Secondary forming device for meat substitutes

Abstract

The secondary forming device for the meat substitute is used for heating a subdivided protein raw material in a pressurized state, joining protein components of the subdivided raw material, and forming the protein components into a desired shape to obtain a secondary formed product. A relatively large secondary molded article can be better molded by using moisture as a plasticizer irrespective of the source of the raw material and the thermal history of the raw material. The secondary forming device for the meat substitutes comprises a closed pressurizing and heating chamber. The secondary molding device for meat substitutes comprises: a pressurizing device for pressurizing a subdivided raw material filled in a lower die at a predetermined pressure in a pressurizing and heating chamber; and a high-frequency power supply device that supplies a high-frequency current to the raw material within 300 seconds in accordance with the type of the raw material in the pressure heating chamber, and heats the raw material at a temperature of 110-140 DEG C (inclusive).

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the priority of Japanese patent application serial number 2023-181651 filed on October 23, 2023. The entire contents of the above patent application are hereby incorporated by reference herein and constitute a part of this specification. Technical Field

[0003] The present disclosure relates to a device for producing a meat substitute, and more particularly to a secondary forming device for a meat substitute. Background Art

[0004] The technology for producing foods made of vegetarian or vegan materials that can be eaten instead of meat, so-called meat substitutes, is evolving year by year. Typical materials are wheat and soybeans. Meat substitutes are also called artificial meat, imitation meat or plant-based meat, and their market is expanding. The protein raw materials of meat substitutes are segmented, and the segmented raw materials are solidified into the desired shape to produce secondary molded products of meat substitutes. As a device for manufacturing protein raw materials, a twin-screw extruder is known. The twin-screw extruder presses the raw materials containing the required moisture at a high temperature of more than 100°C while extrude them through a die. The twin-screw extruder makes it possible to continuously produce the raw materials of meat substitutes.

[0005] In a twin-screw extruder, the raw material itself acts as a seal to prevent the raw material from leaking out of the die head through the flow resistance generated in the die head. Due to the fluidity of the raw material, or the shape or area of ​​the die head opening, the raw material cannot stay in the die head and is extruded explosively. As a result, there is a concern that the forming of the raw material fails and the operation is interrupted. In this way, in a twin-screw extruder, there are restrictions on the amount of water contained in the raw material, the shape of the die head opening, and the area of ​​the die head opening.

[0006] In a twin-screw extruder, even if the raw material is well formed from the outside, there is a concern that the internal structure of the raw material will become spongy due to the expansion phenomenon caused by the evaporation of water when the raw material is extruded from the die head. As a result, the taste may be reduced and the appearance of the raw material may be distorted. Therefore, in order to obtain the final secondary processed product, it is necessary to combine the raw material cut into particles again with auxiliary materials such as egg white as a binder.

[0007] Due to this situation, a technology is needed to convert protein raw materials into secondary processed products that show a structure and physical properties closer to real edible meat. Japanese Patent Laid-Open No. 5-103593 and Japanese Patent No. 6649640 disclose a secondary forming device for meat substitutes, which is capable of filling one or more soybean protein raw materials into a metal mold, and heating and pressurizing the raw materials filled in the metal mold while adjusting the heating temperature and heating speed. In the disclosed secondary forming device, compared with a twin-screw extruder, there are fewer restrictions on the moisture content, shape and size of the secondary processed products, and a wider variety of textured soybean protein foods with different textures can be obtained.

[0008] There is room for improvement in the secondary molding apparatus for meat substitutes. In particular, in order to obtain secondary molded products with better quality and larger size than before, regardless of the type of protein in the raw material, the secondary molding apparatus needs to meet at least the following conditions.

[0009] First, the subdivided raw materials are compacted more accurately and fully to allow the proteins of the raw materials to be firmly and better bonded. Second, even if the thermal conductivity of the raw materials is relatively low and a relatively long heating time is required, the temperature is raised to the specified temperature in the shortest possible time until the inside. Third, the high-temperature heating treatment of more than 100°C is mainly carried out in a state where water is included as a plasticizer in a state of coexistence with the raw materials. Fourth, the secondary molded product after heat curing is cooled in a shorter time and the secondary molded product is taken out.

[0010] The main purpose of the present disclosure is to provide a secondary forming device for meat substitutes, which can use moisture as a plasticizer to better form relatively large secondary molded products regardless of the source of the raw materials and the thermal history of the raw materials. Here, the so-called source of raw materials refers to, for example, whether the main raw material is plant food protein or animal food protein. In addition, the so-called thermal history of the raw materials refers to whether the protein raw materials have been heat-treated. Several advantages that can be obtained by the secondary forming device of the present disclosure are specifically shown in the description of the embodiments. Summary of the invention

[0011] According to the present disclosure, a secondary molding device for a meat substitute is provided, which heats a subdivided protein raw material (MT) under pressure to join the protein components of the subdivided raw material (MT), and molds it into a desired shape to obtain a secondary molded product. The secondary molding device includes a closed pressurized heating chamber (1B), and includes: a pressurizing device (3), which pressurizes the subdivided raw material (MT) filled between molds (8U, 8L) at a specified pressure in the pressurized heating chamber (1B); and a high-frequency power supply device (2), which supplies a high-frequency current to the raw material (MT) for a period of time within 300 seconds corresponding to the type of the raw material (MT) in the pressurized heating chamber (1B), and heats the raw material (MT) at a temperature of 110° C. to 140° C. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram showing a first embodiment of the secondary molding device of the present disclosure.

