Method for producing soybean-containing processed food, system for producing soybean-containing processed food, and soybean-containing processed food

Abstract

To provide a method for producing, by using soybeans as a raw material, a new soybean-containing processed food having appearance and taste like a terrine (like pate of a terrine de pate).SOLUTION: The method comprises: a dough base preparation process P10 for preparing a dough base 1 that serves as a base for a target soybean-containing processed food 10; an auxiliary material-mixing process P20 for mixing an auxiliary material 2 with the dough base 1 obtained in the dough base preparation process P10; and a post-treatment process P30 for subjecting an auxiliary material mixture 3 obtained in the auxiliary material-mixing process P20 to a post-treatment. The post-treatment process P30 includes at least a thermal treatment step for the auxiliary material mixture 3. In addition, the lipid content in the component composition of the dough base 1 is less than the protein content thereof, and the solid content derived from the dough base 1 in the obtained soybean-containing processed food 10 is at least 25 wt.%. Furthermore, the dough base preparation process P10 includes a component separation step for separating coagulated product components and water-soluble components by performing a coagulation treatment on soybean milk 02.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for producing soybean-containing processed foods, a system for producing soybean-containing processed foods, and soybean-containing processed foods, and in particular to a method for producing soybean-containing processed foods using soybeans as a main ingredient, which can provide novel textures, tastes, uses, etc. [Background technology]

[0002] There have long been many processed foods that use soybeans as an ingredient, and many new research and development projects and patent applications have been filed. For example, the applicant's patent document 1, listed below, discloses an invention that extracts necessary ingredients from soy milk and remixes them in the appropriate ingredient ratio for each product, in order to solve the problem of having to set up different production lines for each product, such as tofu, frozen tofu, fried tofu, and yuba. This has resulted in the consolidation of production lines, which has resulted in reduced costs, space savings, improved hygiene management, and promotion of new product development.

[0003] In addition, Patent Document 2 listed below discloses a method for producing a tofu-like food with a sea urchin flavor that is made into a paste-like form by increasing the dietary fiber, lipid, and water content, while Patent Document 3 discloses a method for producing a soybean processed food similar to processed meat food, using yam and defatted soybeans or soybean protein, and Patent Document 4 discloses a method for producing a soybean processed food with a cheese-like texture by increasing the water content.

[0004] In addition, there are protein bars that are formed into a fixed shape, such as wafer type or crunch type, as foods that allow protein to be ingested more easily than in amorphous powder form. When soybeans are used as the raw material, the soybeans are powdered, hydrated, and then added with auxiliary ingredients and baked to a solid content of about 75-90%. Foods formed into a fixed shape include terrine de pâté, or so-called terrine, which is served by filling a mold or container with ingredients and cooking by heating, and processed foods such as terrine-style prepared foods and sweets are also available on the market. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 6598564 "Soybean processed food manufacturing method and soybean processed product manufacturing system" (by the applicant) [Patent Document 2] Patent No. 7479708 "Method for producing soybean paste-like or gel-like foods" [Patent Document 3] JP 2022-128426 A "Soybean-containing processed food and its manufacturing method" [Patent Document 4] Patent No. 4928425 "Soybean processed food with cheese texture and its manufacturing method" Summary of the Invention [Problem to be solved by the invention]

[0006] Thus, research and development of processed foods made from soybeans, a plant-based resource and high-protein foodstuff, is being actively carried out, and new products are being introduced to the market at a high rate due to diversifying consumer needs. The providers of such products are required to continue to provide new benefits to the market and consumers. For example, processed soybean foods with lower lipid content meet the needs of those who want to maintain and improve their health, processed soybean foods that are suitable for room temperature distribution or freezing through retort processing in consideration of advantages in terms of distribution and storage, and soybean terrine-like processed soybean foods from the perspective of improving product quality by matching them to the consumer's perspective and sensibilities, etc.

[0007] Therefore, the problem that the present invention aims to solve is to provide, in light of the state of the prior art, a production technology for new soy-containing processed foods that can provide new textures, tastes, flavors, uses, etc., such as soybean processed foods with reduced lipid content, soybean processed foods that are suitable for room temperature distribution or freezing after retort treatment, soybean processed foods with excellent productivity, or soybean processed foods that are suitable for terrine-like product forms, and a production technology for soy-containing processed foods suitable for them. [Means for solving the problem]

[0008] The inventors of the present application have conducted extensive research into the above-mentioned problem. As a result, based on the separation / extraction and reconstitution method of necessary components from soybean raw materials disclosed in the above-mentioned Patent Document 1, they have invented an invention of a method for producing a solid processed food by molding, which has relatively high viscosity properties, by mixing appropriate auxiliary materials with the soybean raw materials, homogenizing the soybean raw materials as necessary, and then heating the soybean raw materials. As the auxiliary materials, seasonings, food polysaccharides, powdered vegetable proteins, vegetable powders, confectionery powders, fish powders, dairy products such as cheese and milk powders, etc. can be appropriately used. In addition, it has been confirmed that not only soy milk but also soybean flour can be used as a raw material, and a sol-like tofu-like emulsion can be prepared by using the soybean raw materials, and a terrine-like food can be produced by adding auxiliary materials.

