Method for producing meat-like protein processed food and dried meat-like protein processed food

Abstract

The present invention provides a method for producing a meat-like protein processed food having excellent elasticity, and a method for producing a dried meat-like protein processed food. A tissue-like plant protein is mixed with a methylcellulose slurry prepared by mixing methylcellulose in water, and a blank is prepared. The blank is shaped, and the blank is heated until the product temperature reaches 60 to 100°C, and is gelled. The blank is then cooled to 10°C or lower, and the methylcellulose in the blank is re-dissolved. The blank is heated again until the product temperature reaches 60 to 100°C, and is gelled. The blank is cooled again to 10°C or lower, and a meat-like protein processed food is produced. Alternatively, the cooling step is replaced with a freezing step, and the frozen food is subjected to vacuum freeze-drying, thereby producing a dried meat-like protein processed food.

Description

TECHNICAL FIELD

[0001] The present application relates to a method for producing a meat-like protein processed food and a dried meat-like protein processed food, which contain a tissue-like plant protein and a methylcellulose slurry. BACKGROUND

[0002] In recent years, from the viewpoint of not only being suitable for vegetarians but also being environmentally friendly, alternative meats (meat-like protein processed foods) using plant-derived proteins are being studied, and many alternative meats are on the market. As a method for producing these alternative meats, a plant protein powder of soybeans, peas, wheat, or the like, a tissue-like plant protein produced by extruding them with an extruder, is used, and as a binding material of an emulsion curd containing the plant protein powder, a tissue-like plant protein, methylcellulose is used (for example, Patent Documents 1 to 4).

[0003] However, in the case where the meat-like protein processed food and the dried meat-like protein processed food are produced using methylcellulose as a binding material, only the raw material is heated by being grilled, and sufficient elasticity of the meat-like protein cannot be obtained.

[0004] PRIOR ART DOCUMENTS

[0005] PATENT DOCUMENTS

[0006] Patent Document 1: Japanese Patent Publication No. 2018-533945

[0007] Patent Document 2: Japanese Patent Publication No. 2017-509349

[0008] Patent Document 3: Japanese Patent Application Laid-Open No. 2018-29565

[0009] Patent Document 4: Japanese Patent Application Laid-Open No. 2005-21163 SUMMARY

[0010] PROBLEMS TO BE SOLVED BY THE INVENTION

[0011] An object of the present application is to provide a method for producing a meat-like protein processed food and a dried meat-like protein processed food, which have excellent elasticity of the meat-like protein.

[0012] MEANS FOR SOLVING THE PROBLEMS

[0013] The inventors of the present application have conducted intensive studies on the production of a meat-like protein processed food using a plant protein manufactured from a plant-derived protein, and have found that, in the case where methyl cellulose is used as a binding material, there is a problem in that the elasticity as a meat piece is lacking. As a result of intensive studies on the cause thereof, it has been found that the cause is methyl cellulose in the blank. Further intensive studies have been conducted, and as a result, a meat-like protein processed food having a meat-like elasticity compared with conventional ones and a method for producing a dried meat-like protein processed food have been found, thereby achieving the present application.

[0014] That is, a method for producing a meat-like protein processed food, characterized by comprising: a blank production step of mixing a plant protein in a tissue form with a methyl cellulose slurry prepared by mixing water and methyl cellulose to produce a blank; a molding step of molding the blank produced in the blank production step; a first heating step of heating the blank molded in the molding step to a product temperature of 60 to 100°C; a first cooling step of cooling the blank heated in the first heating step to 10°C or lower; a second heating step of reheating the blank cooled in the first cooling step to a product temperature of 60 to 100°C; and a second cooling step of cooling the blank reheated in the second heating step to 10°C or lower.

[0015] Further, the first cooling step of the present application is preferably a step of freezing to -10°C or lower.

[0016] Further, the heating method of the first heating step and the second heating step of the present application is preferably steaming or boiling.

[0017] Further, the content of the plant protein in a tissue form contained in the blank of the present application is preferably 9 to 36% by weight, and the content of methyl cellulose is preferably 0.8 to 1.5% by weight.

[0018] Further, the blending amount of methyl cellulose in the methyl cellulose slurry of the present application is preferably 1.5 to 4% by weight.

[0019] Further, by freezing and vacuum freeze-drying the meat-like protein processed food of the present application, a dried meat-like protein processed food can be produced.

[0020] Effects of the Invention

[0021] According to the present application, it is possible to provide a meat-like protein processed food having excellent elasticity and a method for producing a dried meat-like protein processed food. DETAILED DESCRIPTION

[0022] Hereinafter, the present application will be described in detail. However, the present application is not limited to the following description.

[0023] 1. blank making step

[0024] (textured vegetable protein)

[0025] The textured vegetable protein of the present application is produced by extruding soybean protein (including soybean flour), pea protein, wheat protein, and the like, plant protein powder, plant materials such as starch, and inorganic substances such as calcium salt, using a twin-screw extruder under high temperature and high pressure, and examples thereof include puffed granular protein, fibrous protein having a fiber directionality by extruding while cooling the discharge port using a cooling die and the like to suppress puffing. The puffed granular protein can obtain a granular texture having elasticity such as ground meat of a hamburger patty, and the fibrous protein can obtain a fibrous texture such as muscle of a beef steak. These textured vegetable proteins can be used alone or in combination according to the texture of the meat-like protein processed food desired. In addition, by performing crushing and cutting, the size, length, and the like can be appropriately adjusted and used thereafter.

