Producing method of frozen rolled cabbage and frozen rolled cabbage

Abstract

To provide a producing method of frozen rolled cabbages capable of automatizing a producing line capable of producing a product of stable quality even under labor shortage.SOLUTION: The invention is configured to prepare small pieces of cabbage, adjust a konjac yam binder to a paste consistency, add this binder to the small pieces of cabbage, knead the binder and the small pieces of cabbage together, create an outer skin material, mix seasonings into the ground meat to create a filling material, place the filling material and outer skin material into a wrapping machine, extrude the filling material from a central nozzle while simultaneously extruding the outer skin material from the annular nozzle, covering an outer circumference of the extruded filling material with the synchronously extruded outer skin material, cut the filling material being extruded from the central nozzle while supplying the outer skin material from the annular nozzle, and wrap the filling material with the outer skin material to create the wrapped product, which is then subjected to freezing treatment.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to a method for producing frozen cabbage rolls, which is produced by wrapping a filling material including meat of poultry or livestock with an outer covering material including vegetables such as cabbage and mushrooms such as shiitake mushrooms, and to the frozen cabbage rolls. [Background technology]

[0002] Cabbage rolls are a cooked food in which minced meat or other ingredients are wrapped in relatively large leaves of cabbage, and frozen cabbage roll products that can be easily eaten by heating are sold in supermarkets, convenience stores, etc. In food factories that produce these frozen cabbage rolls, several to a dozen workers and quality control personnel are stationed on an air-conditioned semi-automatic belt conveyor system, but because the cabbage leaves used for the outer skin are irregular in shape and size, the task of wrapping the ingredients in cabbage must be done exclusively by hand. In other words, the wrapping task is extremely difficult to mechanize and can only be done by hand, and currently many workers are assigned to this task.

[0003] In recent years, with the world situation changing rapidly, it is said that it is necessary to relocate production bases from overseas to Japan, i.e. to switch supply chains. The problem with relocating a production base from overseas to Japan is that it is difficult to bring locally hired workers to Japan, so new workers must be recruited domestically. However, in Japan, where the birthrate is falling and the population is aging, there is a serious labor shortage, and many companies are competing for not only Japanese workers but also foreigners living in the country. For this reason, the reality is that it is either impossible or extremely difficult to hire new workers (including part-timers) to work on the production lines of food factories. In addition, the manual wrapping of the cabbage rolls is subject to strict inspections from the perspective of hygiene management to prevent food poisoning. Based on the Food Sanitation Act, food safety in Japan is subject to the exact same standards (quality standards regarding residual pesticides, food additives, and microorganisms) as domestically produced foods, even for foods imported from overseas. Thus, from the perspective of food security, it is becoming increasingly important to switch supply chains from overseas to domestic.

[0004] For these reasons, it has been proposed to automate the manual wrapping process for making cabbage rolls by using a machine. For example, Patent Document 1 proposes a method for producing frozen cabbage rolls that can be mass-produced continuously using a machine that can use all the cabbage leaves regardless of their size. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 57-138355 Summary of the Invention [Problem to be solved by the invention]

[0006] In the conventional manufacturing method for frozen cabbage rolls described in Patent Document 1, pretreated small pieces of cabbage are lined up with no gaps between them, a thin film of starch is applied to one side of the cabbage sheet using a roller to form a sheet, a powdered binder is sprinkled on the other side of the cabbage sheet, ingredients are placed on top of the cabbage sheet, and the ingredients are then wrapped around the cabbage sheet to form a cylindrical shape. This is then cut to a fixed length with or without pressure, sterilized by heating, and frozen to produce a cylindrical frozen cabbage roll product.

[0007] However, in the conventional manufacturing method, a thin layer of starch is pressed onto one side of the laid cabbage to form a sheet, a powdered binder is sprinkled onto the other side of the cabbage sheet, ingredients are placed on top of the sheet, and the cabbage sheet is wrapped around the ingredients to form a cylinder, and appropriate positions of the long cylindrical body are pressed from above with a pressing member to push the ingredients in the center of the cylindrical body to both sides, so that the cabbage sheet at the outer end of the upper surface and the cabbage sheet at the outer end of the lower surface come into contact from above and below without sandwiching the ingredients, are pressure-bonded by the binder dissolved in water, and are cut at the center of the bonded part by a descending blade. This results in the ingredients being exposed at the cut part, and there is a problem that the umami components are lost from the cut surface that is not covered by the outer skin when the user finally cooks it. Furthermore, in the conventional manufacturing method described in Patent Document 1, the product is heat sterilized immediately before the freezing step, which causes the inherent umami components of the cabbage to be thermally denatured, resulting in a loss of flavor during the frozen storage period until consumption.

[0008] The present invention has been made to solve the above-mentioned problems, and has an object to provide a method for producing frozen roll cabbage that can respond to supply chain changes, can realize an automated production line that can produce products of stable quality even when there is a shortage of workers, and can fully retain the original umami components, texture, and flavor of the roll cabbage during the frozen storage period until the expiration date when the roll cabbage is consumed by consumers, and to provide frozen roll cabbage produced thereby. [Means for solving the problem]

[0009] The method for producing frozen cabbage rolls according to the present invention is a method for producing frozen cabbage rolls comprising wrapping a meaty filling material with a cabbage-like outer skin material, (i) preparing cabbage pieces by pre-treating leafy vegetables including at least cabbage and cutting them into pieces of a predetermined size range; (ii) preparing a binder containing at least konjac root in a paste or gel form, adding the binder in the paste or gel form to the cabbage pieces, and kneading the binder and the cabbage pieces to obtain a raw material for the outer skin material; (iii) preparing the ingredient by mixing a suitable amount of seasoning with ground meat comprising at least one of poultry, livestock, and seafood; (iv) placing the ingredients for the filling in a first supply section of the enveloping machine and the ingredients for the outer shell in a second supply section of the enveloping machine; (v) extruding the ingredient of the filling from a central nozzle communicating with the first supply unit while simultaneously extruding the ingredient of the outer skin from an annular nozzle communicating with the second supply unit, thereby covering the outer periphery of the extruded ingredient of the filling with the ingredient of the outer skin which is extruded synchronously; (vi) a step of cutting the ingredients extruded from the central nozzle into predetermined lengths while the ingredients for the outer skin are being fed from the annular nozzle, and wrapping the cut surfaces to obtain an encased product in which the ingredients for the inner skin are wrapped in the ingredients for the outer skin; (vii) obtaining frozen cabbage rolls by freezing the stuffed product; The present invention is characterized by having the following. Effect of the Invention