[0009] It was confirmed that the present invention can provide processed soybean foods with reduced lipid content, processed soybean foods suitable for normal temperature distribution or freezing through retort processing, processed soybean foods with excellent productivity, processed soybean foods suitable for terrine-like product forms as described above, processed soybean foods with novel and good texture, taste and flavor, and processed soybean foods with novel uses such as side dishes and confectioneries. Based on these results, the present invention has been completed. That is, the invention claimed in this application as a means for solving the above problems, or at least the invention disclosed therein, is as follows.

[0010] [1] A method for producing a soy-containing processed food, comprising: a dough base preparation process for preparing a dough base that is the basis of the target soy-containing processed food; a secondary ingredient mixing process for mixing secondary ingredients with the dough base obtained in the dough base preparation process; and a post-treatment process for subjecting the secondary ingredient mixture obtained in the secondary ingredient mixing process to a post-treatment, the post-treatment process including at least a heat treatment process for the secondary ingredient mixture, the dough base having a component composition in which the lipid content is less than the protein content, and the resulting soy-containing processed food contains 25% by weight or more of solids derived from the dough base, and the dough base preparation process includes a component separation process for separating coagulated components produced by a coagulation process of soy milk from water-soluble components. [2] The method for producing a soy-containing processed food according to [1], characterized in that the dough base preparation process comprises a selective component mixing process in which, if necessary, a water-soluble component is mixed with the coagulated component separated in the component separation process to obtain a component mixture, and a selective homogenization process in which, if necessary, a homogenization treatment is performed on the coagulated component or, if the selective component mixing process has been performed, on the component mixture obtained thereby. [3] The method for producing soybean-containing processed foods according to [2], characterized in that in the selective component mixing step, the process is carried out at a mixing ratio of 25% by weight or more and 100% by weight or less of the coagulum component and 0% by weight or more and 75% by weight or less of the water-soluble component so that the concentration of the coagulum component is a concentration suitable for obtaining the target soybean-containing processed food. [4] A method for producing a soy-containing processed food, comprising: a dough base preparation process for preparing a dough base that is the basis of the target soy-containing processed food; a secondary ingredient mixing process for mixing secondary ingredients with the dough base obtained in the dough base preparation process; and a post-treatment process for subjecting the secondary ingredient mixture obtained in the secondary ingredient mixing process to post-treatment, wherein the post-treatment process includes at least a heat treatment step for the secondary ingredient mixture, the dough base has a component composition in which the lipid content is less than the protein content, and the soy-containing processed food obtained has a solid content derived from the dough base of 25% by weight or more, and the dough base preparation process includes obtaining a tofu-like emulsion by water extraction of soybean flour as the dough base. [5] The heat treatment in the heat treatment step is <h>A method for producing a soybean-containing processed food according to any one of [1], [2], [3], and [4], characterized in that the method is any one of the following: <h>Baking in an oven, baking in a convection oven, baking in a steam oven, heat treatment in a drum dryer, boiling treatment in a container or package, retort treatment in a container or package, other heat treatment (excluding baking in an oven, baking in a convection oven, baking in a steam oven, heat treatment in a drum dryer, boiling treatment in a container or package, or retort treatment in a container or package)

[0011] [6] The method for producing a soybean-containing processed food according to [5], wherein the post-treatment process includes a molding step of molding the secondary material mixture, and the molded product obtained by the molding step is subjected to a heat treatment in the heat treatment step. [7] The method for producing a soybean-containing processed food according to [6], wherein the post-treatment step includes a selective secondary ingredient mixture homogenization step of homogenizing the secondary ingredient mixture as necessary, and when the selective secondary ingredient mixture homogenization step has been performed, the homogenized product obtained thereby is subjected to a molding treatment in the molding step. [8] The auxiliary material is <c>The method for producing a soybean-containing processed food according to either [6] or [7], characterized in that the method is one or more of the following: <c>Soy protein, vegetable protein (excluding soy protein), seasonings, food polysaccharides, vegetable powder, fruit powder, confectionery powder, fish meal, dairy products, oils and fats [9] A soy-containing processed food production system comprising a dough base preparation section which prepares a dough base that is the basis of the target soy-containing processed food, a secondary ingredient mixing section which mixes secondary ingredients with the dough base obtained in the dough base preparation section, and a post-treatment section which performs post-treatment on the secondary ingredient mixture obtained in the secondary ingredient mixing section, wherein the post-treatment section at least includes a heat treatment section for the secondary ingredient mixture, and wherein the dough base preparation section obtains a dough base having a lipid content less than its protein content, and the resulting soy-containing processed food contains 25% by weight or more of solids derived from the dough base.