[0026] In the case where they are dried or in a state of low moisture, they can be used after being rehydrated by absorbing water using cold water or hot water at one time. In addition, as needed, the flavor of plant origin possessed by the textured vegetable protein can be reduced by dehydration and frying treatment by heating while being immersed in oil.

[0027] In addition, the content of the textured vegetable protein of the present application is the content of the solid component after removing the oil and moisture, since the moisture value and the oil content differ depending on the treatment.

[0028] (methylcellulose slurry)

[0029] As the production method of the methylcellulose slurry of the present application, methylcellulose is dissolved in water to produce a slurry. The methylcellulose of the present application can be used without particular problems as long as it is methylcellulose, or hydroxypropylmethylcellulose obtained by processing methylcellulose. Although the properties differ depending on the viscosity, the substitution amount of methoxyl group and hydroxypropoxyl group, as long as a methylcellulose having a gelation temperature of 50°C or higher and a gel redissolution temperature of about 10°C to 50°C is used. A methylcellulose having a high viscosity of 2800 mm 2 / s or higher, and particularly preferably 77000 mm 2 / s or higher is preferable. Since the methylcellulose is dissolved in cold water, the temperature of the water in which the dissolution is performed is preferably 10°C or lower.

[0030] In addition, since the methylcellulose slurry of the present application is mainly used as a binder for bonding between the textured vegetable proteins of the meat-like protein processed food using the textured vegetable proteins, an oil and fat for imparting flavor, an emulsifier for dispersing the oil and fat, salt, sugar, a spice, a vegetable protein powder such as soy protein, wheat protein, or the like as a protein material, a pigment for coloring, and the like can be added as other raw materials. The methylcellulose and these raw materials are added to water, and stirred with a blender or the like until it becomes a mousse shape to produce the slurry.

[0031] The blending amount of the methylcellulose in the methylcellulose slurry of the present application is preferably 1.5 to 4% by weight. If it is less than 1.5% by weight, the blending amount of the methylcellulose slurry in the blank needs to be increased in order to bond between the textured vegetable proteins. If it is more than 4% by weight, the methylcellulose slurry itself is hard, and it is difficult to mix with the textured vegetable proteins.

[0032] (Mixing)

[0033] As other materials, in addition to the textured vegetable proteins and the methylcellulose slurry, an ingredient for seasoning, a food material is mixed to produce the blank. As the other materials, salt, nucleic acid, sodium glutamate, soy sauce, red wine, pepper, a vegetable oil such as soybean oil, rapeseed oil, a spice, a soy protein powder, and the like, a food material such as onion, carrot, cabbage, and the like can be cited. The mixing method is not particularly limited, and the mixing can be performed with a blender or the like, or can be performed by hand, as long as it is mixed to be uniformly mixed.

[0034] The blending amount of the methylcellulose slurry in the blank is preferably 30 to 75% by weight. If the methylcellulose slurry is too much, the blending amount of the textured vegetable proteins becomes small, and the texture becomes like kamaboko. If it is too small, the blending amount of the textured vegetable proteins becomes large, it is difficult to retain the shape of the blank, the blending amount of the methylcellulose in the methylcellulose slurry needs to be increased, and the texture becomes poor. In addition, the blending amount of the methylcellulose in the blank is preferably 0.8 to 1.5% by weight. If it is less than 0.8% by weight, the shape retention and the elasticity of the blank are weak, and if it is more than 1.5% by weight, the elasticity becomes too strong.

[0035] In addition, the content of the textured vegetable proteins in the blank is preferably 9 to 36% by weight. If it is too small, the blending amount of the methylcellulose slurry of the blank is increased, and the texture like kamaboko becomes strong, and if it is too large, the blending amount of the methylcellulose slurry of the blank is small, it is not only difficult to retain the shape of the blank, but also not connected, and the texture from the textured vegetable proteins becomes strong.

[0036] 2. forming step

[0037] The prepared blank is shaped using a molding die or the like. As the molding die, there is no particular limitation as long as it has heat resistance, and examples that can be given include a stainless steel molding die, a heat-resistant plastic bag, a heat-resistant plastic container, a casing used in hams, sausages, and the like, and a casing. The prepared blank is placed in these molding dies and shaped into a target shape. In the case of cutting into a prescribed shape after the shaping step, it is preferable to set the thickness of the blank to 30 mm or less. By so doing, heat easily reaches the center, uneven heating is less likely to occur, and the heating time is also shortened.

[0038] 3. first heating step

[0039] The shaped blank is heated. The heating method is not particularly limited, and examples that can be given include boiling, steaming, baking using an oven, and the like. Heating using boiling or steaming easily transfers heat uniformly to the blank, and thus is preferable. At this time, heating is performed until the internal temperature is 60°C or higher, and the entire blank is reliably gelled. The internal temperature in the present application refers to the temperature at the center of the blank. It is preferable to heat until the internal temperature is 60 to 100°C, and more preferably until the internal temperature is 60 to 100°C. If the internal temperature is lower than 60°C, the gelling of the methylcellulose is insufficient, and if the internal temperature is higher than 100°C, the elasticity is not sufficient and the blank becomes hard. More preferably, the internal temperature is in the range of 60 to 90°C. In addition, in the case where the blank is further cut into a prescribed shape after heating, the residual heat is removed and cutting is performed.