[0013] Figure 2 It is a cross-sectional view showing the mold in the first embodiment.

[0014] Figure 3 It is a schematic diagram showing a second embodiment of the secondary molding device of the present disclosure.

[0015] Figure 4 It is a cross-sectional view showing a mold in the second embodiment.

[0016] Figure 5 It is a perspective view showing a lower mold in the secondary molding device of the present disclosure.

[0017] Fig. 6A , Figure 6B , Figure 6C This is a perspective view showing an example of a secondary molded product molded by the secondary molding device of the present disclosure. DETAILED DESCRIPTION

[0018] Figure 1 A first embodiment of the secondary forming device of the meat substitute of the present disclosure is schematically shown. Figure 2 Indicated in Figure 1 A side view of a mold used in a secondary forming apparatus is shown. Figure 1 and Figure 2 The secondary molding device and mold shown are models and do not accurately reflect the actual secondary molding device and mold. The relative positions and sizes of multiple devices and components are different from those of the actual objects.

[0019] Figure 1The secondary forming device of the meat substitute shown performs secondary forming of the raw material by pressurizing and compressing the raw material of the meat substitute filled in the mold and heating it by electric heating. A plurality of additives may be added to the raw material of the protein. Figure 1 The secondary forming device SM shown includes a secondary forming device body 1, a high frequency power supply device 2, a pressurizing device 3, a cooling device 4, a door opening and closing device 5, a conveying device 6, and a control device 7. The secondary forming device body 1 in the embodiment includes a pre-processing chamber 1A, a pressurizing and heating chamber 1B, and a post-processing chamber 1C.

[0020] The pre-processing chamber 1A of the secondary molding apparatus body 1 can be sealed by closing the door 50A. In the pre-processing chamber 1A, one or more protein raw materials MT of meat substitutes are filled into the concave mold portion of the lower mold 8L. Figure 1 and Figure 2 In the secondary molding device SM of the embodiment, the upper mold 8U has a male mold shape obtained by inverting the female mold shape of the lower mold 8L.

[0021] The pressurized heating chamber 1B in the secondary molding device body 1 has a structure that cuts off high-frequency current and electromagnetic waves. In the pressurized heating chamber 1B, the lower mold 8L filled with raw materials is engaged with the upper mold 8U installed on the pressurizing device 3. The lower mold 8L is positioned at a predetermined position where the electrode plate 20P provided on the upper mold 8U and the other electrode plate 20N provided on the lower mold 8L are relatively consistent. At the predetermined position, the raw material MT filled in the lower mold 8L is heated by the high-frequency power supply device 2 while being pressurized by the upper mold 8U.

[0022] In the pressurized heating chamber 1B, the control device 7 operates the pressurizing device 3 to lower the upper mold 8U to a predetermined position. At this predetermined position, the upper mold 8U compresses the raw material MT filled in the lower mold 8L at a predetermined pressure to such an extent that the raw material MT is closely attached without a gap and the moisture contained in the raw material MT does not leak out from the lower mold 8L. At this time, air is squeezed out of the raw material MT, so that the thermal conductivity can be sufficiently improved. The moisture contained in the raw material MT varies depending on the type, and is, for example, 60% by weight.

[0023] When the upper mold 8U compresses the raw material MT at a predetermined pressure, the electrode plate 20P provided on the upper mold 8U is in uniform contact with the surface of the raw material MT. The control device 7 operates the high-frequency power supply device 2 to supply a high-frequency current to the raw material filled in the lower mold 8L, and uses Joule heat to heat the raw material MT from the inside of the raw material MT at a temperature sufficiently exceeding 100°C, preferably at a high temperature of 110°C or more. In the raw material MT that is pressurized and heated and subdivided, the protein components of the adjacent raw materials MT are joined and integrated.

[0024] In order to prevent the raw material MT from being deteriorated, such as liquefaction of the raw material MT, the heating time is a short time of less than 300 seconds. By making the heating time a short time, the time to cool to below 100°C after heating can also be shortened. It is preferable that the steam generated between the upper mold 8U and the lower mold 8L during heating is discharged to the outside through the exhaust duct EH provided in the upper mold 8U. When the upper mold 8U is provided with the exhaust duct EH, it is possible to prevent moisture from overflowing from the gap between the upper mold 8U and the lower mold 8L during heating.

[0025] The post-processing chamber 1C of the secondary molding device body 1 of the embodiment protects the raw material MT from contact with outdoor air, thereby delaying the degradation of the secondary molded product. The post-processing chamber 1C also serves as a cooling chamber. The control device 7, for example, operates the cooling device 4 to cool the raw material to less than 30°C in a short time to prevent the proliferation of bacteria. In the post-processing chamber 1C, the lower mold 8L can be reversed to remove the secondary molded product from the lower mold 8L. The secondary molded product demolded from the lower mold 8L freely falls into a recovery box (not shown) arranged at the lower side of the post-processing chamber 1C or on a conveyor (not shown) to be recovered.