[0012]

[10] The soy-containing processed food production system according to [9], characterized in that the dough base preparation unit is provided with a component separation unit that separates the coagulated components produced by the coagulation process of soy milk from the water-soluble components.

[11] The soy-containing processed food manufacturing system according to

[10] , characterized in that the dough base preparation unit is provided with a selective component mixing unit which, if necessary, mixes a water-soluble component with the coagulated component separated in the component separation unit to obtain a component mixture.

[12] A soybean-containing processed food produced by the soybean product production system described in any one of [9],

[10] , and

[11] .

[13] A soy-containing processed food, characterized in that a secondary ingredient is mixed into a dough base made from soybeans, the dough base has a component composition in which the lipid content is less than the protein content, and the solid content of the obtained soy-containing processed food derived from the dough base is 25% by weight or more, and the soy-containing processed food is formed through a heat treatment.

[14] The soybean-containing processed food according to either

[12] or

[13] , characterized in that it is formed into a specific shape like a pate in a terrine de pate.

[15] See below. <f>The soybean-containing processed food according to

[14] , characterized in that it is any one of the soybean-containing processed food listed in the above. <f>High protein foods, prepared foods, confectioneries, spreads

[16] The soybean-containing processed food according to

[15] , which is a frozen food. Effect of the Invention

[0013] Since the soybean-containing processed food production method, soybean-containing processed food production system, and soybean-containing processed food of the present invention are configured as described above, they can provide novel solid soybean-containing processed foods in terms of texture, taste, flavor, applications, etc. For example, soybean processed foods with reduced lipid content, soybean processed foods suitable for normal temperature distribution or freezing after retort processing, or soybean processed foods suitable for terrine-like commercial forms can be provided with excellent productivity. [Brief description of the drawings]

[0014] [Figure 1] FIG. 1 is a flow chart showing the basic configuration of a method for producing soybean-containing processed foods of the present invention. [Figure 1-2] FIG. 2 is a flow chart showing the configuration of an example of the dough base preparation process shown in FIG. 1. [Figure 1-3] FIG. 2 is a flow chart showing an example of the structure of the dough base preparation process in the method for producing soybean-containing processed foods of the present invention, taking into account aspects such as remixing of ingredients. [Figure 1-4] FIG. 2 is an explanatory diagram showing an item that can be used as a dough base in the method for producing soybean-containing processed food of the present invention shown in FIG. 1. [Diagram 2] FIG. 1 is a flow chart showing the basic configuration of a method for producing a soy-containing processed food of the present invention using soybean flour as a raw material. [Diagram 3] FIG. 1 is a flow chart showing the configuration of a method for producing soybean-containing processed food of the present invention, which includes a molding step in the post-treatment process. [Figure 3-2] FIG. 1 is a flow chart showing the main components of a method for producing soybean-containing processed foods of the present invention, which includes a homogenization step in the post-treatment process. [Figure 3-3] FIG. 4 is an explanatory diagram showing items that can be subjected to a heat treatment step in the method for producing soybean-containing processed food of the present invention shown in FIG. 3. [Diagram 3-4] FIG. 4 is a second explanatory diagram showing items that can be subjected to the heat treatment step in the method for producing soybean-containing processed food of the present invention shown in FIG. 3. [Figure 4] FIG. 1 is a conceptual diagram showing the basic configuration of a soybean-containing processed food production system of the present invention. [Diagram 5] FIG. 1 is a conceptual diagram showing the configuration of a soybean-containing processed food production system of the present invention using soy milk as a raw material. [Figure 6] FIG. 2 is an explanatory diagram conceptually showing the shaping of the soybean-containing processed food of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The present invention will now be described in detail with reference to the drawings. Fig. 1 is a flow diagram showing the basic configuration of the soybean-containing processed food manufacturing method of the present invention. Fig. 1-2 is a flow diagram showing the configuration of an example of the dough base preparation process shown in Fig. 1. As shown in these figures, the manufacturing method flow basically comprises a dough base preparation process P10 for preparing a dough base 1 that is the basis of the soybean-containing processed food 10, a secondary material mixing process P20 for mixing a secondary material 2 with the dough base 1 obtained in the dough base preparation process P10, and a post-processing process P30 for post-processing the secondary material mixture 3 obtained in the secondary material mixing process P20, and the post-processing process P30 includes at least a heat treatment process P38 for the secondary material mixture 3.

[0016] The dough base 1 subjected to the dough base preparation process P10 has a component composition in which the lipid content is less than the protein content, and the solid content derived from the dough base 1 in the obtained soy-containing processed food 10 is 25% by weight or more.Furthermore, as shown in FIG. 1-2, the dough base preparation process P10 mainly comprises a component separation process P15 for separating the coagulated component 04 and the water-soluble component 06 obtained by coagulating the raw material soy milk 02 in the coagulation process P13.