[0040] 4. first cooling step

[0041] The blank heated in the first heating step is cooled. In the first cooling step of the present application, cooling is performed until the internal temperature of the blank is 10°C or lower. The cooling method is not particularly limited, and examples that can be given include cooling using cold air, cooling using immersion in cooling water, cooling using freezing, and the like. More preferably, a method of reliably freezing until the internal temperature is -10°C or lower is used. By reliably performing cooling, the methylcellulose that has been once gelled is redissolved, and the fibers of the methylcellulose are gathered into thick bundles.

[0042] 5. second heating step

[0043] The blank cooled in the first cooling step is reheated. The heating method is the same as in the first heating step, and the heating method is not particularly limited, and examples that can be given include boiling, steaming, baking using an oven, and the like. Heating using boiling or steaming easily transfers heat uniformly to the blank, and thus is preferable. In addition, the internal temperature is the same as in the first heating step, and it is preferable to heat until the internal temperature is 60 to 100°C, and more preferably until the internal temperature is 60 to 100°C, and the entire blank is reliably re-gelled.

[0044] 6. second cooling step

[0045] The material cooled in the second heating step is cooled. In the second cooling step of the present application, the material is cooled to a temperature of 10°C or lower. The cooling method is not particularly limited, and examples include cooling using cold air, cooling using immersion in cooling water, cooling using freezing, and the like. In the second cooling step, the material is cooled to a temperature at which the meat-like protein processed food is stored, and in the case of refrigerated storage, the material is cooled to about 4 to 8°C, and in the case of frozen storage, the material is frozen to -18°C or lower. The freezing method for frozen storage is not particularly limited, and conventional techniques can be used. For example, not only commercial freezing devices such as a tunnel-type freezer, a spiral freezer, a box-type freezer, a quick freezer, a flexible freezer using salt water, and the like can be used, but also a general commercial freezer or a household freezer can be used. The freezing is performed using a quick freezer at about -35°C, and the material is preferably reliably frozen to -18°C or lower.

[0046] The material cooled in the second cooling step can be stored as a refrigerated or frozen meat-like protein processed food. The meat-like protein processed food stored by refrigeration or freezing can be heated by cooking using a frying pan or the like, or by a microwave oven, and then eaten.

[0047] In the case of a dried meat-like protein processed food, the second cooling step can be replaced by a freezing step described later, and the frozen material can be dried using a drying step described later.

[0048] 7. third heating step

[0049] In the case of a dried meat-like protein processed food, a third heating step in which the material cooled in the second cooling step is heated again can be provided as needed. The third heating step can be performed using the same method as the first and second heating steps described above, or can be a heating method in which the surface is cooked or the like. However, since the material becomes harder as the heating step and the cooling step are repeated, it is preferable that the material is not further cooled and heated by repeating the steps.

[0050] 7. freezing step

[0051] In the case of the dried meat-like processed food, the material is frozen before the drying process described later, and the residual heat of the material heated in the second heating process or the third heating process is eliminated by freezing the material. Note that, as described above, in the case of the dried meat-like processed food, the second cooling process can be set as a freezing process. The freezing method is not particularly limited, and a conventional technique can be applied. For example, not only a commercial freezing device such as a tunnel-type freezing machine of the air-blast type, a spiral freezing machine, a box-type freezing machine, a quick freezing warehouse, a flexible freezing machine of the brine type, but also a general commercial or household freezer can be used. The freezing can be performed by, for example, a quick freezing warehouse at about -35°C, or a commercial freezer at -18°C. The freezing temperature is not particularly limited, but in order to perform the drying process described later, it is preferable to reliably freeze the material to a temperature of -18°C or lower. In the freezing process, as in the cooling process, the methyl cellulose that has been gelatinized when the material is frozen is redissolved, and the fibers of the methyl cellulose are gathered into thicker bundles.

[0052] 8. drying step

[0053] In the case of the dried meat-like processed food, the frozen material shaped into a predetermined shape is filled into a tray used in vacuum freeze drying, and vacuum freeze drying is performed using a vacuum freeze drying machine under reduced pressure. The vacuum freeze drying conditions are not particularly limited, and the drying can be performed as long as the vacuum degree at which the frozen material is not thawed and the shelf heating temperature are used. As a preferable range, the vacuum freeze drying is performed so that the vacuum degree is 1.5 torr or lower, the shelf heating temperature is 90°C or lower, and the moisture after drying is 1 to 7% by weight, and a dried meat-like processed food is produced. If the drying is excessive, the dried meat-like processed food is easily broken, and thus the moisture can be adjusted by a moisture adjustment process after the drying, as necessary.

[0054] 9. others

[0055] The dried meat-like processed food subjected to the vacuum freeze drying can be used as a food material for instant noodles, instant soup, instant rice, or the like, which is cooked after hot water is added or which is cooked in a microwave oven after cold water is added. At this time, by the cooking, the methyl cellulose fibers are gelatinized in a state of being thickened while being rehydrated, and thus a dried meat-like processed food having excellent elasticity like meat is obtained.

[0056] The present embodiment is further described in detail below by citing examples.

[0057] Example

[0058] <Experiment 1> Study of the number of times of heating and cooling

[0059] (Example 1-1)

[0060] The granular soybean protein (NEWSOY MY (registered trademark) S11 (manufactured by Nisshin OilliO Food Ingredients Corporation) and NEW FUJINIK (registered trademark) 10 (manufactured by Nijo Seiyu Corporation) were mixed at a ratio of 1 : 1) as a textured vegetable protein, the liquid material (6% by weight of chopped onion and 6% by weight of soy sauce), the powder material (2.2% by weight of salt, 0.1% by weight of pepper, 0.6% by weight of garlic powder, 2.4% by weight of sodium glutamate, 0.6% by weight of caramel color, and 0.1% by weight of tocopherol preparation), and the methylcellulose slurry were mixed in a kneader at a ratio of 20% by weight, 12% by weight, 6% by weight, and 62% by weight, respectively, to produce a dough.