[0026] High frequency power supply device 2-way Figure 2 A high-frequency current is supplied between the electrode plate 20N provided in the lower mold 8L and the electrode plate 20P provided in the upper mold 8U. The high-frequency power supply device 2 preferably supplies a high-frequency alternating current of 1kHz or more. The high-frequency power supply device 2 of the embodiment can supply a high-frequency alternating current of 20kHz. However, the high-frequency power supply device 2 of the embodiment can supply low-frequency alternating current according to the type of raw material MT, for example, it can also be energized and heated at a household power supply frequency of about 50Hz. The frequency of the high-frequency power supply device 2 can be operated by the control device 7.

[0027] The high-frequency power supply device 2 includes a 100V or 200V DC power supply. The DC power is converted into a high-frequency AC power through a conversion device (not shown). The conversion device includes, for example, a bridge circuit of multiple switching elements such as a field effect transistor (metal-oxide-semiconductor field-effect transistor (MOSFET)). Alternatively, it includes multiple switching elements and a ferrite ring core.

[0028] The current is adjusted in accordance with the raw material MT. In the energized heating, since Joule heat is used in the heating, the current that can complete the heating at 110°C or above within 300 seconds can be obtained based on the amount of electricity, voltage value, and resistance value in the energized circuit including the raw material MT. Specifically, the current value can be determined by testing with a sample in advance in accordance with the type of raw material MT as a variable factor of the resistance value and the shape and size of the secondary molded product. The voltage and current in the high-frequency power supply device 2 can be operated by the control device 7.

[0029] The high-frequency power supply device 2 in the secondary forming device SM of the embodiment supplies high-frequency alternating current. Compared with the electric heating using direct current, the electric heating using high-frequency alternating current can reduce the electric corrosion of the pair of electrodes 20P and 20N, thereby preventing the metal contained in the electrodes from being dissolved and mixed into the raw material MT. In the high-frequency power supply device 2, as the material of the pair of electrodes 20P and 20N, for example, a metal that is not easily corroded by electricity and has little effect on the human body, such as titanium alloy, is selected. Alternatively, a metal that has relatively little electric corrosion and little effect on the human body, such as nickel alloy, is selected. The secondary forming device of the embodiment promotes the popularization of secondary forming of larger raw materials using electric heating, which was originally difficult to put into practical use.

[0030] In the embodiment, the lower mold 8L is made of a heat-resistant resin suitable for food containers. When the lower mold 8L is made of resin, the loss of current can be further reduced and the heating efficiency can be further improved. In addition, the lower mold 8L made of resin has the advantages of less contamination of the mold material due to electrical corrosion and easy manufacture in any shape compared to a metal mold.

[0031] In the secondary molding device SM of the embodiment, the lower mold 8L is formed of a resin that can maintain its shape when pressurized, has heat resistance, and is hard and strong. However, as the material of the lower mold 8L, it is not impossible to use a relatively soft resin such as silicone resin. In the case where the material of the lower mold 8L is a relatively soft resin, a structure can be set to reinforce the outer periphery of the lower mold 8L with a stainless steel wall to prevent the lower mold 8L from deforming and expanding outward when pressurized at the pressurized heating position. When the lower mold 8L is a relatively soft resin, it can be expected that the secondary molded product can be easily demolded by deforming the lower mold 8L.

[0032] An electrode plate 20N is provided on the bottom surface of the lower mold 8L. In the secondary molding device SM of the embodiment, a plurality of current-carrying materials 20E are provided on the bottom surface of the lower mold 8L, and at a predetermined heating and pressurizing position in the pressurizing and heating chamber 1B, the power supply plate 20B and the electrode plate 20N fixed to the pressurizing and heating position of the pressurizing and heating chamber 1B are energized through the current-carrying materials 20E, and high-frequency alternating current is supplied from the high-frequency power supply device 2. At the pressurizing and heating position, the raw material MT filled in the lower mold 8L is heated by the high-frequency alternating current while being pressurized by the upper mold 8U.

[0033] The pressurizing device 3 includes a driving device (not shown) which is composed of a hydraulic cylinder or a linear motor and can be positioned by the control device 7. Therefore, the material MT is pressurized with a more appropriate pressure. The fine control of the movement of the upper mold 8U can better prevent the material MT from flowing out more than necessary.

[0034] The upper mold 8U is replaceably mounted on a movable body that is moved by a driving body, corresponding to the shape and size of the desired secondary molded product. In the pressurizing device 3, after pressurization, the upper mold 8U rises together with the movable body. In the pressurizing device 3, when a fine pressurizing force and minute positioning in the height direction are not required for the upper mold 8U, for example, it is also possible to pressurize the raw material MT using only the self-weight of the upper mold 8U. When the raw material MT is pressurized using only the upper mold 8U, the pressurizing device 3 is substantially constituted by the upper mold 8U.

[0035] In the pressurizing device 3 of the embodiment, after pressurization, the upper mold 8U can be deformed so as to be separated from the moving body of the pressurizing device 3. When the upper mold 8U is separated from the moving body, as shown in FIG. Figure 1 As shown by the middle dotted line, the secondary molded product can be cooled in the post-processing chamber 1C while the upper mold 8U compresses the secondary molded product in the lower mold 8L with a pressure corresponding to its own weight, thereby better preventing the secondary molded product from expanding.