[0017] According to the present method for producing soy-containing processed foods having such a configuration, first, in a dough base preparation process P10, a dough base 1 that is the basis of the target soy-containing processed food 10 is prepared, in which soy milk 02 is used as a raw material as shown in Fig. 1-2. Specifically, in a coagulation process P13, soy milk 02 is subjected to a coagulation process to obtain a coagulated component 04 and a water-soluble component 06, and then in a component separation process P15, the coagulated component 04 and the water-soluble component 06 are separated.

[0018] The coagulation process in the coagulation process step P13 may be performed by adding a coagulant, and the component separation process in the component separation step P15 may be performed by centrifugation, or other methods that are conventionally known in the manufacture of tofu, etc. How the coagulated component 04 and the water-soluble component 06 separated in this manner are used will be described later with reference to FIG. 1-3.

[0019] The composition of the dough base 1 finally obtained in the dough base preparation step P10 of the soybean-containing processed food production method of the present invention is such that the fat content is less than the protein content. That is, the dough base preparation step P10 is carried out to obtain such a composition.

[0020] The dough base 1 obtained in the dough base preparation process P10 is then subjected to a secondary ingredient mixing process P20, where a secondary ingredient 2 is mixed into the dough base 1 to obtain a secondary ingredient mixture 3. The range of secondary ingredients 2 that can be mixed is wide, but will be described in detail later. The obtained secondary ingredient mixture 3 is then subjected to a post-treatment process P30, where the secondary ingredient mixture 3 is subjected to a post-treatment, which includes at least a heat treatment process P38 of the secondary ingredient mixture 3.

[0021] That is, the secondary ingredient mixture 3 is subjected to a heat treatment by an appropriate heating method, and finally the target soy-containing processed food 10 is obtained. The soy-containing processed food 10 thus obtained is characterized in that the solid content derived from the dough base 1 is 25% by weight or more in the soy-containing processed food 10 obtained by the method of the present invention. The more preferable ratio of the solid content of the obtained soy-containing processed food 10 is 30 to 75% by weight.

[0022] The applicant has disclosed a soybean product manufacturing technology that separates the coagulated component from the water-soluble component produced by the coagulation process of the starting soybean milk and remixes the two components in a mixing ratio suited to the target product (Patent No. 6541509, Patent No. 6598564, Patent No. 6605258, Patent No. 6757126). For example, the remixing ratio is about 14% by weight for the target product such as cotton tofu, about 18% by weight for frozen tofu, about 25% by weight for membrane-like soybean processed foods such as yuba, crepes, and seaweed, and about 30% by weight for meat-like soybean processed foods such as hamburger steak, fish paste, and scrambled eggs.

[0023] On the other hand, one of the objects of the present invention is that the final product is in a terrine-like product form. In other words, it is a soy-containing processed food that is formed into a specific shape like a pate, such as a terrine de pate, regardless of the purpose such as a prepared dish or a confectionery. Such a pate-like, or so-called terrine-like form also includes products with a more fixed shape, such as a protein bar. The suitable range of solid content in the final product in a terrine-like form is 30 to 75% by weight, and the remixing ratio of the coagulated component 04 and the water-soluble component 06 after the coagulation process of soy milk 02 can be determined accordingly.

[0024] FIG. 1-3 is a flow diagram of a configuration example of the dough base preparation process according to the soybean-containing processed food production method of the present invention, taking into consideration the viewpoint of component remixing and the like. As shown in the figure, in the soybean-containing processed food production method of the present invention, in which the raw material is soy milk 02, a selective component mixing step P16 can be provided in the dough base preparation step P10. In this step P16, the water-soluble component 06 is remixed as necessary with the coagulated component 04 separated from the water-soluble component 06 in the component separation step P15 to obtain a component mixture 08. Since it is "when necessary," there may be cases where remixing is not necessary to obtain the specifications of the final product. Even when the coagulated component 04 and the water-soluble component 06 are remixed, the mixing ratio can be appropriately designed according to the specifications of the final product.

[0025] As shown in the figure, this flow can also be configured to include a selective homogenization step P18. This step P18 homogenizes the coagulated component 04, or the component mixture 08 obtained when the components are remixed in the selective component mixing step P16, as necessary, to obtain a dough base level homogenized product 09. Since it says "when necessary," there are cases where homogenization is not required to obtain the specifications of the final product. The specific method for homogenization can be designed as appropriate according to the specifications of the final product.

