Method for manufacturing dual-temperature managed frozen package comprising frozen battered shrimp and low-temperature maintenance cream sauce pouch, and packaging system manufactured thereby

Abstract

The present invention relates to a method for manufacturing a two-way temperature-controlled frozen food package that provides frozen fried shrimp and a low-temperature-maintaining cream sauce pouch as a single package, and a frozen food packaging system manufactured thereby. Since the frozen fried shrimp and cream sauce are provided in a package form that is individually packaged using an aluminum pouch, it provides consumers with a crispier texture when cooking at home and improves convenience of consumption. The present invention for realizing this comprises: a shrimp raw material receiving step (ST 1); a size sorting step (ST 2) for sorting the received shrimp by size; a first washing step (ST 3) for washing the sorted shrimp with water to remove foreign substances; a head, internal organs, and shell removal step (ST 4) for removing the head, internal organs, and shell of the shrimp; a second washing step (ST 5) for washing the shrimp meat with water; a flour dough mixing step (ST 6) for adding the washed shrimp meat to a flour dough mixture and mixing; a breadcrumb coating step (ST 7) for coating with breadcrumbs after the flour dough coating; a frying step (ST 8) for frying the breadcrumb-coated shrimp at a high temperature; a rapid freezing step (ST 9) for rapidly freezing the fried shrimp at -80℃ or lower; and a sealing packaging step (ST 10) for placing the rapidly frozen fried shrimp into an aluminum pouch and sealing the packaging. Includes the step of enclosing the frozen fried shrimp pouch and the cream sauce pouch inside a kraft box (ST 11).

Description

Technology Field

[0001] The present invention relates to a method for manufacturing a frozen food package, and more specifically, to a method for manufacturing and providing a composite frozen food package containing frozen fried shrimp and cream sauce in a composite package form to improve cooking convenience, hygiene, and consumer satisfaction, and to a frozen food packaging system manufactured thereby. Background Technology

[0003] Generally, frozen cream shrimp products are distributed by (i) mixing fried shrimp and sauce and freezing them together, (ii) freezing the fried shrimp and cream sauce separately and packaging them individually, or (iii) separating the frozen fried shrimp from the refrigerated sauce while operating separate frozen and refrigerated displays in stores.

[0004] However, assuming microwave heating, the following problems occur repeatedly. Issues with the pre-mixing and freezing of the sauce (quality issues): Moisture from the sauce penetrates the coating of the fried shrimp, weakening the coating layer even during frozen storage. When heated in a microwave, moisture and steam rapidly soak the coating, causing sogginess and reducing satisfaction with the texture. In the case of fried shrimp and cream sauce that are frozen separately, the thawing conditions and methods differ, which can cause inconvenience and confusion for consumers, and the taste of the sauce may deteriorate after thawing from the freezer. Issues with the separate display method for frozen and refrigerated items (operational issues): Since components of the same product must be managed in different temperature zones (frozen / refrigerated), the burden of display and inventory management on store staff increases, and the likelihood of customers missing components or making mistaken purchases rises. Regarding shelf life, frozen items last 24 months, while refrigerated items typically last within one month, which can significantly reduce store operational efficiency.

[0005] Meanwhile, regarding the incomplete problem of the single-pack separate packaging method (lack of cooking optimization), even if the fried food and sauce are packaged separately, there was a problem in that it was difficult to maintain a state optimized for microwave cooking environments, such as the sauce freezing excessively under the same conditions as the fried food (the sauce freezing hard and becoming unusable immediately), or conversely, the sauce overheating and separating during the heating process (separation of fat / water), which resulted in a decrease in flavor and viscosity.