[0036] Among them, it is necessary to recover the next upper mold 8U from the post-processing chamber 1C and reuse it, or prepare the next upper mold 8U near the pressurizing and heating chamber 1B. In addition, in the present disclosure, by properly treating the steam or air generated during pressurization, or by making the internal pressure of the pressurizing and heating chamber 1B slightly higher than the atmospheric pressure, pressure can be applied to the upper mold 8U to prevent expansion. The upper mold 8U is made of a material that is highly corrosion-resistant and safe, relatively heavy, and easy to form. Specifically, the upper mold 8U is made of, for example, a nickel alloy covering the surface of iron.

[0037] The pressurizing device 3 can pressurize the material MT by changing the pressurizing pressure according to the type of the material MT through the control device 7. The pressurizing device 3 in the secondary molding device SM of the embodiment can pressurize the material MT at a maximum pressure of 0.5 MPa (about 5.1 kgf / cm 2 ) Pressurize the material MT. The required pressure is a pressure below which the material MT is sufficiently in close contact and water contained in the material MT does not flow out from the lower mold 8L.

[0038] The cooling device 4 supplies cold air cooled to a temperature below a predetermined temperature to the post-processing chamber 1C to maintain the room temperature below the predetermined temperature. In addition, the cooling device 4 directly sprays and supplies cold air near the lower mold 8L, thereby forcibly cooling the raw material MT in a short time. Alternatively, the cooling device 4 directly sprays and supplies cold air to cool the secondary processed product in the lower mold 8L.

[0039] The cooling device 4 may be configured to directly cool the raw material MT filled in the lower mold 8L by bringing a cooling plate (not shown) into contact with the surface of the raw material MT. The cooling plate may be, for example, a structure in which a plurality of cooling lines are formed and a refrigerant is supplied, or a structure including a plurality of Peltier elements. In addition, the cooling device 4 may be configured to directly cool the secondary molded product by directly spraying it onto the lower mold 8L or the secondary molded product, or by immersing the secondary molded product together with the lower mold 8L in cooling water stored in a cooling tank, thereby cooling the secondary molded product with cooling water. The water temperature supplied from the cooling device 4 is below room temperature. When cooling the secondary molded product with cooling water, the cooling time can be further shortened.

[0040] The door opening and closing device 5 operates the doors 50A, 50B, 50C, and 50D that open and close the entrances and exits of the pre-processing chamber 1A, the pressurized heating chamber 1B, and the post-processing chamber 1C of the secondary molding apparatus body 1. The door opening and closing device 5 can be remotely controlled by the control device 7. In addition, the control device 7 can cause the door opening and closing device 5 to perform sequential operations to automatically and continuously mold a plurality of raw materials MT.

[0041] The conveying device 6 includes a conveyor 60A, a conveyor 60B, a conveyor 60C, a conveyor 60D, and a plurality of motors (not shown) that independently drive each conveyor. The conveyor is, for example, a belt conveyor or a roller conveyor. The conveying device 6 is controlled by a control device 7. The control device 7 drives and controls the motors and remotely controls each conveyor arbitrarily to automatically and continuously heat and pressurize the raw material MT.

[0042] The control device 7 can make the high-frequency power supply device 2, the pressurizing device 3, the cooling device 4, the door opening and closing device 5 and the conveying device 6 independently perform sequential operations. The control device 7 can make the high-frequency power supply device 2, the pressurizing device 3, the cooling device 4, the door opening and closing device 5 and the conveying device 6 operate in conjunction with each other, so that a plurality of raw materials MT can be automatically and continuously filled into the lower mold 8L for heating and pressurization and cooling and recovery.

[0043] The secondary molding device SM of the embodiment includes a pressurizing device 3 that can pressurize the raw material at an arbitrary pressure through a control device 7, so that the subdivided raw material MT can be fully compacted before heating. Therefore, the protein components of the raw material MT can be firmly and better bonded, and a secondary molded product of a meat substitute with a chewy texture and a better taste can be obtained.

[0044] The secondary molding device SM includes a high-frequency power supply device 2 that heats the raw material MT by heating with high-frequency alternating current, so that even the raw material MT of a type that has a relatively low thermal conductivity and takes time to heat can be heated at a high temperature of 110° C. or higher in a short time of less than 300 seconds, almost evenly to the inside of the raw material MT. Therefore, even if the protein raw material MT is larger than before, the raw material MT can be firmly and better joined without deterioration such as liquefaction, regardless of the source of the raw material and the thermal history of the raw material, so that a secondary molded product of a meat substitute with excellent quality can be obtained.

[0045] The secondary molding device SM does not keep the raw material MT at a high temperature for a long time due to the power-on heating by the high-frequency power supply device 2, so the time required for cooling is also shorter than before. Therefore, even with a relatively large raw material MT, a high-quality secondary molding product can be obtained. In particular, the secondary molding device SM includes the cooling device 4, so the secondary molding product can be rapidly cooled and taken out in a shorter time.

[0046] Figure 3 A second embodiment of the secondary forming device of the meat substitute of the present disclosure is schematically shown. Figure 4 Indicated in Figure 3 A side view of a mold used in a secondary forming apparatus is shown. Figure 3 and Figure 4 The secondary forming device and mold shown are models and do not accurately reflect the actual secondary forming device and mold. The relative positions and sizes of the multiple devices and components are different from the actual ones. Figure 3 and Figure 4 In the use of Figure 1 and Figure 2 When the secondary molding devices and dies shown have the same names, they are described with the same reference numerals even if the structures or functions are different.