[0010] According to the present invention, the following various effects can be obtained. 1) The wrapping work, which is the most tedious and requires skill, will be automated, significantly reducing the burden on on-site workers and making it possible to switch supply chains even in times of labor shortages. 2) Since the wrapping process is mechanized rather than done manually, there is no risk of bacteria or foreign matter being introduced on the production line, making it possible to provide safe and secure food. 3) It does not lose its shape during cooking and its appearance is not easily damaged. 4) It has a soft and pleasant texture, making it easy to eat even for young children and the elderly, who have relatively weak chewing ability. 5) The cabbage and meat harmonize well together and do not have the fishy smell that is typical of meat, making it easy to eat and leaving a pleasant aftertaste. [Brief description of the drawings]

[0011] [Figure 1] Figure 1 is a process diagram showing the preparation process of raw materials. [Diagram 2] Figure 2 is a process diagram showing the manufacturing process after preparation processing. [Diagram 3] FIG. 3 is a front view showing a schematic overall configuration of the encrusting machine. [Figure 4] FIG. 4 is a partial cross-sectional view showing a part of the main part of the encrusting machine. [Diagram 5] FIG. 5(a) is a plan view showing the shutter device in an open state, and (b) is a schematic diagram showing the positional relationship between the shutter device / conveyor belt / elevator and the cylindrical molded body before cutting, as viewed from the front. [Figure 6] FIG. 6(a) is a plan view showing the shutter device in a half-open state, and (b) is a schematic diagram showing the positional relationship between the shutter device / conveyor belt / elevator and the cylindrical molded body being cut, as viewed from the front. [Figure 7] FIG. 7(a) is a plan view showing the shutter device in a closed state, and FIG. 7(b) is a schematic diagram showing the positional relationship between the shutter device / conveyor belt / elevator and the wrapped products after cutting and wrapping, as viewed from the front. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] A method for producing frozen cabbage rolls according to an embodiment of the present invention is a method for producing frozen cabbage rolls comprising wrapping a meaty filling with a cabbage-like outer skin material, and includes the following steps (i)-(vii). (i) preparing cabbage pieces by pre-treating leafy vegetables, including at least cabbage, and cutting the leafy vegetables into pieces within a predetermined size range; (ii) preparing a binder containing at least konjac root in a paste or gel form, adding the binder in the paste or gel form to the cabbage pieces, and kneading the binder and the cabbage pieces to obtain a raw material for the outer skin material; (iii) preparing the ingredient for the filling by mixing a suitable amount of seasoning with ground meat comprising at least one of poultry, livestock, and seafood; (iv) placing the ingredients for the filling in a first supply section of an encrusting machine and the ingredients for the outer shell in a second supply section of the encrusting machine; (v) extruding the ingredient of the filling from a central nozzle communicating with the first supply unit while simultaneously extruding the ingredient of the outer skin from an annular nozzle communicating with the second supply unit, thereby covering the outer periphery of the extruded ingredient of the filling with the ingredient of the outer skin which is synchronously extruded; (vi) a step of cutting the ingredients extruded from the central nozzle into predetermined lengths while the ingredients for the outer skin are being fed from the annular nozzle, and wrapping the cut surfaces to obtain an encased product in which the ingredients for the inner skin are wrapped in the ingredients for the outer skin; (vii) A process for obtaining frozen cabbage rolls by freezing the stuffed product.

[0013] Each of steps (i)-(vii) of the above embodiment will be described in detail below. [Making small pieces of cabbage] In the step (i) of the present invention, leafy vegetables including at least cabbage are pretreated and cut into pieces of a predetermined size range to prepare pieces of cabbage. The prepared pieces of cabbage are stored in a freezer until the next step (ii) in which a binder is added and kneaded.

[0014] (raw materials) The raw cabbage used must be fresh cabbage that has not been substantially heated or dried after harvest, except for pre-treatment, which will be described later. Domestic cabbage with a clear origin label must be used. However, imported cabbage may also be used as long as it has clear traceability and fully meets the standards of the Food Sanitation Act. As cabbage, cabbage species having a moisture content above a certain level, such as winter cabbage (kandama) and spring cabbage (harudama), can be suitably used. However, in the present invention, dry species with a low moisture content, such as kale and savoy cabbage, are not suitable as raw materials for cabbage. Leafy vegetables other than cabbage species may be added to the cabbage. Leafy vegetables that can be used in combination with the cabbage include Chinese cabbage, Japanese mustard spinach, bok choy, nozawana, and spinach. Other yellow-green vegetables such as bell peppers can be added in addition to the leafy greens, and mushrooms such as shiitake mushrooms can also be added.

[0015] In the frozen cabbage rolls of the present invention, it is desirable to mix the above-mentioned other leafy vegetables, other yellow-green vegetables, and mushrooms in amounts not exceeding the standard amount of cabbage.

[0016] (Pretreatment) The cabbage is pre-processed by disassembling, washing, blanching, and draining. In the butchering process, the outer worm-eaten leaves, tough leaves and cores are removed from the raw cabbage, and the leaves are separated one by one. If the separated leaves have tough, thick stems attached, it is desirable to remove the stems as well. In the cleaning process, the disassembled cabbage leaves are transported to a conveyor-type shower cleaning room, where foreign matter that has become mixed in or is attached to the cabbage leaves (mud, weeds, insects, etc.) is removed using a combination of running water from the shower and manual removal. In the blanching process, washed cabbage leaves are exposed to steam or boiling water for a short period of time (e.g., 95°C for 150 seconds). Blanching temporarily stops or inhibits (inactivates) the activity of enzymes and microorganisms, and is effective in preventing changes (deterioration) during processing or storage of food ingredients. In the draining process, the moisture adhering to the surface of the blanched cabbage leaves is removed. Methods for removing the adhering moisture include blowing hot air onto the leaves, blowing cold air onto the leaves using the residual heat from the blanching process, or naturally drying the leaves.