[0026] Figure 1-4 is an explanatory diagram showing materials that can be used as the dough base in the method for producing soybean-containing processed foods of the present invention shown in Figure 1. As shown in the figure, a plurality of materials can be used as the dough base 1 obtained in the dough base preparation process P10 of the method for producing soybean-containing processed foods using soy milk 02 as a raw material. That is, any of the coagulated material component 04 obtained in the component separation process P15, the component mixture 08 obtained in the selective component mixing process P16, and the homogenized material 09 obtained in the selective homogenization process P18 during dough base preparation can be used as the dough base 1 and subjected to the subsequent processes.

[0027] In the selective component mixing step P16, the remixing process can be performed at a mixing ratio of 25% by weight to 100% by weight of the coagulated component 04 and 0% by weight to 75% by weight of the water-soluble component so that the concentration of the coagulated component 04 is suitable for obtaining the target soybean-containing processed food. By using these remixing ratios, the soybean-containing processed food of the present invention can be obtained satisfactorily with a solid content of 30 to 75% by weight, which is the more preferable ratio.

[0028] FIG. 2 is a flow diagram showing the basic configuration of the method for producing soybean-containing processed foods of the present invention using soybean flour as a raw material. As shown in the figure, this soy-containing processed food production method using soy flour 03 as a raw material has a basic structure consisting of a dough base preparation process P210 for preparing a dough base 21 that is the basis of the target soy-containing processed food 210, a secondary ingredient mixing process P220 for mixing secondary ingredients 22 with the dough base 21 obtained in the dough base preparation process P210, and a post-processing process P230 for post-processing the secondary ingredient mixture 23 obtained by the secondary ingredient mixing process P220. The post-processing process P230 at least includes a heat treatment step P238 of the secondary ingredient mixture 23. The composition of the dough base 21 has a lipid content that is less than the protein content, and the solid content derived from the dough base 21 in the obtained soy-containing processed food 210 is 25% by weight or more. These are common to the production method of the present invention using soy milk 02 as a raw material shown in FIG. 1 etc., but differ from the method in the present invention in that a tofu-like emulsion is obtained as the dough base 21 by extracting soy flour 03 with water in the dough base preparation process P210.

[0029] That is, in the dough base preparation process P210, a tofu-like emulsion obtained by water extraction of soy flour 03 is used as dough base 21 and is subjected to each subsequent process, and other than that, each process P220, P230 is performed with the same variation as the manufacturing method using soy milk 02 as the raw material described in Figures 1, 1-3, and 1-4. In this way, by preparing a sol-like tofu-like emulsion from soy flour 03 and adding auxiliary materials, a soy-containing processed food 210 can be obtained, as in the case of soy milk as the raw material shown in Figure 1, etc., and a terrine-like final product can also be obtained. Note that, of course, the characteristic point of showing component separation based on the coagulation process of soy milk 02, as explained using Figure 1-3, is not present in this flow using soy flour 03 as the raw material.

[0030] Regardless of whether the raw material is soy milk 02 or soy flour 03, the heat treatment carried out in the heat treatment step of the post-processing process can be various heating methods and heating conditions, including baking in an oven, convection oven, or steam oven, heat treatment in a drum dryer, boiling or retort treatment in a container or package, etc., as long as the moisture content of the final product can be reduced to the desired solid content ratio. In the present invention, a heat treatment step by any of these methods is essential as a post-processing process.

[0031] If this step is not carried out sufficiently, the final product will be in a paste or slurry state, and the terrine-like processed food with a high solids content that is the main form of the final product envisaged by the present invention will not be obtained. Therefore, it is important that the degree of heating in the heat treatment is at least at a level that will give such a high solids content in the final product, depending on the specific treatment method. For example, if the boiling treatment is carried out after filling into a container or package, if the degree is too low, the final product will become paste-like, so it is important to carry out a sufficient boiling treatment. A high solids content in the final soybean-containing processed food product is also meaningful in that it will be a product more suitable for distribution.

[0032] Fig. 3 is a flow diagram showing the configuration of the method for producing soy-containing processed foods of the present invention, which includes a molding step in the post-processing steps. As shown in the figure, the method for producing soy-containing processed foods of the present invention can be configured such that a molding step P336 for molding the secondary ingredient mixture 33 is included in the post-processing step P330 to which the secondary ingredient mixture 33 obtained through the dough base preparation step P310 and the secondary ingredient mixing step P320 is provided, regardless of whether the soy-containing processed food raw material 01 is soy milk or soy flour.

[0033] According to this flow having such a configuration, the secondary material mixture 33 is subjected to a molding step P336 in the post-treatment process P330 to obtain a shaped product 38. For the shaping process in the molding step P336, a molding machine, a filling machine, or other shaping means suitable for forming the shape to be imparted to the shaped product 38 can be used as appropriate. The shaped product 38 is then subjected to a heat treatment step P338 where it is heat-treated to obtain a soybean-containing processed food 310 shaped into the shape to be imparted.