[0047] Figure 3 The secondary forming device of the meat substitute shown in the figure performs secondary forming of the raw material by pressurizing and compressing the raw material of the meat substitute filled in the mold and heating it by saturated steam heating. A plurality of additives may be added to the raw material of the protein. Figure 3 The secondary molding device SM shown includes at least a secondary molding device body 1, a pressurizing device 3, a door opening and closing device 5, a conveying device 6, a control device 7, a saturated steam supply device 9, and a decompression device 10. The secondary molding device body 1 in the embodiment includes a pre-processing chamber 1A, a pressurizing and heating chamber 1B, and a post-processing chamber 1C. In addition, the secondary molding device body 1 includes a raw material filling station 1D and a metal mold recovery station 1E.

[0048] The pre-treatment chamber 1A of the secondary molding device body 1 has a structure that can seal the interior of the chamber by closing the door 50A and the door 50B. In the secondary molding device SM of this embodiment, the pre-treatment chamber 1A is a decompression chamber. The pre-treatment chamber 1A includes a plurality of sub-chambers corresponding to the required air pressure value, for example, the air pressure can be reduced in stages to about 0.05Pa, which is closer to a vacuum. In addition, the pre-treatment chamber 1A can be provided with a re-pressure chamber in a sub-chamber adjacent to the pressurized heating chamber 1B among the plurality of sub-chambers, and the pressure can be re-pressurized to atmospheric pressure, so that the pressure in the pressurized heating chamber 1B will not be sharply increased from the low pressure environment.

[0049] Since air has a higher specific gravity than steam, when steam flows into the room, air is difficult to be discharged to the outside and tends to stay at the bottom of the room. Since air has a heat-insulating effect when heating the raw material MT, it becomes an obstacle to the operation of heating to a specified temperature in a shorter time. By depressurizing the room in the pre-treatment chamber 1A, air can be removed to the outside as much as possible, which helps to heat the relatively large raw material MT in a required short time.

[0050] The pressurized heating chamber 1B can be sealed by closing the door 50B and the door 50C. When the raw material MT is pressurized and heated, the steam compressed to high pressure is quickly supplied from the saturated steam supply device 9 while the pressurized heating chamber 1B is sealed. At this time, if the raw material MT is exposed to the high-temperature saturated steam for a long time, the protein will be hydrolyzed and liquefied. Therefore, it is required to heat the raw material MT to a specified temperature in a short time before the liquefaction. Specifically, the temperature of the saturated steam supplied by the saturated steam supply device 9 is above 120°C and below 140°C, and the heating time is within 300 seconds.

[0051] The pressurizing device 3 is a device that can work in a high-temperature and high-humidity room without malfunction. The pressurizing device 3 of the embodiment is not provided with a driving device, but is a structure that applies pressure using the following force: the force is a pressure that depends on the weight obtained by adding the mass of the upper mold 8U to the mass of the weight 80A provided on the upper mold 8U, and the force added by the steam pressure of the high-pressure steam supplied to the pressurized heating chamber 1B acting in the direction of gravity. Therefore, in the embodiment, the pressurizing device 3 is essentially composed of the saturated steam supply device 9 that supplies high-pressure saturated steam and the upper mold 8U including the weight 80A.

[0052] The pressurizing device 3 without a driving device can obtain sufficient pressurizing force for most types of raw materials MT. However, for raw materials MT with strong rebound force, high water content and relatively large size, there is a concern that the pressurizing force may be insufficient only by using the upper mold 8U including the weight 80A and steam pressure, depending on the type of raw material MT and the size of the upper mold 8U. The pressurizing device 3 may be configured to include a pushing device such as a pusher (not shown) that can work in a high-temperature room, so that the pusher can be used as an auxiliary when the pressurizing force is insufficient.

[0053] The operator can set the temperature and time of the saturated steam to be supplied in the operation panel of the control device 7. The saturated steam supply device 9 supplies high-temperature saturated steam of 120°C or higher and 140°C or lower for an appropriate time within 300 seconds in accordance with the type of the raw material MT and the size of the secondary molded product. The raw material MT in the lower mold 8L receives the heat energy of the condensation latent heat and sensible heat of the steam generated on the surfaces of the upper mold 8U and the lower mold 8L, and is heated to the temperature of the saturated steam in an extremely short time of less than 1 second.

[0054] The pressurized raw material MT uses the water contained in the raw material MT and the steam condensed water generated on the surface of the raw material MT as a plasticizer, and obtains thermoplasticity through thermal energy for molding. When the water content is sufficient, the overall plasticity of the secondary molded product formed by solidification of the raw material MT makes the fusion of the raw materials MT better. In addition, when the water content is limited to the surface condensed water of the secondary molded product, the fusion of the raw materials MT on the outer surface of the raw material MT and the deformation of the raw material MT due to softening can achieve better molding.

[0055] In this way, when the raw material MT is heated by the saturated steam heating method, the raw material MT shows some fluidity according to the amount of water given. Since the raw material MT has fluidity, there is a concern that the raw material MT will flow out from the gap between the upper mold 8U and the lower mold 8L. However, the raw material MT heated at an appropriate temperature and time has sufficient viscoelasticity, so the raw material MT will not leak out from the gap between the upper mold 8U and the lower mold 8L.