[0006] Therefore, there is a need for new packaging technology that maintains the crispness of fried food and preserves the usability (viscosity / fluidity) of sauces while selling in a single pack, and simultaneously satisfies operational convenience for stores and customers. Prior art literature

[0008] Republic of Korea Patent Registration No. 2276919 (Registered July 7, 2021) Republic of Korea Patent Registration No. 0512136 (Registered August 26, 2005) The problem to be solved

[0009] The present invention is proposed to improve upon the problems of the aforementioned conventional technology and aims to provide a frozen food packaging supply technology that improves the storage and distribution stability of fried shrimp, maintains a crispy texture when cooked in a microwave, air fryer, or oven, and enhances convenience in distribution and consumption. means of solving the problem

[0011] The method for manufacturing a package according to the present invention for achieving the above objective comprises: a shrimp raw material receiving step in which shrimp raw material, which is the main ingredient, is received; a size sorting step in which the received shrimp are sorted by size; a first washing step in which the sorted shrimp are washed first with water to remove foreign substances; a visceral and shell removal step in which the head, visceral and shell of the washed shrimp are removed; a second washing step in which the shrimp meat is washed a second time with water; a flour dough mixing step in which the washed shrimp meat is added to a flour dough mixture and mixed; a breadcrumb coating step in which breadcrumbs are coated after the flour dough coating; a frying step in which the breadcrumb-coated shrimp are fried at a high temperature; a rapid freezing step in which the fried shrimp are rapidly frozen at -80℃ or lower; and a sealing packaging step in which the rapidly frozen fried shrimp are placed into an aluminum pouch and sealed. The method is characterized by including a packaging step of enclosing a frozen fried shrimp pouch containing the above-mentioned frozen fried shrimp and a separately manufactured cream sauce pouch inside a kraft box, plastic pack, or paper box.

[0012] In addition, the cream sauce pouch enclosed in the above-mentioned packaging step is characterized by being sealed by placing a separately manufactured cream sauce into an aluminum pouch while maintaining a refrigerated state. Effects of the invention

[0014] The method for manufacturing a composite two-component frozen food package according to the present invention provides frozen fried shrimp and cream sauce ingredients in a package form in which they are individually packaged using an aluminum pouch, thereby providing consumers with a crispier texture than when cooking at home and improving convenience of consumption by eliminating the need to thaw the sauce.

[0015] In particular, the soggy texture resulting from the pre-mixing and freezing method of the sauce is improved, which demonstrates the advantage of enhancing consumer satisfaction. Brief explanation of the drawing

[0017] FIG. 1 is a flowchart of the manufacturing process of a composite frozen food package according to one embodiment of the present invention. FIG. 2 is a diagram showing the opened state of the frozen fried shrimp pouch and cream sauce pouch in the present invention. FIG. 3 is a sealed packaging diagram of a frozen fried shrimp pouch and a cream sauce pouch in the present invention. FIG. 4 is a diagram showing two types of pouches in a kraft box according to the present invention. FIG. 5 is a cross-sectional structural diagram of a kraft box according to another embodiment of the present invention. FIG. 6 is a diagram of a kraft box packaging state according to another embodiment of the present invention. Specific details for implementing the invention

[0018] Hereinafter, specific embodiments of the present invention will be examined in detail with reference to the accompanying drawings.

[0019] Embodiments of the present invention may be modified in various forms, and the scope of the present invention should not be interpreted as being limited to the embodiments described in detail below. These embodiments are provided to more fully explain the present invention to those with average knowledge in the art.

[0020] Accordingly, the shapes of components depicted in the drawings may be exaggerated to emphasize clearer explanations. It should be noted that identical components may be illustrated with the same reference numerals in each drawing. Furthermore, detailed descriptions of functions and configurations of known technology that are deemed to unnecessarily obscure the essence of the invention may be omitted.

[0021] First, the manufacturing process of a dual-temperature controlled frozen food package that provides frozen fried shrimp and a low-temperature maintaining cream sauce pouch as a single package according to one embodiment of the present invention is as follows through the flowchart of FIG. 1.

[0022] <Shrimp Raw Material Receiving Stage>(ST 1)

[0023] In the shrimp raw material receiving stage, the shrimp raw material (fresh shrimp, frozen shrimp) that serves as the main ingredient in the manufacturing process of the present invention is received.

