JPS6234376B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a novel method for producing a processed food material having a fibrous structure without using a spinning method by blending wheat protein alone or other plant proteins and adding meat and/or food materials. Due to the structural characteristics of wheat protein, various fiberization techniques that do not rely on spinning methods have been attempted. However, many of these techniques have a flake-like, thread-like, or spongy-like appearance rather than a fibrous form, which is far from the concept of fibrous form. On the other hand, there are techniques for obtaining a continuous fiber structure without using spinning methods, but it is still far from satisfactory in terms of quality, utility, equipment cost, etc. In view of these circumstances, the present invention provides a method for producing a processed food material having a fibrous structure that overcomes the above-mentioned problems. That is, the present invention involves adding meat and/or food materials to wheat protein alone or a blend containing other vegetable proteins to form a water-containing kneaded product, and then exposing the water-containing kneaded product to the atmosphere alone or to the atmosphere mixed with an inert gas. The content includes a method for producing a food material with a continuous fiber structure, which is characterized by mixing water vapor and heating in a high temperature dry atmosphere maintained at a relative humidity of 75% to less than 100%. Wheat proteins used in the present invention include raw gluten and active gluten obtained from wheat flour by the Martin method, etc., and these can be used alone or in combination. Other plant proteins used in the present invention include various forms of protein such as isolated protein types and concentrated protein types of plant proteins such as soybean, cottonseed, corn, and leaf proteins, which may be used alone or in combination. . As the meat used in the present invention, farmed meat, poultry meat, seafood meat, mollusk meat, etc. are used alone or in combination. Food materials include nuts such as cashew nuts, peanuts, and almonds; pulps such as peaches, plums, and apricots; dairy products such as butter and cheese; various food materials such as seaweed such as wakame and kelp, and seasonings and fats and oils. , dye,
Supplementary food materials that improve the flavor, texture, and appearance of foods, such as flavorings, can be used alone or in combination. When preparing a water-containing kneaded product (hereinafter simply referred to as kneaded product), there is no preclude the addition of a reducing agent, protease, glutathione, etc. as appropriate depending on the required physical properties. The kneaded material contains water.
It is adjusted to 40W/W% to 80W/W% and quantitatively sent to the next spreading process. At that time, the kneaded material may be extruded into a pipe-like, cylindrical, or belt-like form from a nozzle with a slit, and in the spreading process, it is formed into a continuous belt-like sheet with a thickness of about 4 mm to 20 mm and a width of about 100 mm to 1000 mm. Shaped. The belt-shaped sheet is stretched by 2.5 times or more during the spreading process, giving directionality to the randomly intertwined fiber structure. The strip-shaped sheet that has been given directionality enters the next heating step. In the heating process, water vapor is introduced into the atmosphere at a relative humidity of 75%~
The mixture is mixed so that the concentration is less than 100%, and the strip-shaped sheet is heated in a so-called dry atmosphere using a heating device whose temperature can be adjusted to 75°C to 120°C. Atmospheric conditions in the heating device If the heating temperature is outside the range of 75°C to 120°C and the relative humidity is 75% to less than 100%, for example, if it is less than 75°C, the fiber organization within the belt-like sheet due to heating may be uneven and insufficient. easy to become,
The heating time also becomes significantly longer, which is undesirable from the standpoint of quality stability and productivity. Furthermore, when the temperature exceeds 120°C, foaming within the belt-like sheet becomes significant, resulting in poor appearance and quality problems such as the structure becoming brittle. On the other hand, if the relative humidity is less than 75%, the rise in the surface temperature of the strip sheet will be suppressed, resulting in the surface becoming too dry and forming a film. This leads to variations in moisture distribution due to non-uniform drying after the drying process, which adversely affects the texture of the product. Also,
When the relative humidity is 100% or more, heating is carried out in saturated steam, which poses the problems of increased steam cost and loss of flavor components due to attached drips, as described later. It is desirable to heat the belt-shaped sheet while stretching it in this heating device, and thereby the fiber properties can be improved. Although the stretching ratio varies depending on the composition of the kneaded material, a stretching ratio of 3 to 15 times, including the stretching step, is a desirable range in consideration of productivity. The heating temperature is 75℃ as the atmospheric condition inside the heating device.
By adjusting the relative humidity to ~120°C, especially 75% to less than 100%, the following effects can be achieved. (1) Energy costs, that is, steam costs, can be significantly reduced. For example, the steam cost can be reduced by 50% to 70% compared to heating with hot water or heated salt solution, and it is also possible to reduce the steam cost by nearly 10% compared to moist heat heating using normal steam. (2) Significant improvement in quality and diversification of formulations become possible. In other words, in the case of heating with hot water or heated salt solution, the amount of blended seasonings etc. lost during the process reaches as much as 5% to 10%, and even in the case of moist heat heating with normal water vapor, the amount of seasonings etc. that adhere to the strip sheet is lost. The loss of seasonings etc. due to dripping is as high as 2% to 4%, and beyond the physical loss, it is difficult to develop seasoning techniques to adjust the lost taste. Such problems in seasoning technology are also solved by heating in a dry atmosphere according to the present invention, and as a result, even substances that are easily lost in water can be added, making it possible to diversify flavors. It is also possible to mix an inert gas such as nitrogen gas into the atmosphere to increase its ratio and adjust the atmosphere to a dry, high-temperature atmosphere. In this way, when a substance that is easily oxidized is mixed, it is possible to heat the product while suppressing oxidation, and a wide range of quality stability can be expected. (3) It is not affected by changes in the physical properties of the kneaded material. That is, if the kneaded material is very soft or brittle when heated with hot water or a heated salt solution, heating may not be possible because it will stretch too much or its structure will collapse. The method according to the present invention has almost no limitations due to such physical properties, and even compared to conventional moist heat heating using steam, the elongation of the belt-shaped sheet during heating is much easier to control since there is less moisture transfer to the sheet due to dripping. This makes it possible to make the device more compact. Therefore, according to the method of the present invention, various types of meat and food materials, such as meat such as beef and pork; poultry such as chicken, duck, and turkey; fish such as cod, tuna, bonito, and horse mackerel; squid and octopus; It is possible to add meat such as clams, freshwater clams, etc., as desired.
Nuts such as almonds, hazelnuts, pine nuts, and morning beans; Dried vegetables such as parsley and green onions; Algae such as seaweed and kelp; Dairy products such as cheese, butter, yogurt, and casein; Soybean oil, cottonseed oil, beef tallow, and pork Oils and fats such as fat; mushrooms such as enoki mushrooms and shiitake; polysaccharides such as agar, starch, and konnyaku; and food materials such as seasonings, pigments, fragrances, vitamins, and minerals can be arbitrarily combined.
It is possible to obtain a wide variety of processed foods, from nutritionally fortified foods to health foods, that could not be obtained using conventional technology. The time required for the heating step varies depending on the formulation specifications, but is preferably in the range of 3 to 15 minutes. The fiber-forming effect of stretching in the heating step has already been described, but it is more effective to impart fibrous properties if the stretching is carried out in multiple stages rather than once. The belt-shaped sheet that has undergone the heating process is passed through a seasoning tank if necessary, and then enters the next drying process. In the drying process, care must be taken to ensure uniform drying so that only the surface of the sheet does not become too dry, and the moisture content of the product is set to suit the purpose. The dried belt-shaped sheets are cut into pieces depending on the purpose. For example, it can be processed into a variety of shapes, such as the shape of squid and wild squid found in delicacies, strips shaped like beef jerky found in dried meat, and dice shaped like braised meat. Furthermore, it is possible to combine it with other foods, and it is possible to provide a processed food material that has the potential to be used as a new type of food. The present invention will be described in detail below using experimental examples, but the present invention is not limited to these experimental examples. Experimental example 1 Raw gluten 70Kg Cod surimi 10Kg Cornstarch 5Kg Squid extract 13Kg Salt 2Kg Squid flavor 0.1Kg A water-containing kneaded material with approximately 57% water content was prepared from the above mixture and extruded through a nozzle with a slit height of 10 mm and a width of 500 mm. The film was placed in a stretching process, stretched approximately 3 times as much, and then sent to a heating process. In the heating process, while maintaining the atmosphere inside the device at a temperature of 85°C and a relative humidity of 90%, the belt-shaped sheet is stretched twice in the first stage and further twice in the second stage.
It was heated for 15 minutes. Next, after drying to a specified moisture level in the drying process, it is cut into sheet pieces, which are then put through a squid tearing machine to form squid shapes, with a moisture content of approximately 25%.
Approximately 57Kg of squid type fibrous food was obtained. On the other hand, the same amount of water-containing kneaded product with the above formulation was processed using the same equipment and conditions as above, except that only the heating process was changed as described below, to obtain about 46 kg of squid-type fibrous food with a moisture content of about 25%. Ta. The heating process in this case consists of a two-stage tank filled with hot salt solution at a temperature of 85°C with a salt concentration of 8%, and the strip-shaped sheet is stretched twice in the first stage and further twice in the second stage. The sample was passed through the hot solution while heating for about 15 minutes. Table 1 shows the results of comparing the yield, flavor loss, and flavor evaluation of the squid-like fibrous foods produced by both methods. Table 1 clearly confirms the effects of the present invention.