[0056] The post-processing chamber 1C is a re-pressurizing chamber for re-pressurizing the upper mold 8U and the lower mold 8L to the atmospheric pressure environment when the pressure in the pressurizing and heating chamber 1B becomes high pressure during the pressurizing and heating process. The post-processing chamber 1C also serves as a cooling chamber. In the re-pressurizing chamber 1C, the air and steam in the chamber are exhausted during re-pressurization, and the external air or cold air is introduced into the post-processing chamber 1C, thereby rapidly cooling the secondary molded product through the mold 8U and the mold 8L having relatively high thermal conductivity.

[0057] The raw material filling station 1D is a work station for filling the subdivided raw material MT into the concave mold portion of the lower mold 8L from a raw material filling device 11 such as a hopper. Water can be supplied as a plasticizer to the raw material filling station 1D as needed. When adding water, the water content contained in the raw material MT is accurately adjusted, so that there is no quality deviation for a plurality of secondary molded products produced continuously.

[0058] In the raw material filling station 1D, the upper mold 8U including the weight 80A is placed on the lower mold 8L in a state aligned with the concave mold portion filled with the raw material MT after adding water. At this time, the raw material MT may sink to a certain height due to the weight of the upper mold 8U obtained by adding the weight of the weight 80A to the weight of the upper mold 8U. However, since there is almost no gap between the upper mold 8U and the lower mold 8L and the water content contained in the raw material MT is adjusted, the raw material MT does not flow out from the gap.

[0059] The metal mold recovery station 1E is a work station for recovering the molds 8U and 8L. In the metal mold recovery station 1E, the upper mold 8U is removed from the secondary molding device main body 1 by a demolding device not shown in the figure and recovered. The lower mold 8L remaining on the workbench is turned over with the bottom surface located at the top by a reversing device not shown in the figure. At this time, a plurality of demolding ejector pins 80B protruding from the bottom of the lower mold 8L are ejected by a pin pressing device not shown in the figure, and the movable plate 80C moves downward. By the movement of the movable plate 80C, the secondary molded product is demolded and falls freely, and is recovered by an appropriate method.

[0060] The door opening and closing device 5 operates the doors 50A, 50B, 50C, and 50D that open and close the entrances and exits of the pre-processing chamber 1A, the pressurized heating chamber 1B, and the post-processing chamber 1C of the secondary molding apparatus body 1. The door opening and closing device 5 can be remotely controlled by the control device 7. In addition, the control device 7 can cause the door opening and closing device 5 to perform sequential operations to automatically and continuously mold a plurality of raw materials MT.

[0061] The conveying device 6 includes a conveyor 60A, a conveyor 60B, a conveyor 60D, a conveyor 60E, and a plurality of motors (not shown) that independently drive each conveyor. The conveyor is, for example, a belt conveyor or a roller conveyor. The conveying device 6 is controlled by a control device 7. The control device 7 drives and controls the motors and remotely controls each conveyor arbitrarily to automatically and continuously heat and pressurize the raw material MT.

[0062] The saturated steam supply device 9 includes a boiler and a compression device (not shown) and a plurality of supply pipes, and can supply high-pressure saturated steam compressed to a predetermined pressure to the pressurized heating chamber 1B. The saturated steam supply device 9 can supply saturated steam at 120°C or higher and 140°C or lower.

[0063] The decompression device 10 includes a vacuum pump. When the pre-treatment chamber 1A has a plurality of sub-chambers corresponding to the required gas pressure value, the decompression device 10 includes a vacuum pump in each sub-chamber, so that the pressure can be reduced in stages to a low pressure close to vacuum. The decompression device 10 in the secondary molding device SM of the embodiment can reduce the pressure of the pre-treatment chamber 1A to any gas pressure of a minimum of 0.05 Pa. In addition, if necessary, the pressure can be restored to atmospheric pressure in the sub-chamber adjacent to the pressurized heating chamber 1B.

[0064] exist Figure 3 In the secondary forming device SM shown, the cooling device 4 also serves as a re-pressurizing device. The re-pressurizing device opens the safety valve provided in the post-processing chamber 1C to open the exhaust port, and re-pressurizes the air pressure in the post-processing chamber 1C that has been increased by the high-pressure saturated steam in the pressurized heating chamber 1B. The cooling device 4 supplies cold air from room temperature to about -10°C to the post-processing chamber 1C, so that the post-processing chamber 1C can always be maintained at a predetermined temperature.

[0065] The cooling device 4 can directly spray and supply cold air or cooling water to the mold 8U and the mold 8L, so that the secondary processed product formed in the pressurized heating chamber 1B can be rapidly cooled. The cooling device 4 can be modified to directly cool the secondary processed product by immersing the secondary processed product together with the mold 8U and the mold 8L in the cooling water stored in the cooling tank. When the secondary processed product is directly cooled by the cooling water, the secondary processed product can be cooled in a shorter time.

[0066] The control device 7 can make the pressurizing device 3, the cooling device 4, the door opening and closing device 5, the conveying device 6, the saturated steam supply device 9, and the decompression device 10 independently and sequentially operate. The control device 7 can make the pressurizing device 3, the cooling device 4, the door opening and closing device 5, the conveying device 6, the saturated steam supply device 9, and the decompression device 10 operate in conjunction with each other, so that a plurality of raw materials MT can be automatically and continuously filled into the lower mold 8L for heating and pressurization and cooling and recovery.