[0017] (cutting) A food slicer equipped with a cutting function like a shredder can be used to cut cabbage leaves. The cabbage leaves are cut vertically along the fibers at a specified pitch width, and the thin, noodle-like pieces are cut horizontally at a specified pitch interval. This allows small square pieces of cabbage of the desired size to be obtained. The cutting size is set to a size that allows the outer skin material to easily pass through the annular nozzle of the enveloping machine without clogging when it is extruded from the nozzle. The cutting size depends on the performance of the enveloping machine, and currently, for example, can be set to a maximum of 5.0 mm x 5.0 mm increments, but since the performance of the enveloping machine may be improved in the near future, the cutting size can be set to a range of 5.0 mm x 5.0 mm to 10.0 mm x 10.0 mm.

[0018] [Preparation of raw materials for outer skin] In the present invention, in step (ii), a binder containing at least konjac yam is prepared into a paste or gel form, the paste or gel form of the binder is added to the cabbage pieces, and the binder and the cabbage pieces are kneaded to obtain the raw material for the outer skin material.

[0019] Various additives that are added to the above-mentioned pieces of cabbage to prepare the raw material for the outer skin material will be described below. (Binding agent) In order to give the raw material for the outer skin the desired adhesiveness and fluidity so that it can be shaped into a filling, a binder containing konjac root as the main ingredient is added to the small pieces of cabbage. The binder adheres the small pieces of cabbage together and gives the raw material for the outer skin a sense of unity. The binder is used in a paste or gel state with the desired viscosity and fluidity by adding an appropriate amount of water and mixing and stirring. Such a konnyaku-containing binder is added not only to the mutual adhesion of the small pieces of cabbage, but also to the filling material described below in order to bond the filling material and the outer skin material in a good compatibility manner. For example, Magic Mannan (registered trademark) by Ogino Shoten Co., Ltd. can be used as the binder.

[0020] The amount of binder added is preferably in the range of 1.05 to 1.45%, more preferably in the range of 1.15 to 1.35%, and most preferably in the range of 1.22 to 1.30%, in terms of the relative content (mass %) with respect to the standard cabbage.

[0021] (shape retention aid) A shape-retaining aid mainly composed of a wheat flour processed product is further added to stabilize the viscosity of the mixture of cabbage shreds / binder to prevent the shape of the stuffed product from collapsing. The shape-retaining aid stabilizes the viscosity of the outer skin material, not only improving the shape retention during stuffing molding, but also preventing a decrease in the viscosity of the outer skin material during storage (deterioration over time). An example of a shape-retaining aid that can be used is Hybrid Alpha (product name) from Nippon Shokken Holdings Co., Ltd. This type of shape-retaining aid contains a small amount of emulsifier (glycerin fatty acid ester) in addition to the wheat flour processed product as the main ingredient.

[0022] The amount of shape-retaining aid added can be substantially the same as the amount of binder added, and is preferably in the range of 1.05 to 1.45% by mass, more preferably 1.15 to 1.35%, and most preferably 1.22 to 1.30%, relative to the standard cabbage.

[0023] [Preparation of ingredients] In the present invention, in step (iii), a raw material for the filling is prepared by mixing an appropriate amount of seasoning with ground meat containing at least one of poultry, livestock, and seafood.

[0024] (Minced meat) The minced meat, which is the main ingredient of the filling, can be poultry such as chicken and / or livestock such as pig and / or seafood such as Alaska pollock. For example, in the case of chicken, minced chicken breast, minced chicken thigh, or a mixture of chicken breast and minced chicken bellies can be used. In the case of pig, minced pork belly, minced pork thigh, etc. can be used. In the case of seafood, minced shrimp, minced squid, minced Alaska pollock, etc. can be used.

[0025] (seasoning) As seasonings, finely chopped onion, grated garlic, salt, white pepper, etc. can be added to the above-mentioned minced meat. The onion can be finely chopped, for example, in increments of 4.0 mm. Grated garlic not only serves as a seasoning but also plays a role in masking the odor of livestock meat. As grated garlic, for example, Suri Garlic (product name) by Kaneka Sunspice Co., Ltd. can be used.

[0026] In addition to the above-mentioned seasonings, other additives that are added to the minced meat to prepare the ingredients for the filling will be described below. (Excipients) Fillers that can be added include bread crumbs, modified starch, granular soy protein, etc. These fillers contribute to the retention of shape during the filling process and to preventing the filling from falling apart during cooking.

[0027] (Water retention agent) Dried egg white is added as a water retention agent. A small amount of dried egg white is added to prevent the delicious meat juice from leaking out of the filling during cooking. The amount of dried egg white added is limited to a small amount of 0.01% by mass or less, but since the Food Labeling Act requires the labeling of designated allergens, this is indicated on the product.

[0028] [Preparing the outer skin and filling ingredients] In the present invention, in step (iv), the raw material for the filling is placed in a first supply section of an encrusting machine, and the raw material for the outer shell is placed in a second supply section of the encrusting machine.

[0029] Step (iv) will now be outlined with reference to FIGS. As shown in Fig. 3, a filling material feeder 5 as a first supply unit and an outer skin material feeder 7 as a second supply unit are detachably attached to the upper part of the main frame 3 of the encrusting machine 1. The filling material feeder 5 stores a first preparation material which is a mixture of minced meat, seasonings, and additives and which becomes the filling material raw material 31. The outer skin material feeder 7 stores a second preparation material which is a mixture of small pieces of cabbage, a binding agent, and a shape-retaining aid and which becomes the outer skin material raw material 32.

[0030] As shown in FIG. 4, the inner ingredient feeder 5 is equipped with a first vane pump 15A and a first screw conveyor (not shown), and the outer ingredient feeder 7 is equipped with a second vane pump 15B and a second screw conveyor (not shown).

[0031] When both the first vane pump 15A and the first screw conveyor are driven, the driving force of the first screw conveyor supplies the inner ingredient raw material 31 to the suction port of the first vane pump 15A, and the driving force of the first vane pump 15A extrudes the inner ingredient raw material 31 at a predetermined pressure from the discharge port of the first vane pump 15A toward the flow path 8A of the central nozzle 9A (the inner nozzle of the polymerization nozzle 9).