[Table] Evaluation experiment example 2 Raw gluten 55Kg Active gluten 5Kg Wheat starch 5Kg Beef 10Kg Beef extract 20Kg Salt 3Kg Natural coloring 1Kg Meat flavor 0.01Kg A water-containing kneaded material with approximately 60% water content was prepared using the above composition, and the slit height was 15 mm and the width was It is extruded through an 800mm nozzle to form a band-shaped sheet, and then put through the rolling process for about 2 hours.
The film was stretched twice as much and sent to a heating process. In the heating process, 1/2 amount of nitrogen gas is separately mixed with the amount of air being sent into the device, and while maintaining the temperature at 95℃ and relative humidity at 95%, the first stage is doubled, and the second stage is heated. The film was heated for about 10 minutes while being stretched by 1.5 times and further stretched by 1.5 times in the third stage.
Next, it is transferred to the drying process, where it is dried to a predetermined moisture content.
I cut it into a strip of paper for Mr. Beef Jerky. In this way, approximately 50 kg of meat-flavored processed food with fibrous properties was obtained. On the other hand, for comparison, a beef jerky-like product was produced by processing the water-containing kneaded product with the above formulation by changing the heating method to a method using saturated steam or a method using a heated salt solution, and keeping other conditions the same. .
These were stored in an air bath at a temperature of 60°C and humidity of 60% for a long period of time, and changes in taste over time during storage were examined. The results are shown in Table 2. As is clear from the values in Table 2, it is recognized that the flavor stability according to the present invention is superior to other methods.