[0061] The granular soybean protein (NEWSOY MY (registered trademark) S11 (manufactured by Nisshin OilliO Food Ingredients Corporation) and NEW FUJINIK (registered trademark) 10 (manufactured by Nijo Seiyu Corporation) were mixed at a ratio of 1 : 1) as a textured vegetable protein, the liquid material (6% by weight of chopped onion and 6% by weight of soy sauce), the powder material (2.2% by weight of salt, 0.1% by weight of pepper, 0.6% by weight of garlic powder, 2.4% by weight of sodium glutamate, 0.6% by weight of caramel color, and 0.1% by weight of tocopherol preparation), and the methylcellulose slurry were mixed in a kneader at a ratio of 20% by weight, 12% by weight, 6% by weight, and 62% by weight, respectively, to produce a dough.

[0062] The dough was placed in a metal mold (φ80 mm, height 10 mm) to perform molding.

[0063] The molded dough was taken out of the mold, placed on a tray, and heated in a steamer (about 100°C) until the product temperature reached 80°C (first heating).

[0064] The heated dough was frozen in a quick freezer at -40°C so that the product temperature reached -10°C (first cooling).

[0065] The frozen dough was placed on a tray and heated again in a steamer (about 100°C) until the product temperature reached 80°C (second heating).

[0066] The reheated dough was frozen in a quick freezer at -40°C so that the product temperature reached -20°C or lower (second cooling), to produce a meat-like protein processed food (frozen) sample.

[0067] (Comparative Example 1-1)

[0068] The molded dough in Example 1-1 was not heated but directly frozen in a quick freezer at -40°C so that the product temperature reached -20°C or lower, to produce a meat-like protein processed food (frozen) sample.

[0069] (Comparative Example 1-2)

[0070] The heated dough in the first heating of Example 1-1 was frozen in a quick freezer at -40°C so that the product temperature reached -20°C or lower, to produce a meat-like protein processed food (frozen) sample.

[0071] Each sample of the meat-like protein processed product (frozen) prepared in Experiment 1 was cooked in a frying pan heated to 150°C for 3 minutes on each side, eaten and subjected to sensory evaluation. For the sensory evaluation, 5 experienced panelists were used, and the evaluation was performed according to the following sensory evaluation criteria.

[0072] < Sensory Evaluation Criteria >

[0073] 5: Has a suitable meat-like springiness, and is a very good product.

[0074] 4: Is slightly hard or has a strong springiness or is slightly soft or has a weak springiness, but is a good product.

[0075] 3: Is somewhat hard or has a strong springiness or is somewhat soft or has a weak springiness, but is an acceptable product as a commodity.

[0076] 2: Is hard or has a strong springiness or is soft or has a weak springiness, and is a poor product in terms of quality.

[0077] 1: Is extremely hard or has a strong springiness or is soft or has an extremely weak springiness, and is a significantly poor product in terms of quality.

[0078] The formulation of the methylcellulose slurry of Experiment 1 is shown in Table 1 below, the formulation of the blank is shown in Table 2 below, and the results of the sensory evaluation are shown in Table 3 below.

[0079] [Table 1]

[0080]

[0081] [Table 2]

[0082]

[0083] [Table 3]

[0084]

[0085] As shown in Comparative Example 1-1, if the blank is frozen without being heated, and is heated only by cooking at the time of eating, the springiness is very weak, and the texture is soft. As shown in Comparative Example 1-2, if the blank is heated once by steaming to gelatinize it, and is frozen, and the resulting material is heated by cooking at the time of eating, the springiness is exhibited compared to Comparative Example 1-1, but the texture is still soft and weak. In contrast, as shown in Example 1-1, if the blank is heated by steaming to gelatinize the methylcellulose, the methylcellulose is redissolved by cooling, and is further heated to gelatinize it, and is frozen, and is heated by cooking at the time of eating, a texture very close to meat is formed, which has a moderate springiness and hardness.

[0086] <Experiment 2> Verification of Heating Temperature

[0087] (Example 2-1)

[0088] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the product temperature of the first heating and the second heating was set to 60°C.

[0089] (Example 2-2)

[0090] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the product temperature of the first heating and the second heating was set to 70°C.

[0091] (Example 2-3)

[0092] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the product temperature of the first heating and the second heating was set to 90°C.

[0093] (Example 2-4)

[0094] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the product temperature of the first heating and the second heating was set to 100°C.

[0095] (Comparative Example 2-1)

[0096] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the product temperature of the first heating and the second heating was set to 50°C.

[0097] The meat-like protein processed food samples of Experiment 2 were eaten and evaluated in the same manner as Experiment 1. The results of the evaluation are shown in Table 4 below.

[0098] [Table 4]

[0099]

[0100] As shown in Comparative Example 2-1 of Experiment 2, if the gelation temperature of the methyl cellulose is below 55°C, the gelation is weak, and the result is a meat-like protein processed food after cooking that is weak in elasticity and soft. It is thus considered that it is necessary to reliably gel the methyl cellulose using the heating process. In addition, as shown in Example 2-1, Example 2-2, and Example 1-1, the higher the product temperature, the stronger the elasticity and the more the hardness is exhibited, but as shown in Example 2-3 and Example 2-4, if the product temperature is further increased, there is a tendency for the hardness and elasticity to become too strong. It is thus considered that the preferred product temperature at the time of heating is 60 to 90°C.