[0032] When both the second vane pump 15B and the second screw conveyor are driven, the raw material skin material 32 is supplied to the suction port of the second vane pump 15B by the driving force of the second screw conveyor, and the raw material skin material 32 is extruded and supplied at a predetermined pressure from the discharge port of the second vane pump 15B toward the flow path 8B of the annular nozzle 9B (the outer nozzle of the polymerization nozzle 9).

[0033] [Polymerization and extrusion of the outer skin material and the filling material] In the present invention, in step (v), the raw material for the inner filling is extruded from a central nozzle communicating with the first supply section while the raw material for the outer skin is simultaneously extruded from an annular nozzle communicating with the second supply section, thereby covering the outer periphery of the extruded raw material for the inner filling with the raw material for the outer skin that is extruded synchronously.

[0034] Step (v) will now be described with reference to FIGS. As shown in Fig. 4, when the inner ingredient raw material 31 is extruded at a predetermined pressure into the central nozzle flow path 8A while the outer skin raw material 32 is extruded at a predetermined pressure into the annular nozzle flow path 8B, the outer skin raw material 32 adheres to cover the outer peripheral surface of the inner ingredient raw material 31, as shown in Fig. 5, and the two raw materials are integrated to form a cylindrical molded body 33. This cylindrical molded body 33 is inserted into the central opening 12C of the fully opened shutter assembly 12 shown in Fig. 5(a) of the cutter 13 arranged directly below the discharge port of the polymerization nozzle 9 shown in Fig. 4 and Fig. 5(b).

[0035] In this polymerization extrusion process (v), the supply ratio of the outer shell material raw material to the inner filling material raw material is preferably in the range of 60:40 to 76:24, more preferably in the range of 65:35 to 74:26, and most preferably in the range of 68:32 to 72:28.

[0036] [Cutting and wrapping to form filling] In the present invention, in step (vi), while the raw material for the outer skin is being supplied from the annular nozzle, the raw material for the filling material extruded from the central nozzle is cut into predetermined lengths and the cut surfaces are wrapped to obtain a stuffed product in which the raw material for the inner filling material is wrapped in the raw material for the outer skin material.

[0037] Step (vi) will now be described with reference to FIGS. As shown in (a) of FIG. 6, the fully opened shutter assembly 12 begins to close to reduce the central opening 12C, and as shown in (b) of FIG. 6, the lifting rod 19 of the lifter 20 is raised and the push-up member 19A attached to the upper end of the rod 19 pushes up a portion of the conveyor belt 16 of the belt conveyor device to a predetermined height level. As the shutter assembly central opening 12C shrinks, the blade 11A of the shutter piece 11 comes into contact with the appropriate position of the cylindrical molded body 33, and the filling precursor 34 shown in FIG. 6(b) is formed.

[0038] Next, as shown in Fig. 7(a), when the shutter assembly 12 is closed all the way to completely close the central opening 12C, a portion of the filling precursor 34 is separated from the cylindrical molding 33 to become a filling product 35, as shown in Fig. 7(b), and this filling product 35 falls onto the pushed-up conveyor belt 16. At this time, the lifter 20 pushes up a portion of the conveyor belt 16 to reduce the falling distance from the shutter assembly 12 to the conveyor belt 16, so that the filling product 35 lands softly on the conveyor belt 16 and no damage such as crushing, tearing, or breakage of the filling product 35 occurs.

[0039] In step (vi), the cutting of the inner ingredient raw material 31 extruded from the central nozzle 9A is completed while the outer skin raw material 32 is being discharged and fed from the annular nozzle 9B, so that the outer skin raw material 32 immediately wraps around the cut surface, and the cut surface of the filling precursor 34 is enveloped (completely covered) by the outer skin raw material 32. As a result, an almost spherical filled product 35 is obtained.

[0040] [Freezing process for packed products] In the present invention, in step (vii), the stuffed product is subjected to a freezing treatment to obtain frozen cabbage rolls. The freezing process is carried out after the sorting process, in which defective products are removed from the filled products. In the freezing process, the sorted filled products are placed in a spiral freezer controlled at -35°C or below, and the filled products are frozen so that the surface temperature is kept at -18°C or below.

[0041] The frozen packed products are subjected to a prescribed weighing inspection to remove any non-standard products, then bagged, sealed, and subjected to a prescribed metal detection inspection to remove any defective products, before being boxed. A final weighing inspection is conducted just before storage to remove any non-standard products, and only products that pass are placed in a freezer for storage. The packed products are then stored in the freezer so that the core temperature of the packed products is maintained at -18°C or below until they are shipped as products. EXAMPLES

[0042] An example of a method for producing frozen cabbage rolls will be described below. [Preparing ingredients] The steps of preparing the outer skin material and the inner filling material will be described with reference to FIG.

[0043] (Preparation process for raw materials for outer skin) First, the steps S1-1 to S1-4 for preparing the raw material for the outer skin will be described. The harvested raw cabbage was disassembled, washed, blanched, and then subjected to primary cooling (removal of residual heat by cooling with running water) and secondary cooling (cooling to a product temperature of 20°C or less by cooling with chiller water at a temperature of less than 15°C). The cabbage thus pretreated was cut using an Emla food slicer (model number ECD-403) to prepare small pieces of cabbage with an average size of 5.0 mm x 5.0 mm. The prepared small pieces of cabbage were washed with water and drained. The cabbage pieces treated as described above were stored in a freezer at a temperature of -18°C or lower (step S1-1).

[0044] The required lot amount or number of lots is measured according to the production plan or according to demand, and the measured amount of frozen small pieces of cabbage is taken out from the freezer. The taken out frozen small pieces of cabbage are thawed (step S1-2).

[0045] Next, a binder containing konjac yam and a shape-retaining aid were added to the thawed small pieces of cabbage, and the mixture was mixed and stirred using a mixer (step S1-3).

[0046] In this example, the binder containing konjac yam and the shape-retaining aid were added at a ratio of 1.26% each to the amount of the reference small piece cabbage. Magic Mannan (registered trademark) from Ogino Shoten Co., Ltd. was used as the binder containing konjac yam. Furthermore, Hybrid Alpha (product name of wheat flour processed product) from Nippon Shokken Holdings Co., Ltd. was used as the shape-retaining aid. The ingredients of Hybrid Alpha (product name) are 99.2% wheat flour and 0.8% emulsifier.

