid ingredients that take time to sterilize directly steam sterilized One of the solid ingredients and the remaining solid ingredients are transferred under sterile conditions to the inner container filled with the other solid ingredients, and then combined, and then the solid ingredients and the remaining solid ingredients that take a long time to sterilize are used. The inner container filled with both of the solid ingredients is stored in a sterilized outer container under aseptic conditions, or the solid ingredients or the remaining solid ingredients that take a long time to sterilize by direct steam sterilization are filled. Forming the integrated container by storing each of the separate inner containers in the same sterilized outer container under aseptic conditions,
A step of adding a sterilized seasoning liquid to the inner container and / or the outer container under aseptic conditions, and a step of sealing a part or the whole of the integrated container under aseptic conditions,
A method for producing a food containing solid ingredients, comprising:

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