[0101] <Experiment 3> Verification of Cooling Temperature

[0102] (Example 3-1)

[0103] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the first cooling was performed in a quick freezing freezer at -40°C so that the product temperature was -20°C.

[0104] (Example 3-2)

[0105] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the first cooling was performed in a quick freezing freezer at -40°C so that the product temperature was 0°C.

[0106] (Example 3-3)

[0107] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the first cooling was performed in a quick freezing freezer at -40°C so that the product temperature was 5°C.

[0108] (Example 3-4)

[0109] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the first cooling was performed in a quick freezing freezer at -40°C so that the product temperature was 10°C.

[0110] (Comparative Example 3-1)

[0111] A meat-like protein processed food sample was produced in accordance with the method of Example 1-1, except that the first cooling was performed in a quick freezing freezer at -40°C so that the product temperature was 20°C.

[0112] The meat-like protein processed food samples of Experiment 3 were eaten and sensory evaluated in the same manner as Experiment 1. The results of the evaluation are shown in Table 5 below.

[0113] [Table 5]

[0114]

[0115] As shown in Experiment 3, a tendency was observed in which the higher the product temperature, the softer the texture and the weaker the elasticity. If the temperature is higher than the resolubilization temperature of methylcellulose (15°C), a tendency can be observed in which the texture is significantly poor. It is thus considered that it is preferable to resolubilize methylcellulose completely using cooling, preferably at 10°C or lower, more preferably at 5°C or lower.

[0116] <Experiment 4> Investigation of Heating Method

[0117] (Example 4-1)

[0118] The frozen raw material in the first cooling process is placed in a bag, and the second heating is set to be cooked in hot water at 80°C (immersion heating) until the product temperature reaches 80°C. Otherwise, meat protein processed food samples are prepared according to the method of Example 1-1.

[0119] (Example 4-2)

[0120] Set the second heating to oven heating (firing) at 120°C until the product temperature reaches 80°C.

[0121] The meat protein processed food samples from Experiment 4 were consumed and sensory evaluated in the same manner as those from Experiment 1. The results are shown in Table 6 below.

[0122] [Table 6]

[0123]

[0124] The results of Experiment 4 show that steaming and boiling are better heating methods than baking.

[0125] <Experiment 5> On Methylcellulose Slurry and Tissue-like Plant Protein

[0126] (Example 5-1)

[0127] Except that the amount of textured plant protein was set to 10% by weight and the amount of methylcellulose slurry was set to 72% by weight, meat-like protein processed food samples were prepared according to the method of Examples 1-1.

[0128] (Example 5-2)

[0129] Except that the amount of textured plant protein was set to 30% by weight and the amount of methylcellulose slurry was set to 52% by weight, meat-like protein processed food samples were prepared according to the method of Examples 1-1.

[0130] (Example 5-3)

[0131] Except that the amount of textured plant protein was set to 40% by weight and the amount of methylcellulose slurry was set to 42% by weight, meat-like protein processed food samples were prepared according to the method of Examples 1-1.

[0132] (Example 5-4)

[0133] Except that the amount of methylcellulose in the methylcellulose slurry was set to 1.5% by weight and the amount of water was set to 88% by weight, meat-like protein processed food samples were prepared according to the method of Examples 1-1.

[0134] (Example 5-5)

[0135] Except that the amount of methylcellulose in the methylcellulose slurry was set to 1.8% by weight and the amount of water was set to 87.7% by weight, meat-like protein processed food samples were prepared according to the method of Examples 1-1.

[0136] (Examples 5-6)

[0137] Except that the amount of methylcellulose in the methylcellulose slurry was set to 2.2% by weight and the amount of water was set to 87.3% by weight, meat-like protein processed food samples were prepared according to the method of Examples 1-1.

[0138] (Examples 5-7)

[0139] Except that the amount of methylcellulose in the methylcellulose slurry was set to 2.4% by weight and the amount of water was set to 87.1% by weight, meat-like protein processed food samples were prepared according to the method of Examples 1-1.

[0140] (Examples 5-8)

[0141] Except that the amount of methylcellulose in the methylcellulose slurry was set to 4% by weight and the amount of water was set to 85.5% by weight, the methylcellulose slurry was prepared according to the method of Examples 1-1.

[0142] For granular soy protein (a 1:1 mixture of NEWSOYMY (registered trademark) S11 (manufactured by Nissin Oriyo Co., Ltd.) and NEWFUJINIK (registered trademark) 10 (manufactured by Fuji Oil Co., Ltd.), which is a textured plant protein, after rehydration with an equal amount of water, it is gently dehydrated using a centrifugal dehydrator, and then water is added again to allow it to absorb water until the same weight is achieved.

[0143] Relative to 40g of rehydrated textured vegetable protein, 3g of rapeseed oil was added and thoroughly stirred to prepare the textured vegetable protein used in Examples 5-8. The prepared textured vegetable protein was then mixed in a kneader with 43% by weight, liquid materials (6% by weight of chopped onion, 6% by weight of soy sauce, and 9% by weight of water), powder materials (2.2% by weight of salt, 0.1% by weight of pepper, 0.6% by weight of garlic powder, 2.4% by weight of monosodium glutamate, 0.6% by weight of caramel coloring, and 0.1% by weight of tocopherol preparation), and 30% by weight of methylcellulose slurry to form a raw material. Other processes followed the method in Examples 1-1 to produce meat-like protein processed food samples.