[0047] The mixture of small pieces of cabbage / binder / shape-retaining aid was stirred at low speed for 5 minutes using a mixer or stirrer, resulting in a pre-prepared raw outer skin material 32 as a work-in-progress (step S1-4). The raw outer skin material 32 obtained was temporarily stored in the chilled compartment of a refrigerator or on a stainless steel cart until it was used in the filling machine.

[0048] (Preparation process for ingredients) Next, steps S2-1 to S2-7 for preparing ingredients will be described. The required amount of frozen meat was taken out from the frozen storage, and the condition (temperature and mass) of the frozen meat was adjusted so that it was suitable for loading into the encrusting machine (step S2-1).

[0049] The frozen meat was thawed and tempered to a product temperature of 2°C (step S2-2). Next, large chunks of the thawed meat were crushed with a flaker (step S2-3). Next, small chunks of the crushed meat were chopped with a chopper at 3.2 mm pitch intervals to produce minced meat with the desired softness (step S2-4).

[0050] The seasonings, water, salt, WP, and grated garlic prepared in advance in step S3-1 were added to the prepared minced meat, and the mixture was mixed and stirred in a mixer or stirrer (step S2-5).

[0051] Next, the konjac-containing binder and shape-retaining aid prepared in advance in step S3-2 were further added to the mixture stirred in the previous step S2-5, and mixed and stirred with a mixer or stirrer (step S2-6).

[0052] In this example, the binder containing konjac yam and the shape-retaining aid were added at a ratio of 0.30% each to the amount of standard minced meat. In addition, Magic Mannan (registered trademark) from Ogino Shoten Co., Ltd. was used as the binder containing konjac yam. Furthermore, Hybrid Alpha (product name of wheat flour processed product) from Nippon Shokken Holdings Co., Ltd. was used as the shape-retaining aid.

[0053] The mixture of minced meat / binder / shape-retaining aid was stirred at low speed for 5 minutes using a mixer or stirrer, resulting in a pre-prepared filling ingredient 31 as a work-in-progress (step S2-7).

[0054] The obtained filling material raw material 31 was temporarily stored in the chilled compartment of a refrigerator or on a stainless steel cart until it was used in the filling machine.

[0055] [Manufacturing of stuffed products] The manufacturing process of the filled product will be described below with reference to Figs. Before explaining the manufacturing process, we will first explain the filling machine used in the filling process, which is the most important step in the manufacturing process.

[0056] As shown in Figure 3, the encrusting machine 1 comprises a main body frame 3 supported on casters with stoppers so that it can be pushed by hand, two feeders 5, 7 removably attached to the upper part of the frame, two flow paths 8A, 8B (see Figure 4) that correspond to and communicate with the corresponding feeders, an overlapping nozzle 9 including an inner nozzle 9A and an outer nozzle 9B (see Figure 4) that correspond to and communicate with the ends of the corresponding flow paths, a cutter 13 including a shutter assembly 12 (see Figures 4 to 7) arranged directly below the overlapping nozzle, a belt conveyor mechanism 17 including a conveying belt 16, and an adjustment handle 28 for adjusting the shutter assembly.

[0057] An inner ingredient feeder 5 and an outer skin material feeder 7 are detachably attached to the top of the main frame 3. The containers of the feeders 5 and 7 are configured so that they can be removed from the top of the frame, and the container of the inner ingredient feeder 5 contains prepared ingredients for the inner ingredients, and the container of the outer skin material feeder 7 contains prepared ingredients for the outer skin.

[0058] As shown in FIG. 4, the overlapping nozzle 9 has a coaxial double structure including a central nozzle 9A (inner nozzle) including a flow path 8A communicating with the discharge port of the inner ingredient feeder container, and an annular nozzle 9B (outer nozzle) arranged approximately coaxially to surround the outer periphery of the central nozzle 9A and including a flow path 8B communicating with the discharge port of the outer skin feeder container.

[0059] The inner ingredient feeder 5 is equipped with a first vane pump 15A and a first screw conveyor (not shown), and the outer skin material feeder 7 is equipped with a second vane pump 15B and a second screw conveyor (not shown).

[0060] When both the first vane pump 15A and the first screw conveyor are driven, the driving force of the first screw conveyor supplies the inner ingredient raw material 31 to the suction port of the first vane pump 15A, and the driving force of the first vane pump 15A extrudes and supplies the inner ingredient raw material 31 from the discharge port of the first vane pump 15A toward the flow path 8A of the central nozzle 9A (the inner nozzle of the polymerization nozzle 9) at a predetermined pressure.

[0061] When both the second vane pump 15B and the second screw conveyor are driven, the raw skin material 32 is extruded and supplied to the suction port of the second vane pump 15B by the driving force of the second screw conveyor, and the raw skin material 32 is extruded and supplied at a predetermined pressure from the discharge port of the second vane pump 15B toward the flow path 8B of the annular nozzle 9B (outer nozzle).

[0062] As shown in Fig. 4, the cutter 13 includes a casing 22 fixed to the frame 3 and a shutter assembly 12 drivably connected to the casing 22. Six rotating shafts 12A are provided rotatably and slidably at equal intervals on the same circumference within the casing 22. The rotating shafts 12A are disposed in the slot holes 11B of the shutter piece 11 together with corresponding sliders 12B.

[0063] The shutter assembly 12 is disposed at a predetermined interval directly below the overlapping nozzle 9 that extends downward through the casing 22. The shutter piece 11 of the shutter assembly 12 is supported by the fixed casing 22 so as to be rotatable via a corresponding rotation shaft 12A.

[0064] As shown in Figures 5 to 7, the rotating shaft 12A is connected to a motor drive shaft so that a rotational drive force from the drive shaft of a motor (not shown) can be transmitted. The drive motor is fixed to a movable plate (not shown), to which two vertical shafts (not shown) are attached. These two vertical shafts are fitted to two cylindrical holes (not shown) provided in a fixed block (not shown) attached to the main body frame 3, and are provided to be slidable.

[0065] When each rotating shaft 12A is rotated in the reverse direction, a cam plate (not shown) attached to the upper end of the rotating shaft 12A rotates together with the rotating shaft 12A. As a result, an eccentric protrusion (not shown) attached to the cam plate rotates (eccentrically rotates) at a position eccentric from the axis of the rotating shaft 12A, and the six shutter pieces 11 constituting the shutter assembly 12 are fully opened as shown in FIG. 5(a). When the shutter assembly is fully opened, a large opening 12C is formed in the center surrounded by the shutter pieces 11. The diameter of the central opening 12C in the fully opened state is sufficiently larger than the diameter of the cylindrical molded body 33 so that the cylindrical molded body 33 can pass through with sufficient clearance, as shown in FIG. 5(a).