[0024] <Size Selection Stage>(ST 2)

[0025] The shrimp received in this manner are sorted by size, selecting shrimp of uniform size and excluding those that are too large or too small.

[0026] <1st Washing Step>(ST 3)

[0027] Afterwards, the selected shrimp are washed with water to remove any foreign substances remaining on the surface of the shell.

[0028] <Step to remove head, internal organs, and skin> (ST 4)

[0029] Afterward, the head, internal organs, and shell of the shrimp that has been washed are removed.

[0030] In other words, at this time, the shell is removed along with the head, and then the shrimp is cleaned by making a cut in the back to open it up and remove the intestines, or by using a toothpick or fork to remove the intestines from the back.

[0031] <Second Washing Step>(ST 5)

[0032] Afterwards, the shrimp meat from which the head, internal organs, and shell have been removed is subjected to a second washing process using washing water.

[0033] The washing water used at this time is prepared by mixing vinegar with water in a certain ratio to remove the fishy smell, and washing with cold water helps maintain the elasticity of the shrimp meat.

[0034] Meanwhile, in the washing step, to improve washing efficiency, it is preferable to immerse the product in a sterilizing immersion solution having a sterilization function for 30 minutes to 1 hour and then wash it with running water. The sterilizing immersion solution used at this time preferably has a mixed composition in the ratio of 30-45% by weight of inorganic salt ion water, 10-30% by weight of alkylbenzyl dimethylammonium chloride, 5-20% by weight of zinc pyrithione (ZPT), 10-20% by weight of sodium thiophosphate, 1-10% by weight of sodium hypophosphite, 1-10% by weight of benzotriazole, 1-5% by weight of polyhydroxyalkanoate, and 1-5% by weight of chlorhexidine.

[0035] In this embodiment, the sterilization immersion water contains a mixture of alkylbenzyldimethylammonium chloride and zinc pyrithione, thereby enhancing the sterilization function during the immersion process. Sodium thiooxide performs a catalytic function to prevent discoloration of the inorganic salt ion water, sodium hypophosphite prevents the formation of scale, and benzotriazole and polyhydroxyalkanoate perform a function to increase the surface elasticity of the shrimp meat. Additionally, the added chlorhexidine performs an antibacterial function.

[0036] <Flour Dough Mixing Step> (ST 6)

[0037] Afterwards, the shrimp meat that has undergone the aforementioned washing and sterilization soaking is added to the flour dough and mixed.

[0038] <Breadcrumb Coating Step> (ST 7)

[0039] Afterwards, a coating process is carried out to evenly coat the surface of the shrimp coated with the aforementioned flour dough with breadcrumbs.

[0040] <Frying Level>(ST 8)

[0041] Afterwards, the breadcrumb-coated shrimp is fried at a high temperature.

[0042] At this time, the shrimp is placed in cooking oil heated to 170~175℃ and fried. By performing a pre-fry for about 40~55 seconds, a golden brown color is produced, and consumers can purchase the product and simply fry it a second time to achieve a crispier texture.

[0043] <Rapid Freezing Stage> (ST 9)

[0044] Afterward, the fried shrimp is rapidly frozen at -80℃ or below.

[0045] <Sealing and Packaging Step> (ST 10)

[0046] Afterward, the rapidly frozen fried shrimp is placed into an aluminum pouch and sealed.

[0047] In other words, at this stage, the individual packaging process is completed by placing the items in heat-resistant aluminum pouches and sealing them.

[0048] Enclosed Packaging Step (ST 11);

[0049] Afterwards, the frozen fried shrimp pouch (10) containing the above-mentioned frozen fried shrimp and the separately manufactured cream sauce pouch (20) are enclosed in a plastic pack, paper box, or kraft box (30) to complete the packaging.

[0050] That is, at this time, as shown in FIGS. 2 to 4, each pouch (10, 20) containing frozen fried shrimp and cream sauce is individually packaged and enclosed together in a paper kraft box (30) for packaging.