[Table] Used as an index of deterioration.
Experimental example 3 Raw gluten 60Kg Soy protein isolate 5Kg Wheat starch 8Kg Wakame 10Kg Salad oil (safflower oil) 5Kg HVP 10Kg KCL 2Kg A water-containing kneaded mixture with approximately 45% water content was prepared using the above formulation, and it was shaped into a cylinder through a 60mm diameter pipe. It was extruded and held flat with a roll while being stretched 5 times and sent to a heating process. In the heating process, the first stage is heated while maintaining the atmosphere inside the device at a temperature of 105℃ and a relative humidity of 97%.
The film was stretched 1.5 times, and further stretched 1.5 times in the second step, and heated for about 3 minutes. Next, it is dried to a predetermined moisture content in a drying process, and then processed into approximately 6 mm cubes to produce approximately 64 cube-shaped fibrous food materials suitable for health foods with a moisture content of approximately 30%.
Got Kg. On the other hand, for comparison, when obtaining 1000 kg of food material using the water-containing kneaded material with the above formulation, only the heating method was the above method according to the present invention, moist heat heating with saturated steam, and 8% sodium chloride at 95°C to 98°C. The amount of steam used when changing to a solution was measured, and the results are shown in Table 3. From the values in Table 3, it is recognized that the present invention has a remarkable effect of reducing courtesy costs.

【table】

Claims (1)

[Scope of Claims] 1. A water-containing kneaded product is obtained by adding meat and/or food materials to wheat protein alone or a mixture containing other vegetable proteins, and the water-containing kneaded product is prepared by mixing air alone or with an inert gas. A method for producing a processed food material having a continuous fiber structure, which is characterized by mixing water vapor with the air and heating the mixture in a high-temperature dry atmosphere maintained at a relative humidity of 75% to less than 100%. 2. The production method according to claim 1, wherein the wheat protein is raw gluten and/or active gluten. 3. The method according to claim 1, wherein the other vegetable protein is at least one type of protein selected from each type of protein, such as soybean, cottonseed, corn, peanut, leaf protein isolated protein, and concentrated protein. 4. The manufacturing method according to claim 1, wherein the inert gas is nitrogen gas. 5. The manufacturing method according to claim 1, wherein the temperature of the high temperature dry atmosphere is 75°C to 120°C. 6 Claim 1 in which the meat quality is selected from at least one of farmed meat, poultry meat, seafood meat, and mollusk meat.
Manufacturing method described in section. 7. Claim 1, in which the food material is at least one selected from edible materials such as nuts, fruit pulp, algae, and dairy products, and auxiliary materials such as seasonings, pigments, fragrances, and fats and oils. Manufacturing method described.