[0066] In contrast, when each rotating shaft 12A is rotated in the forward direction, the central opening 12C surrounded by the six shutter pieces 11 gradually shrinks as shown in Fig. 6(a). As a result, as shown in Fig. 6(b), the cutting blade 11A of the shutter piece 11 bites into the cylindrical molded body 33 inserted into the central opening 12C, causing a constriction slightly above the lower end of the cylindrical molded body 33 due to the cutting blade, and a filling precursor 34 is provisionally formed below the constriction.

[0067] When each rotating shaft 12A is further rotated to the bottom dead center in the forward direction, the inner acute angle parts of each shutter piece 11 gather and align at the center of the longitudinal axis, the shutter assembly 12 is completely closed, and the central opening 12C disappears, as shown in Fig. 7(a). As a result, as shown in Fig. 7(b), the filling precursor 34 is separated from the cylindrical molding 33 connected to the upper nozzle 9, and the separated part becomes the filling product 35 and falls onto the conveyor belt 16 pushed up by the lifter 20.

[0068] As shown in FIG. 3, a belt conveyor mechanism 17 is disposed below the cutter 13, and after the wrapped product 35 cut and wrapped by the cutter 13 is landed, it is transported to the next process (not shown).

[0069] The belt conveyor mechanism 17 includes a drive roller to which rotational driving force is transmitted from a drive motor (not shown), a bridle roller to adjust the belt tension, a guide roller to guide the belt, and an endless conveyor belt 16 supported by these various rollers so that it can move along an endless track.

[0070] A lifter 20 is provided below the cutter 13 with the conveyor belt 16 sandwiched therebetween. The lifter 20 is equipped with a push-up member 19A for temporarily lifting a part of the conveyor belt 16 in synchronization with the operation of the cutter 13, and a lifting rod 19 for supporting the push-up member 19A so as to be movable in the vertical direction. That is, the upper end of the lifting rod 19 is connected to the lower surface of the push-up member 19A, the main part of the lifting rod 19 is guided by a guide 18, and the base end of the lifting rod 19 is supported by a drive motor via a cam mechanism (not shown) so as to be capable of reciprocating in the vertical direction.

[0071] In the lifter 20, the bottom dead point of the up and down movement of the lifting rod 19 is the position where the lower surface of the push-up member 19A abuts the upper surface of the upper guide plate 18A, and the top dead point of the up and down movement of the lifting rod 19 is the position where a stopper (not shown) abuts the lower surface of the upper guide plate 18A.

[0072] As shown in FIG. 3, an adjustment handle 28 that is operated manually or automatically is attached to the lower front part of the main frame 3. One end of a screw rod covered with a protective casing (not shown) is rotatably connected to the adjustment handle 28. A screw rod support member (not shown) having an internal thread that screws into the screw part of the screw rod is slidably supported inside the protective casing (not shown) on the other end side of the screw rod. One end of the screw rod support member (not shown) is connected to one arm (not shown) of an L-shaped lever (not shown) inside the frame 3 via a sliding member (not shown). A corner portion located approximately in the center of the L-shaped lever (not shown) is rotatably attached to the frame 3, and two support members (not shown) are arranged opposite to the other arm (not shown) of the L-shaped lever (not shown) via a connecting member (not shown). A cam follower (not shown) is attached to the inside of the tip part of each of these two support members (not shown). The bottom surface of the cam (not shown) is placed on this cam follower. By rotating the adjustment handle 28, the cam (not shown) can be positioned in the vertical direction via an L-shaped lever (not shown) which operates in response to the rotation of the cam (not shown).

[0073] As shown in Fig. 3, an opening / closing shaft 12A integrally equipped with an opening / closing lever 23 is provided rotatably about its axis within a casing 22 of the cutter 13. This opening / closing shaft 12A and a plurality of pivots (not shown) arranged at equal intervals on the same circumference of the casing 22 are connected to each other via gears (not shown) and each of the shutter pieces 11 which are mutually constrained. When the opening / closing shaft 12A is rotated by swinging the opening / closing lever 23, each of the shutter pieces 11 turns about its axis to open and close the central opening 12C of the shutter assembly 12.

[0074] The encrusting machine 1 is equipped with a controller (not shown) for automatically controlling the operation of each component. Under automatic control by the controller, the processing time required for changing from the cylindrical molded body 33 in FIG. 5 to the encrusting precursor 34 in FIG. 6 to the encrusting product 35 in FIG. 7 is very short. That is, the repeated opening and closing cycle time of the shutter assembly 12 of the cutter 13 is set to be very short. In addition, the repeated transport / stop cycle time of the belt conveyor mechanism 17 driven in conjunction with the cutter 13 is also set to be very short. Furthermore, the intermittent push-up cycle time of the lifter 20 driven in conjunction with the belt conveyor mechanism 17 is also set to be very short.

[0075] The manufacturing process of the filled products will be explained. (Adjustment of the filling machine) In the above-mentioned encrusting machine 1, each part was adjusted as follows in preparation for the encrusting and forming step K2 (step K1). 1) Clean the feeders 5, 7, the overlapping nozzle 9, the shutter assembly 12, and the conveyor belt 16 to remove any foreign matter adhering to each part. 2) The filling ingredients 31 and the outer skin ingredients 32 are weighed and placed in the corresponding containers of the feeders 5 and 7, respectively. 3) The drive mechanism of the cutter 13 is adjusted by manually or automatically operating the adjustment handle 28. 4) Other adjustment handle levers (not shown) are manually or automatically operated to adjust the discharge pressures (extrusion driving forces for the raw materials) from the two vane pumps 15A, 15B.

[0076] In this embodiment, the supply ratio of the inner filling ingredient 31 and the outer covering ingredient 32 was adjusted to 30:70 (30% inner filling:70% outer covering) by operating the adjustment handle 28 and / or other adjustment handle levers (not shown).