[0144] The meat protein processed food samples from Experiment 5 were consumed and sensory evaluated in the same manner as those from Experiment 1. The formulations of the methylcellulose slurry for each test area in Experiment 5 are shown in Table 7, the formulations of the raw materials for each test area are shown in Table 8, and the evaluation results are shown in Table 9.

[0145] [Table 7]

[0146]

[0147] [Table 8]

[0148]

[0149] [Table 9]

[0150]

[0151] As shown in Example 5-1, if the amount of textured plant protein in the raw material decreases, the amount of methylcellulose slurry increases. Although this is acceptable for a commercial product, the texture is perceived as a gel-like, fish cake-like consistency. Conversely, as shown in Examples 5-2 and 5-3, if the amount of textured plant protein in the raw material increases, the amount of methylcellulose slurry decreases. Not only does the shape retention of the raw material deteriorate, but although it is acceptable for a commercial product, the soft texture derived from the textured plant protein increases, weakening the overall consistency of the texture of the raw material. Since the moisture content of the textured plant protein changes depending on the processing, it is considered that the content of the textured plant protein as a solid component, excluding oil and water, is preferably in the range of 9 to 36% by weight.

[0152] As shown in Examples 5-4 and 5-5, if the amount of methylcellulose in the methylcellulose slurry is reduced, although it is above acceptable level for a commercial product, the adhesion between the tissue-like plant proteins weakens, and the overall elasticity also tends to weaken. Conversely, as shown in Examples 5-6 and 5-7, if the amount of methylcellulose in the methylcellulose slurry is increased, although it is above acceptable level for a commercial product, the elasticity tends to become too strong.

[0153] Furthermore, as shown in Examples 5-8, if the amount of methylcellulose in the methylcellulose slurry is set to 4% by weight, the methylcellulose slurry becomes hard and difficult to mix with the raw material. However, if the content of methylcellulose in the raw material is appropriate, the taste is as good as in Examples 1-1. It is believed that in this invention, the methylcellulose in the raw material gelled in the first heating step is re-dissolved in the first cooling step and re-gelled in the second heating step. Therefore, water dissolves from the rehydrated, textured plant protein, resulting in a product with a suitable overall taste. In addition, regarding flavor, the flavor derived from the textured plant protein is less pronounced, which is better than in Examples 1-1.

[0154] <Experiment 6> Study on the number of heating and cooling cycles in dried meat protein processed foods

[0155] (Example 6-1)

[0156] For the meat-like protein processed food (frozen product) prepared in Example 1-1, a vacuum freeze dryer (Toyo Giken Co., Ltd. TFD10LF4) was used to dry the product to a temperature of 58°C at a temperature below 0.1 torr, with the shelf temperature set at 87°C for 4 hours, 75°C for 3 hours, and then at 60°C, until the product temperature reached 58°C. In this case, the second cooling step in Example 1-1 was converted into a freezing step in Example 6-1.

[0157] (Example 6-2)

[0158] The raw material that was reheated (second heating) in Example 1-1 was frozen (second cooling) until the product temperature was below -10°C. It was then reheated in a steamer (about 100°C) (third heating) until the product temperature was 80°C. The reheated raw material was then frozen in a rapid freezing chamber at -40°C (freezing) until the product temperature was below -20°C. Otherwise, dried meat protein processed food samples were prepared using the same method as in Example 6-1.

[0159] (Comparative Example 6-1)

[0160] Except for omitting the first cooling and second heating, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0161] Take 10g of each sample of the dried meat-like protein processed product prepared in Experiment 6, pour 370g of boiling water into a foamed paper cup, cover and let stand for 3 minutes, then remove from the hot water and consume for sensory evaluation. The sensory evaluation was conducted by 5 senior evaluation team members according to the following evaluation criteria.

[0162] Sensory Evaluation Criteria

[0163] 5. It has suitable meat-like elasticity, making it an excellent product.

[0164] 4: Slightly hard or highly elastic, or slightly soft or less elastic, but still a good product.

[0165] 3: Slightly hard or highly elastic, or slightly soft or less elastic, but still a qualified product as a commodity.

[0166] 2: Products that are hard or have strong elasticity, or soft or have weak elasticity, and are of poor quality.

[0167] 1: Set products that are extremely hard or highly elastic, or soft or extremely weakly elastic, and that are significantly of poor quality to 1.

[0168] The sensory evaluation results of Experiment 6 are shown in Table 10 below.

[0169] [Table 10]

[0170]

[0171] As shown in Comparative Example 6-1, if the raw material is simply frozen and dried after heating, the dried meat sample reconstituted with hot water has weak elasticity and a soft texture. As shown in Example 6-1, after heating the raw material, it is cooled once, then heated again, and then frozen and dried. This results in increased hardness and elasticity in the dried meat sample reconstituted with hot water, resulting in a very good texture. As shown in Example 6-2, after repeating the heating and cooling process twice, the raw material is further heated, frozen, and dried. This results in a further increase in elasticity compared to Example 6-1, but also an increase in hardness. Based on these results, it can be concluded that, as a manufacturing process, heating-cooling-heating-freezing-drying of the raw material is preferable.

[0172] <Experiment 7> Verification of heating temperature in dried meat protein processed foods

[0173] (Example 7-1)

[0174] Except that the temperature of the first and second heating is set to 60°C, dried meat protein processed food samples are prepared according to the method of Example 6-1.