[0034] Fig. 3-2 is a flow diagram showing the main configuration of the method for producing soy-containing processed foods of the present invention, which includes a homogenization step in the post-processing process. As shown in the figure, in this method for producing soy-containing processed foods, regardless of whether the soy-containing processed food raw material 01 is soy milk or soy flour, the post-processing process P330 to which the secondary ingredient mixture 33 obtained through the dough base preparation process and the secondary ingredient mixing process is subjected can be configured to include a selective secondary ingredient mixture homogenization process P335 for homogenizing the secondary ingredient mixture 33 as necessary.

[0035] According to this flow having such a configuration, the secondary ingredient mixture 33 is subjected to a selective secondary ingredient mixture homogenization step P335 in the post-treatment process P330, and if homogenization is performed here as necessary, a homogenized product 35 is obtained. The homogenized product 35 is then subjected to a shaping step P336 to obtain a shaped product 38. The shaped product 38 is then subjected to a heat treatment step P338 to obtain a soybean-containing processed food 310 shaped into the desired form.

[0036] FIG. 3-3 is an explanatory diagram showing objects that can be subjected to the heat treatment step in the method for producing soybean-containing processed foods of the present invention shown in FIG. 3. As shown in the figure, a plurality of objects can be used as objects to be subjected to the heat treatment step P338. That is, any of the auxiliary ingredient mixture 33 obtained in the auxiliary ingredient mixing step P320, the homogenized product 35 obtained in the selective auxiliary ingredient mixture homogenization step P335, and the molded product 38 obtained in the molding step P336 can be subjected to the heat treatment step P338. However, the present invention particularly cites a terrine-like product form as one of its main objects. Therefore, it is more desirable to have a configuration in which the molding step P336 is essential. An explanation will be given from that viewpoint.

[0037] Fig. 3-4 is a second explanatory diagram showing the material that can be subjected to the heat treatment step in the soybean-containing processed food manufacturing method of the present invention shown in Fig. 3, and it is assumed here that the molding step is essential. As shown in the figure, the secondary material mixture 33 obtained by the secondary material mixing process P320, and the homogenized material 35 obtained when homogenization is performed in the selective secondary material mixture homogenization step P335 (indicated by the "Y" arrow in the figure), are both necessarily subjected to molding in the molding step P336 before being subjected to the heat treatment step P338 to form a molded product 38. When homogenization is not selected in the selective secondary material mixture homogenization step P335 (indicated by the "N" arrow in the figure), the material that is subjected to the molding step P336 is the secondary material mixture 33.

[0038] The secondary materials used in the method for producing soybean-containing processed foods of the present invention are not particularly limited and can include a wide range of materials. In particular, any one of the following, or a suitable combination of two or more of the following, can be suitably used as secondary materials: soybean protein, vegetable protein other than soybean protein, seasonings, food polysaccharides, vegetable powders, fruit powders, confectionery powders, fish meal, dairy products (cheese, milk powder, etc.), and oils and fats. Since the final soybean-containing processed food product of interest has a high solids ratio and high viscosity, it is desirable to use a device with strong mixing power such as a food processor, cutter mixer, or shear mixer for production.

[0039] Fig. 4 is a conceptual diagram showing the basic configuration of the soybean-containing processed food production system of the present invention. As shown in the figure, the soybean-containing processed food production system S1000 comprises a dough base preparation section S100 for preparing a dough base that is the basis of the target soybean-containing processed food, a secondary material mixing section S200 for mixing secondary materials with the dough base obtained in the dough base preparation section S100, and a post-treatment section S300 for post-treatment of the secondary material mixture obtained in the secondary material mixing section S200, and the post-treatment section S300 includes at least a heat treatment section S380 for the secondary material mixture, and the main configuration is that the dough base has a lipid content less than the protein content, and the solid content derived from the dough base in the soybean-containing processed food obtained as the final product is 25% by weight or more.

[0040] In the soybean-containing processed food manufacturing system S1000 of the present invention having such a configuration, first, in the dough base preparation section S100, a dough base that is the basis of the target soybean-containing processed food is prepared, and the dough base prepared here has a lipid content less than the protein content, and has a property such that the solid content derived from the dough base in the soybean-containing processed food obtained as the final product is 25% by weight or more.More preferably, the solid content derived from the dough base in the soybean-containing processed food obtained as the final product is 30% by weight or more and 75% by weight or less.

[0041] The dough base is mixed with the secondary ingredients in the secondary ingredient mixing section S200 to produce a secondary ingredient mixture. As in the above-mentioned method for producing soy-containing processed foods of the present invention, various secondary ingredients can be used depending on the purpose of the final product. The obtained secondary ingredient mixture is subjected to post-processing in the post-processing section S300 to obtain the final product soy-containing processed food. In the post-processing section S300, at least the secondary ingredient mixture is subjected to heat treatment in the heat treatment section S380. The heat treatment method in the heat treatment section S380 can be any suitable method known in the art, as in the above-mentioned method for producing soy-containing processed foods of the present invention.