[0077] (Preparation of raw materials) The required lot amount or number of lots was measured according to the production plan or according to demand, and the measured amounts of the inner filling raw material 31 and the outer skin raw material 32 were taken out of the freezer. The lump of the inner filling raw material 31 and the outer skin raw material 32 were each temporarily stored. The filling material raw material 31 was charged into the container of the first feeder 5 of the encrusting machine, and the outer skin material raw material 32 was charged into the container of the second feeder 7 of the encrusting machine (step K2).

[0078] (Enveloping) The filling step K3 using the filling machine 1 will be described with reference to Figs.

[0079] The main switch of the encrusting machine 1 is turned ON to start the electric motor, which starts driving the first and second screw conveyors, the first and second vane pumps 15A, 15B, the cutter 13, the belt conveyor mechanism 17, and the lifter 20, respectively. As a result, the inner ingredient raw material 31 is supplied to the suction port of the first vane pump 15A by the driving force of the first screw conveyor, and the inner ingredient raw material 31 is extruded and supplied at a predetermined pressure from the discharge port of the first vane pump 15A toward the flow path 8A of the central nozzle 9A by the driving force of the first vane pump 15A.

[0080] In addition, the raw material skin 32 is extruded and supplied to the suction port of the second vane pump 15B by the driving force of the second screw conveyor, and the raw material skin 32 is extruded and supplied from the discharge port of the second vane pump 15B toward the flow path 8B of the annular nozzle 9B at a predetermined pressure. As a result, the filling material raw material 31 and the outer skin material raw material 32 which are coaxially extruded in parallel and synchronously from the overlapping nozzle 9 are integrated into a cylindrical molded body 33 .

[0081] On the other hand, each rotating shaft 12A is rotated in the reverse direction, and a cam plate (not shown) attached to the upper end of the rotating shaft 12A is rotated together with the rotating shaft 12A, whereby an eccentric protrusion (not shown) attached to the cam plate rotates (eccentrically rotates) at a position eccentric from the axis of the rotating shaft 12A, and the six shutter pieces 11 constituting the shutter assembly 12 are fully opened. When the shutter assembly is fully opened, a large opening 12C is formed in the center surrounded by the shutter pieces 11. As shown in FIG. 5(a), a cylindrical molded body 33 from the overlapping nozzle 9 is inserted into the fully opened central opening 12C.

[0082] Next, each rotating shaft 12A is rotated in the forward direction, and the central opening 12C surrounded by the six shutter pieces 11 is reduced in diameter. As a result, as shown in Fig. 6(b), the cutting blade 11A of the shutter piece 11 bites into the cylindrical molding 33 inserted into the central opening 12C, and the cutting blade bites into the cylindrical molding 33, causing a constriction slightly above the lower end thereof, and a filling precursor 34 is provisionally formed below the constriction.

[0083] When each rotating shaft 12A is further rotated to the bottom dead center in the forward direction, the inner acute angle portion of each shutter piece 11 is aligned at the center of the longitudinal axis, the shutter assembly 12 is completely closed, and the central opening 12C disappears, as shown in Fig. 7(a). As a result, as shown in Fig. 7(b), the filling precursor 34 is separated from the cylindrical molding 33 connected to the upper nozzle 9, and the separated part becomes the filling product 35 and falls onto the conveyor belt 16 pushed up by the lifter 20.

[0084] Next, when the push-up member 19A of the lifter 20 descends and the conveying belt 16 returns to a horizontal position, the conveying belt 16, which had been temporarily stopped, is driven by the belt conveyor mechanism 17, and the packed products 35 on the conveying belt 16 are transported to the next process.

[0085] The series of processes for filling and forming the filling paste in step K2 described above is all carried out automatically and mechanically by the filling machine 1 without any human intervention.

[0086] Next, an operator visually inspects the appearance of all of the filled products produced, and selects and removes products with poor appearance, such as those with poor shape or damage such as tears.

[0087] The stuffed products that passed the visual inspection were subjected to a freezing process to obtain frozen cabbage rolls (step K4). In the freezing process, the selected stuffed products were placed in a spiral freezer controlled at -35°C or less, and the stuffed products were frozen so that the surface temperature was kept at -18°C or less.

[0088] Next, the frozen stuffed products are weighed and inspected, and any non-compliant products are removed. Only the products that pass the inspection are packed into bags and sealed (step K5). Next, the bagged frozen packed products were subjected to a metal detector inspection to remove defective products (step K6).

[0089] Next, only products that pass the metal detector inspection are boxed (process K7). A final weighing inspection is carried out immediately before storage to eliminate non-standard products, and only products that pass are placed in a freezer for storage. The finished products are kept in the freezer until they are shipped, with the product temperature adjusted to -18°C or lower. The storage period is a maximum of 12 months.

[0090] Sampling was done from finished products in storage, and each sample was subjected to a bacterial test. The bacterial test was performed in accordance with the bacteriological ingredient standard for "frozen foods (products consumed after heating or not heated before freezing)" stipulated in the Food Sanitation Act. This standard requires that the general viable bacteria count be 3 million / g or less, and that E. coli (Escherichia coli) be negative.

[0091] Products are shipped from lots that have been confirmed to meet the bacterial testing criteria.

[0092] [Raw material ingredients] Table 1 shows examples of ingredients contained in the raw materials for the covering material.

[0093] [Table 1]

[0094] Table 2 shows examples of ingredients contained in the filling ingredients.

[0095] [Table 2]

[0096] [Preparing ingredients] Table 3 shows an example of the conditions for feeding the raw materials.

[0097] [Table 3] [Enveloping conditions] Table 4 shows an example of the filling forming conditions.

[0098] [Table 4]

[0099] [Preparation of filled sample] Example 1 As Example 1, a filling sample was prepared using the raw material for the outer skin having the components shown in Table 6 under the filling molding conditions shown in Table 4. For the sample of Example 1, the raw material for the outer skin contained, by mass%, 97.00% cabbage, 1.50% konjac yam binder, and 1.50% shape-retaining aid. Example 2 As Example 2, a filling sample was prepared using the raw material for the outer skin having the components shown in Table 6 under the filling molding conditions shown in Table 4. For the sample of Example 2, the raw material for the outer skin contained, by mass%, 97.50% cabbage, 1.25% konjac yam binder, and 1.25% shape retention aid. Example 3 As Example 3, a filling sample was prepared using the raw material for the outer skin having the components shown in Table 6 under the filling molding conditions shown in Table 4. For the sample of Example 3, the raw material for the outer skin contained, by mass%, 98.00% cabbage, 1.00% konjac yam binder, and 1.00% shape retention aid.