[0051] Meanwhile, the cream sauce pouch (20) enclosed in this step is sealed by placing a separately manufactured cream sauce into an aluminum pouch while maintaining a refrigerated state.

[0052] The kraft box (30) packaged in this manner is refrigerated and stored at -18℃, and consumers open the kraft box (30) after purchase and cook the fried shrimp contained in the frozen fried shrimp pouch (10) together with the pouch in an air fryer, oven, or microwave.

[0053] Then, the heated fried shrimp is transferred to a kraft box (30), and the cream sauce pouch (20), which is a frozen product but is kept refrigerated, is opened so that the fried shrimp can be poured over or dipped in the sauce and eaten, making it possible to cook without a separate container.

[0054] The packaging system of the present invention delays the point of contact between the sauce and the fried food until after cooking, thereby suppressing moisture penetration into the fried food coating layer even in a home heating environment and significantly reducing sogginess.

[0055] In addition, since the cream sauce maintains a fluid low-temperature state at the time of opening and cooking, it offers the advantage of being able to be consumed immediately without a separate thawing process.

[0056] Accordingly, the method for manufacturing a composite frozen food package and the packaging system of the present invention provide frozen fried shrimp and cream sauce ingredients in a package form individually packaged using aluminum pouches, thereby providing consumers with a crispier texture than when cooking at home and improving convenience of consumption.

[0057] In particular, the soggy texture resulting from the pre-mixing and freezing method of the sauce is improved, which demonstrates the advantage of enhancing consumer satisfaction.

[0058] In addition, during storage, distribution, and store display, the efficiency of storage and store operations can be maximized through frozen storage and distribution and single frozen display.

[0060] Meanwhile, in another embodiment of the present invention, a lid body (34) is integrally connected to one side of a kraft box (30) used in the kraft box sealing step (ST 11) so as to be openable and closable, and the kraft box (30) is divided by a partition (33) into a fried shrimp storage section (31) where a frozen fried shrimp pouch (10) is stored and a cream sauce storage section (32) where a cream sauce pouch (20) is stored, and the fried shrimp storage section (31) is provided with a support net (35) made of aramid fiber material to reduce the impact force transmitted to the frozen fried shrimp pouch (10), and a pouch protection layer (34a) is formed as a thin film coating on the inner side of the lid body (34) corresponding to the fried shrimp storage section (31) to improve thermal insulation and impact resistance, as can be seen through FIG. 5 and FIG. 6.

[0061] At this time, the pouch protective layer (34a) preferably has a mixed composition in the ratio of 20-40% by weight of polyolefin elastomer, 10-30% by weight of benzalkonium chloride, 10-20% by weight of benzotriazole, 5-20% by weight of titanium dioxide, 15-25% by weight of polybutylene adipate terephthalate (PBAT), 5-15% by weight of potassium benzoate, 1-10% by weight of dolninium fluoride, and 1-10% by weight of sodium silicate.

[0062] When a frozen food package is manufactured in this manner, the kraft box (30) is provided with a protective mesh (35) made of aramid fiber material and the lid body (34) is coated with a pouch protective layer (34a), so the impact transmitted to the frozen fried shrimp pouch (10) during storage and distribution can be reduced, thereby preventing damage to the fried shrimp.

[0063] In particular, since the pouch protective layer (34a) contains a mixture of benzalkonium chloride and benzotriazole components, the occurrence of coating deterioration and discoloration can be prevented. The mineral component titanium dioxide performs the function of suppressing surface cracks by improving coating stability, and polybutylene adipate terephthalate performs the function of improving the elasticity of the pouch protective layer (34a) by acting as a catalyst for the polyolefin elastomer. Potassium benzoate prevents the adhesion of foreign substances by improving the lubricity of the coating surface. Additionally, the added dolninium fluoride and sodium silicate each perform the function of suppressing bubble formation during the coating agent application process for forming the pouch protective layer (34a) and ensuring that the coating layer is formed with a uniform thickness.