[0042] Fig. 5 is a conceptual diagram showing the configuration of the soy-containing processed food production system of the present invention, which uses soymilk as a raw material. As shown in the figure, the soy-containing processed food production system S1000X can be configured to include, in addition to the components described with reference to Fig. 4, a component separation section S115X that separates the coagulated components resulting from the coagulation treatment of soymilk from the water-soluble components in the dough base preparation section S100X. That is, the soy-containing processed food production system S1000X uses soymilk as a production raw material, and in the dough base preparation section S100X, the component separation section S115X separates the coagulated components resulting from the coagulation treatment of soymilk from the water-soluble components.

[0043] The dough base obtained through the separation of the soy milk components in the component separation section S115X is mixed with the auxiliary ingredients in the auxiliary ingredient mixing section S200X to form an auxiliary ingredient mixture, which is then subjected to post-processing, at least a heat treatment in the heat treatment section S380 in the post-treatment section S300X, to obtain the final product soy-containing processed food. Note that in the dough base preparation section S100X, the coagulated components separated in the component separation section S115X can be output as the dough base, but other dough base compositions are also possible.

[0044] That is, by providing a selective component mixing section S116X downstream of the component separation section S115X as shown in the figure, the dough base preparation section S100X can be configured to remix the separated components at an appropriate ratio. That is, the selective component mixing section S116X has the function of mixing a water-soluble component with the coagulated component separated in the component separation section S115X as necessary, and obtaining a component mixture by remixing both components. Since it is "when necessary," there may be cases where the remixing process is not necessary if it is not necessary to obtain the specifications of the final product. Note that the specific method and mixing ratio of the remixing process can be designed appropriately according to the specifications of the final product.

[0045] The soybean-containing processed food itself produced by the soybean processed product production system S1000 having any of the above-described configurations is also within the scope of the present invention. In addition, the production means is not limited to the soybean processed product production system S1000 of the present invention, and the soybean-containing processed food formed by heat treatment in which a secondary material is mixed with a dough base made of soybeans, the dough base has a composition in which the lipid content is less than the protein content, and the solid content derived from the dough base in the obtained soybean-containing processed food is 25% by weight or more is within the scope of the present invention.

[0046] Fig. 6 is an explanatory diagram conceptually showing the formation of the shape of the soybean-containing processed food of the present invention. As shown in the figure, the soybean-containing processed food 610 is filled into an appropriate mold structure 65 of a specific shape for forming, for example, to obtain a specific form as the soybean-containing processed food p610 before being removed from the mold structure ((a) in the figure), and is finally removed from the mold structure 65 to obtain the soybean-containing processed food 610 that has been formed into a specific shape like a pate for terrine de pate ((b) in the figure).

[0047] The soybean-containing processed food of the present invention is manufactured with a solid content of 25% by weight or more, more preferably 30% to 75% by weight or less, is low in fat due to the use of natural emulsions, and is a food close to nature, and its uses are not limited. For example, it can be suitably used as a high-protein food, side dish, confectionery, etc., and also can be used as a spread food when the solid content ratio is low. In addition, since the soybean-containing processed food of the present invention has a high solid content and low moisture content, it is suitable for distribution at room temperature by retort processing, and for production, distribution, and sale as a frozen food regardless of the purpose. EXAMPLES

[0048] Examples of the present invention will be described below, but the present invention is not limited to these examples. Note that % is by weight. <1. Production of soybean processed composition (= dough base)> Soy milk produced in a tofu factory according to a conventional method was used in the test. This soy milk is made by soaking Canadian soybeans overnight, grinding them in a grinder while adding water, heating them directly in a steamer, and separating the soybean lees with a screw press. Water was added so that the solid content of the soy milk becomes 10%, and it was heated to 80℃ in a hot water bath.

[0049] 17.5 mL of 10% aqueous solution of magnesium chloride hexahydrate (Kanto Chemical Co., Ltd.) was added to 500 g of soy milk, stirred with a rubber spatula, and left to stand for 10 minutes. The mixture was separated into a coagulated material and an aqueous solution using a tabletop centrifuge (H-112, Kokusan Co., Ltd.) at 5,000 rpm. The solid content of the separated coagulated material was 24%.

[0050] <2 Physical property measurement method (viscosity)> Viscosity measurements were performed at 25°C on unheated samples. A rheometer (Anton Paar, MCR-302e) was used with a 12 mm diameter parallel plate spindle (Anton Paar, PP12) plunger. To obtain the rheological profile using RheoCompass software, the rheometer was set in oscillation mode with an angular frequency of 10 (1 / s), a gap of 3 mm, and 25 data points were collected while the strain was increased from 0.01% to 100% on a logarithmic scale. Shear strain (%), shear stress (Pa), storage modulus (Pa), loss modulus (Pa), loss tangent (-), torque (μNm), complex viscosity (Pa·s), and normal force (N) were recorded. Complex viscosity (Pa·s) at a shear strain of 0.1% was also recorded.