[0067] In the secondary molding device SM of the saturated steam heating method, the mold 8U and the mold 8L are metal molds. In particular, when the size of the mold 8U and the mold 8L is large, in order to heat the raw material MT to a high temperature of 110° C. to 140° C. within a short time of less than 300 seconds, the mold 8U and the mold 8L preferably have high thermal conductivity.

[0068] like Figure 4 As shown, the lower mold 8L has a plurality of concave mold parts. For example, Figure 5 The lower mold 8L shown has the same shape in all its concave mold portions. In order to suppress contamination caused by the elution of metal components contained in the metal mold, at least the surface of the concave mold portion of the lower mold 8L is covered with a material that is not easily eluted into the raw material MT.

[0069] For example, the concave mold part is coated with fluororesin. The coating of the concave mold part formed of fluororesin suppresses contamination and prevents the quality and safety of the secondary molded product from being reduced. In addition, the coating of the concave mold part formed of fluororesin improves the demolding property of the secondary molded product and improves the cleaning efficiency of the lower mold 8L. In addition, for example, the concave mold part is plated with nickel alloy. The metal plating of nickel alloy suppresses contamination and prevents the quality and safety of the secondary molded product from being reduced, and prevents the reduction of thermal conductivity.

[0070] The lower mold 8L is provided with a plurality of demolding ejector pins 80B. The demolding ejector pins 80B eject the metal movable plate 80C disposed on the bottom surface of the concave mold portion of the lower mold 8L, thereby promoting demolding of the secondary molded product. When the raw material MT is subjected to a pressurized heating process in the pressurized heating chamber 1B of the secondary molding device main body 1, demolding properties are originally generated by evaporation of water present between the lower mold 8L and the raw material MT. When the movable plate 80C is moved by the demolding ejector pins 80B, the secondary molded product formed by solidifying the raw material MT can be floated, so that the secondary molded product is easily demolded from the lower mold 8L.

[0071] In the secondary molding device SM of the embodiment, it is set to reverse the lower mold 8L in the metal mold recovery station 1E to recover the secondary molded product. Therefore, after the upper mold 8U moves to a position away from the metal mold recovery station 1E, the demolding ejector pin 80B is moved downward by an ejector device (not shown) arranged at a position higher than the demolding ejector pin 80B. As a result, the secondary molded product is ejected by the movable plate 80C and freely falls below the metal mold recovery station 1E to be recovered. In addition, in the case where the lower mold 8L has the demolding ejector pin 80B and the movable plate 80C, the secondary molded product can be recovered even without reversing the lower mold 8L.

[0072] The upper mold 8U has a male mold shape obtained by inverting the female mold shape of the lower mold 8L. The male mold portion of the upper mold 8U fits with the female mold portion of the lower mold 8L with a small gap. At least the surface of the male mold portion of the upper mold 8U that contacts the material MT is coated with, for example, fluororesin or nickel alloy.

[0073] The upper mold 8U in the embodiment is provided with one or more weights 80A for pressurization. The upper mold 8U provided with the weights 80A is advantageous in that the mass of the weights 80A can be changed in accordance with the required pressurization force. However, when the magnitude of the required pressurization force is determined, the required pressurization force can be obtained by increasing the thickness of the convex mold portion of the upper mold 8U and increasing the mass of the upper mold 8U.

[0074] An air release valve 80D is provided at the convex part of the upper mold 8U. When one upper mold 8U has a plurality of convex parts, an air release valve 80D is provided at each convex part. When the pre-treatment chamber 1A of the secondary molding apparatus main body 1 is depressurized in a state where the concave part of the lower mold 8L is fitted with the convex part of the upper mold 8U and the upper mold 8U is placed on the lower mold 8L, the air release valve 80D exhausts the air existing in the concave part of the lower mold 8L from the concave part. As a result, when the pressurized heating treatment is performed in the pressurized heating chamber 1B, the raw material MT can be heated in a state where the air having a heat insulating effect is removed, thereby achieving heating at a high temperature in a shorter time.

[0075] For example, Figure 5 As shown, the secondary forming device of the meat substitute of the present disclosure can use multiple lower molds 8L having multiple relatively large-sized concave mold parts to produce secondary molded products. Therefore, it is advantageous in that more secondary molded products can be produced at one time. In addition, for example, even the meat substitute that can be formed before can be produced. Fig. 6A The circular plate shape shown or Figure 6B The secondary molded product is a quadrilateral shape shown in the figure, but with a larger size. In addition, it is possible to mold previously difficult Figure 6C The secondary molded product has a complex shape as shown.

[0076] A relatively large metal mold with a circular concave mold portion of 30 cm in diameter and 10 cm in depth was used. Figure 3 The secondary molding device SM shown heats the soybean protein raw material at 120°C to 130°C for 120 seconds to obtain a secondary molded product in the shape of a disk with a diameter of 30 cm and a thickness of 10 cm. The arrangement of the protein in the linear fiber direction of the secondary molded product is adjusted to maintain the required strength and dense fiber structure. The taste is chewy and has no spongy feeling compared to conventional products.