[0175] (Example 7-2)

[0176] Except that the temperature of the first and second heating is set to 70°C, dried meat protein processed food samples are prepared according to the method of Example 6-1.

[0177] (Example 7-3)

[0178] Except that the temperatures of the first and second heating were set to 90°C, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0179] (Example 7-4)

[0180] Except that the temperatures of the first and second heating were set to 100°C, dried meat protein processed food samples were prepared according to the method of Example 6-1.

[0181] (Comparative Example 7-1)

[0182] Except that the temperature of the first and second heating is set to 50°C, dried meat protein processed food samples are prepared according to the method of Example 6-1.

[0183] The dried meat-like protein processed food samples from Experiment 7 were consumed and subjected to sensory evaluation in the same manner as those from Experiment 6. The evaluation results are presented in Table 11 below.

[0184] [Table 11]

[0185]

[0186] As shown in Comparative Example 7-1 of Experiment 7, if the gelation temperature of methylcellulose is below 55°C, gelation is weak, resulting in a soft and elastic product of dried meat-like protein processed food reconstituted with hot water. Therefore, it is considered that methylcellulose needs to be reliably gelled in dried meat-like protein processed foods. Furthermore, as shown in Examples 7-1, 7-2, and 6-1, higher temperatures result in stronger elasticity and increased firmness; however, as shown in Examples 7-3 and 7-4, further increases in temperature lead to an excessively strong firmness and elasticity. Therefore, it is considered that a preferred heating temperature for dried meat-like protein processed foods is 60–90°C.

[0187] <Experiment 8> Verification of cooling temperature in dried meat protein processed foods

[0188] (Example 8-1)

[0189] Except for freezing the cut blanks in a rapid freezing chamber at -40°C (first cooling) to bring the product temperature down to below -20°C, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0190] (Example 8-2)

[0191] Except for cooling the cut blanks in a rapid freezing chamber at -40°C (first cooling) to bring the product temperature below 0°C, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0192] (Example 8-3)

[0193] Except for cooling the cut blanks in a rapid freezing chamber at -40°C (first cooling) to bring the product temperature down to below 5°C, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0194] (Example 8-4)

[0195] Except for cooling the cut blanks in a rapid freezing chamber at -40°C (first cooling) to bring the product temperature down to below 10°C, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0196] (Comparative Example 8-1)

[0197] Except for cooling the cut blanks in a rapid freezing chamber at -40°C (first cooling) to bring the product temperature down to below 20°C, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0198] The dried meat-like protein processed food samples from Experiment 8 were consumed and subjected to sensory evaluation in the same manner as those from Experiment 6. The evaluation results are presented in Table 12 below.

[0199] [Table 12]

[0200]

[0201] As shown in Experiment 8, a trend was observed in dried meat-like protein processed foods that the higher the temperature, the softer the texture and the weaker the elasticity. At temperatures higher than the redissolution temperature of methylcellulose (15°C), a significant deterioration in texture was observed. Therefore, it is considered preferable to use cooling to completely redissolve methylcellulose, preferably at 10°C or below, and more preferably at 5°C or below. Furthermore, as shown in Examples 6-1 and 8-1, the texture of dried meat-like protein processed foods improved when frozen during the cooling process; therefore, freezing at a temperature below 0°C is considered more preferable.

[0202] <Experiment 9> Study on heating methods in dried meat protein processed foods

[0203] (Example 9-1)

[0204] The frozen raw material from the first cooling process was added to a bag and the second heating process was set to cook in hot water at 80°C until the product temperature reached 80°C. Otherwise, a dried meat protein processed food sample was prepared according to the method of Example 6-1.

[0205] (Example 9-2)

[0206] The blanks frozen in the first cooling process are placed on a metal mesh and then heated (fired) in an oven at 120°C until the product temperature reaches 80°C.

[0207] The dried meat-like protein processed food samples from Experiment 9 were consumed and subjected to sensory evaluation in the same manner as those from Experiment 6. The evaluation results are presented in Table 13 below.

[0208] [Table 13]

[0209]

[0210] The results of Experiment 9 show that, as a heating method, steaming and boiling are preferred over baking (roasting).

[0211] <Experiment 10> On Methylcellulose Slurry and Textured Plant Protein in Dried Meat-like Protein Processed Foods

[0212] (Example 10-1)

[0213] Except for setting the amount of textured plant protein to 10% by weight and the amount of methylcellulose slurry to 72% by weight, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0214] (Example 10-2)

[0215] Except for setting the amount of textured plant protein to 30% by weight and the amount of methylcellulose slurry to 52% by weight, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0216] (Example 10-3)

[0217] Except that the amount of textured plant protein was set to 40% by weight and the amount of methylcellulose slurry was set to 42% by weight, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0218] (Example 10-4)

[0219] Except that the amount of methylcellulose in the methylcellulose slurry was set to 1.5% by weight and the amount of water was set to 88% by weight, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0220] (Examples 10-5)

[0221] Except that the amount of methylcellulose in the methylcellulose slurry was set to 1.8% by weight and the amount of water was set to 87.7% by weight, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0222] (Examples 10-6)

[0223] Except that the amount of methylcellulose in the methylcellulose slurry was set to 2.2% by weight and the amount of water was set to 87.3% by weight, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0224] (Examples 10-7)

[0225] Except that the amount of methylcellulose in the methylcellulose slurry was set to 2.4% by weight and the amount of water was set to 87.1% by weight, dried meat-like protein processed food samples were prepared according to the method of Example 6-1.