[0065] Furthermore, although specific embodiments of the present invention have been described and illustrated above, it is obvious that the frozen food package manufacturing technology of the present invention can be implemented with various modifications by those skilled in the art.

[0066] For example, in the above embodiment, the container enclosed is described and illustrated as a kraft box, but if necessary, packaging can be done by enclosing it in a paper box of various sizes and shapes or a container made of synthetic resin.

[0067] Therefore, such modified embodiments should not be understood separately from the technical spirit or scope of the present invention, and such modified embodiments should be considered to be included within the appended claims of the present invention. Explanation of the symbols

[0069] 10: Frozen fried shrimp pouch 20: Cream sauce pouch 30 : Craft Box

Claims

Claim 1 A shrimp raw material receiving stage (ST 1) in which the main ingredient, shrimp, is received; a size sorting stage (ST 2) in which the received shrimp are sorted by size; a first washing stage (ST 3) in which the sorted shrimp are washed with water to remove foreign substances; a head, internal organ, and shell removal stage (ST 4) in which the heads, internal organs, and shells of the washed shrimp are removed; a second washing stage (ST 5) in which the shrimp meat is washed a second time with water; a flour dough mixing stage (ST 6) in which the washed shrimp meat is added to a flour dough mixture and mixed; a breadcrumb coating stage (ST 7) in which breadcrumbs are coated after the flour dough is applied; a frying stage (ST 8) in which the breadcrumb-coated shrimp are fried in high-temperature oil; a rapid freezing stage (ST 9) in which the fried shrimp are rapidly frozen at -80℃ or below; and a sealing packaging stage (ST 8) in which the rapidly frozen fried shrimp are placed into an aluminum pouch and sealed. 10) and;A frozen fried shrimp pouch (10) containing the above-mentioned frozen fried shrimp and a separately manufactured cream sauce pouch (20) are enclosed and packaged within a kraft box (30), wherein a lid body (34) is integrally connected to one side of the kraft box (30) so as to be openable and closable, and the kraft box (30) is divided by a partition wall (33) into a fried shrimp storage section (31) for storing the frozen fried shrimp pouch (10) and a cream sauce storage section (32) for storing the cream sauce pouch (20), and the fried shrimp storage section (31) is provided with a protective net (35) made of aramid fiber material to reduce impact force transmitted to the frozen fried shrimp pouch (10), and on the inner side of the lid body (34), a polyolefin elastomer, benzalkonium chloride, benzotriazole, titanium dioxide, and polybutylene are provided on the inner side corresponding to the fried shrimp storage section (31) to improve thermal insulation and impact resistance. A method for manufacturing a dual-temperature controlled frozen food package that provides frozen fried shrimp and a low-temperature maintaining cream sauce pouch as a single package, characterized by including a sealed packaging step (ST 11) in which a pouch protective layer (34a) having a mixed composition of adipate terephthalate, potassium benzoate, dolninium fluoride, and sodium silicate is coated. Claim 2 A method for manufacturing a dual-temperature controlled frozen food package according to claim 1, wherein the cream sauce pouch enclosed in the enclosed packaging step (ST 11) is sealed by placing a separately manufactured cream sauce into an aluminum pouch while maintaining a refrigerated state. Claim 3 A method for manufacturing a dual-temperature controlled frozen food package according to claim 1, wherein the package packaged in the enclosed packaging step (ST 11) is distributed while being stored frozen at -18℃. Claim 4 A method for manufacturing a dual-temperature controlled frozen food package that provides frozen fried shrimp and a low-temperature maintaining cream sauce pouch as a single package, characterized in that, in the second washing step (ST 5), the frozen fried shrimp and the low-temperature maintaining cream sauce pouch are immersed in sterilizing immersion water having a sterilization function for 30 minutes to 1 hour, and then washed with running water. Claim 5 delete Claim 6 A composite frozen food packaging system that provides frozen fried shrimp and a low-temperature maintaining cream sauce pouch as a single package, characterized by being manufactured by the manufacturing method of any one of claims 1 to 4.

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