[0077] The secondary molding device SM of the saturated steam method is a device that uses saturated steam to heat the raw materials in the metal mold under a high pressure state that can maintain saturated steam at a temperature of 110°C or more and 140°C or less after vacuum compacting the raw materials in the pre-treatment chamber 1A, and uses water as a plasticizer to utilize the thermoplasticity at the glass transition point. The heat energy reaching the glass transition point is supplied in a short time by utilizing the latent heat of condensation of steam and the sensible heat of steam in the mold in the relatively large area of ​​the concave mold. In addition, the compacted state of the subdivided raw materials is maintained by the high density caused by the decompression or vacuum treatment in the pre-treatment chamber and the pressure difference of the saturated steam in the pressurized heating chamber.

[0078] The structure of the subdivided raw materials changes and they are integrally formed by the close contact between the subdivided raw materials while maintaining the thermoplastic state at the glass transition point, in other words, the protein regions come into contact. The protein component will be hydrolyzed and liquefied under high temperature conditions, but the secondary molding device SM can heat at a high temperature of 110°C or more and 140°C or less in a short time of less than 300 seconds, so the protein component will not be hydrolyzed or liquefied.

[0079] The present disclosure is not limited to the above-mentioned embodiments. The embodiments may be modified, components may be replaced, and the secondary molding device of the present disclosure may be combined with a known device without departing from the technical concept of the present disclosure.

Claims

1. A secondary forming device for a meat substitute, which heats a subdivided protein raw material under pressure to join the protein components of the subdivided raw material and forms it into a desired shape to obtain a secondary formed product, the secondary forming device for a meat substitute comprising a sealed pressurized heating chamber and comprising: a pressurizing device for pressurizing the subdivided raw material filled between the upper die and the lower die at a predetermined pressure in the pressurizing and heating chamber; and a high-frequency power supply device for supplying high-frequency current to the raw material for a period of time within 300 seconds in accordance with the type of the raw material, thereby heating the raw material at a temperature of 110° C. or higher and 140° C. or lower in the pressurized heating chamber.

2. The secondary forming device of meat substitute according to claim 1, wherein: The high-frequency power supply device supplies high-frequency alternating current to the raw material.

3. The secondary forming device of meat substitute according to claim 1, wherein: The high-frequency power supply device includes: a lower electrode plate provided on the lower mold for filling the raw material; and an upper electrode plate provided on the upper mold.

4. The secondary forming device of the meat substitute according to claim 1 comprises a sealed post-processing chamber connected to the pressurized heating chamber, and comprises a cooling device, wherein the cooling device cools the secondary formed product formed into a desired shape in the pressurized heating chamber in the post-processing chamber.

5. The secondary forming device of meat substitute according to claim 4, wherein: The cooling device supplies cold air into the interior of the post-processing chamber to cool the secondary molded product.

6. The secondary forming device of meat substitute according to claim 4, wherein: The cooling device cools the secondary molded product by bringing a cooling plate into contact with the secondary molded product in the post-processing chamber.

7. The secondary forming device of meat substitute according to claim 4, wherein: The cooling device cools the secondary molded product by bringing cooling water into contact with the secondary molded product in the post-processing chamber.

8. The secondary forming device of meat substitute according to claim 1, wherein: The lower mold filled with the subdivided raw material is made of resin.

9. A secondary forming device for a meat substitute, which heats a subdivided protein raw material under pressure to join the protein components of the subdivided raw material and forms it into a desired shape to obtain a secondary formed product, the secondary forming device for a meat substitute comprising a sealed pre-treatment chamber and a sealed pressurized heating chamber, and comprising: A decompression device, in the pre-treatment chamber, decompresses the interior of the pre-treatment chamber while the raw material filled in the lower mold is pressed by the upper mold facing the lower mold; a pressurization device, in the sealed pressurized heating chamber, pressurizes the raw material at a specified pressure; and a saturated steam supply device for supplying saturated steam into the pressurized heating chamber, and heating the raw material at a temperature of 110° C. to 140° C. in a short time of less than 300 seconds according to the type of the raw material under the condition of being pressurized by the pressurizing device.

10. The secondary forming device of meat substitute according to claim 9, wherein: The pressurizing device obtains a pressurizing force for pressurizing the raw material by a pressure dependent on the mass of the upper mold and a pressure of the high-pressure saturated steam supplied from the saturated steam supply device.

11. The secondary forming device of meat substitute according to claim 10, wherein: The saturated steam supply device supplies a pressure required to increase the internal pressure of the pressurized heating chamber to a pressure required for maintaining the saturated steam at a predetermined temperature.

12. The secondary forming device of the meat substitute according to claim 9 comprises a sealed post-processing chamber connected to the pressurized heating chamber, and comprises a cooling device, wherein the cooling device cools the secondary formed product formed into a desired shape in the pressurized heating chamber in the post-processing chamber.

13. The secondary forming device of meat substitute according to claim 12, wherein: The cooling device supplies cold air into the interior of the post-processing chamber to cool the secondary molded product.

14. The secondary forming device of meat substitute according to claim 12, wherein: The cooling device cools the secondary molded product by bringing cooling water into contact with the secondary molded product in the post-processing chamber.

15. The secondary forming device of meat substitute according to claim 9, wherein: The upper mold includes an air release valve.

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