[0100] Comparative Example 1 As Comparative Example 1, a filling sample was prepared using the raw material for the outer skin having the components shown in Table 6 under the filling molding conditions shown in Table 4. For the sample of Comparative Example 1, the raw material for the outer skin contained, by mass%, 98.50% cabbage, 0.75% konjac yam binder, and 0.75% shape retention aid. Comparative Example 2 As Comparative Example 2, a filling sample was prepared using the raw material for the outer skin having the components shown in Table 6 under the filling molding conditions shown in Table 4. For the sample of Comparative Example 2, the raw material for the outer skin contained, by mass%, 99.00% cabbage, 0.50% konjac yam binder, and 0.50% shape retention aid.

[0101] [Viscosity measurement conditions] In order to evaluate the formability of each sample, the viscosity of the raw materials for the outer shell was measured under the viscosity measurement conditions shown in Table 5.

[0102] [Table 5]

[0103] [Evaluation test results for filling formability] Table 6 shows the test results evaluating the molding properties of each sample of the above examples and comparative examples.

[0104] The evaluation test was performed by visually inspecting the appearance of the product with the naked eye. Products with a good appearance were deemed acceptable and indicated with a circle in the table, while products with defects such as crushing or deformation, products with uneven thickness of the skin material, and products with torn skin material were deemed defective and indicated with an x ​​in the table.

[0105] [Table 6]

[0106] The sample of Example 1 was a spherical filled product with good appearance. The sample of Example 2 was a spherical filled product with good appearance. The sample of Example 3 was a spherical filled product with good appearance. In the sample of Comparative Example 1, a part of the outer skin material was torn, exposing the filling material. In the sample of Comparative Example 2, a part of the outer skin material was torn, exposing the filling material. (Cooking method) The product of the present invention can be cooked in a variety of ways, such as by taking it out of the package and heating it in a hot water bath, by taking it out of the package and heating it in a steam convection oven (SC), or by taking it out of the package and heating it in a microwave oven.

[0107] (Results of an evaluation test on the shape retention of wrapped products during cooking) The product of the present invention was taken out of the package and boiled in water for a long period of time, varying from 1 hour, 3 hours, 5 hours, to 7 hours. As a result, the product was able to be cooked without falling apart in any case. [Industrial Applicability]

[0108] The frozen cabbage rolls produced according to the present invention are a frozen food that is highly anticipated to be sold and distributed alongside conventional hand-rolled frozen cabbage rolls in supermarkets, convenience stores, and the like. [Explanation of symbols]

[0109] 1... Encrusting machine, 3... Frame, 5... Inner ingredient feeder (first supply section), 7... Outer ingredient feeder (second supply section), 9... Polymerization nozzle, 9A... Central nozzle (inner nozzle), 9B... Annular nozzle (outer nozzle), 11...shutter piece, 11A...cutting blade, 11B...slot hole, 12...shutter assembly, 12A...rotating shaft, 12B...slider, 12C...opening, 13...cutter, 15A, 15B…Vane pump, 16: conveyor belt; 17: belt conveyor mechanism; 18: guide; 18A: upper guide plate with holes; 19: lifting rod; 19A: push-up portion; 20: lifter; 22... casing, 23... opening / closing lever, 25... connecting rod, 28... adjustment handle, 31: Ingredients for filling, 32: Ingredients for outer skin, 33 ... cylindrical molded body, 34 ... filling precursor, 35 ... filling product

Claims

1. A method for producing frozen cabbage rolls, comprising wrapping a meaty filling with a cabbage-like outer skin material, (i) preparing cabbage pieces by pre-treating leafy vegetables including at least cabbage and cutting them into pieces of a predetermined size range; (ii) preparing a binder containing at least konjac root in a paste or gel form, adding the binder in the paste or gel form to the cabbage pieces, and kneading the binder and the cabbage pieces to obtain a raw material for the outer skin material; (iii) preparing a raw material for the filling by mixing a suitable amount of seasoning with ground meat comprising at least one of poultry, livestock, and seafood; (iv) placing the ingredients for the filling in a first supply section of an encrusting machine and the ingredients for the outer shell in a second supply section of the encrusting machine; (v) extruding the ingredient of the filling from a central nozzle communicating with the first supply unit while simultaneously extruding the ingredient of the outer skin from an annular nozzle communicating with the second supply unit, thereby coating the outer periphery of the extruded ingredient of the filling with the ingredient of the outer skin which is extruded synchronously; (vi) a step of cutting the ingredients extruded from the central nozzle into predetermined lengths while the ingredients for the outer skin are being fed from the annular nozzle, and wrapping the cut surfaces to obtain an encased product in which the ingredients for the inner skin are wrapped in the ingredients for the outer skin; (vii) obtaining frozen cabbage rolls by freezing the stuffed product; A method for producing frozen cabbage rolls, comprising the steps of:

2. The method according to claim 1 , wherein the raw material for the outer skin material contains a binder containing the konjac root in an amount of 1.00% to 1.50% by mass.

3. The method according to claim 1 , wherein the raw material for the outer skin material further contains, by mass %, 1.00% to 1.50% of a shape-retaining aid.

4. The method according to claim 3, wherein the content of the shape-retaining aid in the raw material of the outer skin material is substantially the same as the content of the binder containing the konjac root.

5. The method according to claim 1, wherein in the step (iii), the raw material of the filling further contains a binder containing the konjac root.

6. 2. The method of claim 1, wherein in step (i), the cabbage pieces are produced having a diameter of 10 mm or less.

7. The method according to claim 1, wherein the steps (ii) to (vi) are carried out without substantially heating the raw materials for the outer skin material and the raw materials for the filling material.

8. The method according to claim 1, wherein in the step (v), a ratio of the raw materials for the outer skin and the raw materials for the filling is adjusted to a range of 60:40 to 76:

24.

9. 2. The method of claim 1, wherein the source of the casing material comprises one or both of bell peppers and shiitake mushrooms.

10. 10. Frozen cabbage rolls produced using the method according to any one of claims 1 to 9.

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