[0226] (Examples 10-8)

[0227] Except that the amount of methylcellulose in the methylcellulose slurry was set to 4% by weight and the amount of water was set to 85.5% by weight, the methylcellulose slurry was prepared according to the method of Example 6-1.

[0228] For granulated soy protein, which is a type of plant protein, granulated soy protein (NEWSOYMY (registered trademark) S11 (made by Nissin Oriyo Co., Ltd.) and NEWFUJINIK (registered trademark) 10 (made by Fuji Oil Co., Ltd.) are mixed in a 1:1 ratio, rehydrated with an equal amount of water, then gently dehydrated using a centrifugal dehydrator, and water is added again to allow it to absorb water until the same weight is achieved.

[0229] Relative to 40g of rehydrated textured vegetable protein, 3g of rapeseed oil was added and thoroughly stirred to produce the textured vegetable protein used in Examples 10-8. The resulting textured vegetable protein was then mixed in a kneader with 43% by weight of the prepared textured vegetable protein, 21% by weight of liquid materials (6% by weight of chopped onion, 6% by weight of soy sauce, and 9% by weight of water), 6% by weight of powdered materials (2.2% by weight of salt, 0.1% by weight of pepper, 0.6% by weight of garlic powder, 2.4% by weight of monosodium glutamate, 0.6% by weight of caramel coloring, and 0.1% by weight of tocopherol preparation), and 30% by weight of methylcellulose slurry to form a raw material. Subsequent processes followed the method of Example 6-1 to produce dried meat-like protein processed food samples.

[0230] The dried meat protein processed food samples from Experiment 10 were consumed and sensory evaluated in the same manner as those from Experiment 6. The formulations of the methylcellulose slurry for each test area in Experiment 10 are shown in Table 14, the formulations of the raw materials for each test area are shown in Table 15, and the evaluation results are shown in Table 16.

[0231] [Table 14]

[0232]

[0233] [Table 15]

[0234]

[0235] [Table 16]

[0236]

[0237] In dried meat-like protein processed foods, as shown in Example 10-1, if the amount of textured plant protein in the preform decreases, the amount of methylcellulose slurry increases. Although this is acceptable for the product, the texture is perceived as a gel-like, fish cake-like consistency. Conversely, as shown in Examples 10-2 and 10-3, if the amount of textured plant protein in the preform increases, the amount of methylcellulose slurry decreases. Not only does the shape retention of the preform deteriorate, but while it is still acceptable for the product, the soft texture derived from the textured plant protein increases, resulting in a weaker uniformity in texture as a whole preform. Since the moisture content of textured plant protein changes depending on the processing, it is considered that the content of textured plant protein as a solid component, excluding oil and water, is preferably in the range of 9 to 36% by weight.

[0238] Furthermore, in dried meat-like protein processed foods, as shown in Examples 10-4 and 10-5, if the amount of methylcellulose in the methylcellulose slurry is reduced, it is at a level above acceptable for the product; however, the binding between the textured plant proteins weakens, and the overall elasticity also tends to weaken. Conversely, as shown in Examples 10-6 and 10-7, if the amount of methylcellulose in the methylcellulose slurry is increased, although it is at a level above acceptable for the product, the elasticity tends to become excessively strong.

[0239] Furthermore, in dried meat-like protein processed foods, as shown in Examples 10-8, if the amount of methylcellulose in the methylcellulose slurry is set to 4% by weight, the methylcellulose slurry becomes hard and difficult to mix with the raw material. However, if the content of methylcellulose in the raw material is appropriate, a good texture as good as that in Examples 6-1 is achieved. It is believed that in this invention, the methylcellulose in the raw material gelled in the first heating step is redissolved in the first cooling step and regelled in the second heating step, thus water dissolves from the rehydrated textured plant protein, resulting in a product with a suitable overall texture. In addition, regarding flavor, the flavor from the textured plant protein source is less, which is better than in Examples 6-1.

Claims

1. A method for manufacturing a meat-like protein processed food, characterized in that, include: The blank-making process involves mixing the textured plant protein with a methylcellulose slurry made from water and methylcellulose to create the blank. The forming process shapes the blank produced in the blank making process. The first heating step involves heating the blank formed in the forming step to a temperature of 60°C to 100°C. The first cooling process cools the billet that was heated in the first heating process to below 10°C; The second heating process involves reheating the billet, which had been cooled in the first cooling process, to a temperature of 60°C to 100°C; and The second cooling process cools the billet that was reheated in the second heating process to below 10°C. In the blank preparation process. The raw material contains 9% to 36% by weight of textured plant protein and 0.8% to 1.5% by weight of methylcellulose. The amount of methylcellulose in the methylcellulose slurry is 1.5% to 4.0% by weight.

2. The method for manufacturing meat-like protein processed food according to claim 1, characterized in that, The first cooling process is the process of freezing the billet to below -10°C.

3. The method for manufacturing meat-like protein processed food according to claim 1 or 2, characterized in that, The first heating process and the second heating process are heating by steaming or boiling.

4. A method for manufacturing a dried meat-like protein processed food, characterized in that, The second cooling step is set as a freezing step, and the meat-like protein processed food manufactured by the manufacturing method according to any one of claims 1 to 3 is subjected to vacuum freeze-drying.

5. A method for manufacturing a dried meat-like protein processed food, characterized in that, After the meat-like protein processed food manufactured by the manufacturing method according to any one of claims 1 to 3 is subjected to a third heating process, which involves reheating the food to a temperature of 60°C to 100°C, it is frozen and then subjected to vacuum freeze-drying.

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