[0051] <3. Physical property measurement method (breaking stress)> The breaking stress was measured by carrying out a penetration test at three points on a sample cut to a thickness of 1.5 cm and kept at 25°C. A rheometer (Sun Scientific, CR-500DX) was used for the measurement, with a circular plunger with a diameter of 10 mm, a penetration speed of 1.0 mm / min, and the average value of the first peak of the load was evaluated as the breaking stress.

[0052] <4 Comparative Example> Comparative Example 1 (Plain) Only 100 g of the dough base was homogeneously dispersed in a food processor (MK-K48P, Panasonic Corporation) without using any auxiliary ingredients. This was filled into a container and heat-treated in a constant temperature water bath at 90°C for 20 minutes to obtain a soybean processed product (soybean-containing processed food), which was designated as Comparative Example 1.

[0053] Comparative Example 2 (low protein) 97.5 g of dough base and 2.5 g of soy protein 90% (Bioactives Japan) as a secondary ingredient were weighed and uniformly dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and heated in a thermostatic water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Comparative Example 2.

[0054] <5 Example: Highly nutritious food> Example 1 (medium protein) 94 g of dough base and 6 g of 90% soy protein (BioActives Japan) as a secondary ingredient were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and heated in a thermostatic water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 1.

[0055] Example 2 (high protein) 89 g of dough base and 11 g of 90% soy protein (BioActives Japan) as a secondary ingredient were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and heated in a constant temperature water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 2.

[0056] Example 3 (High Protein Retort) 89 g of dough base and 11 g of 90% soy protein (BioActives Japan) as a secondary ingredient were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and retorted (Hirayama Seisakusho) at 121°C for 20 minutes to obtain a soybean processed product, which was designated as Example 3.

[0057] Example 4 (Ultra High Protein) 84 g of dough base and 16 g of soy protein 90% (Bioactives Japan) as a secondary ingredient were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and heated in a thermostatic water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 4.

[0058] <6 Example: Side dishes> Example 5 (Komatsuna spread, low temperature) 90 g of dough base, 8 g of komatsuna powder (Mikasa Sangyo Co., Ltd.) as secondary ingredients, 1 g of consomme powder, and 1 g of edible oil were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic Co., Ltd.). The resulting mixture was filled into a container and heat-treated in a thermostatic water bath at 65°C for 90 minutes to obtain a soybean processed product, which was designated as Example 5.

[0059] Example 6 (Komatsuna terrine, high temperature) 90 g of dough base, 8 g of komatsuna powder (Mikasa Sangyo Co., Ltd.) as secondary ingredients, 1 g of consomme powder, and 1 g of edible oil were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic Co., Ltd.). The resulting mixture was filled into a container and heated in a thermostatic water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 6.

[0060] <7 Example: Confectionery> Example 7 (Matcha terrine boiled) 72.5 g of dough base, 20 g of sugar as secondary ingredients, 5 g of processed starch (Showa Sangyo Co., Ltd.), and 2.5 g of matcha powder were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic Co., Ltd.). The resulting mixture was filled into a container and heated in a thermostatic water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 7.

[0061] Example 8 (Matcha terrine retort) 72.5 g of dough base, 20 g of sugar as secondary ingredients, 5 g of processed starch (Showa Sangyo Co., Ltd.), and 2.5 g of matcha powder were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic Co., Ltd.). The resulting mixture was filled into a container and retorted (Hirayama Seisakusho Co., Ltd.) at 121°C for 20 minutes to obtain a soybean processed product, which was designated as Example 8.

[0062] <8 Measurement and evaluation methods> a Moisture content The measurements were performed using a normal pressure heating and drying method at 105°C.

[0063] b. Texture The texture was judged by sensory evaluation by a panel using the following criteria, with a score of ◯ or higher being considered a pass. ◎: Very good ○: Good ×: Inferior

[0064] c Complex viscosity before heating Pa s The complex viscosity (Pa·s) at a shear strain of 0.1% was recorded. d Breaking stress after heating gf / cm 2 The breaking stress was measured by a penetration test using a rheometer.

[0065] e Protein % The measurement was performed using a total nitrogen analyzer by the combustion method (SUMIGRAPH (registered trademark) NC-220F, Sumika Chemical Analysis Center Co., Ltd.), and the calculation was performed using a nitrogen conversion coefficient of 5.71. f lipid% The lipid content was measured by extraction with a chloroform-methanol mixture.

[0066] g Texture after freezing and thawing The frozen products were slowly frozen in a freezer at -20°C (Shibata Scientific Co., Ltd.), stored for 24 hours, thawed at room temperature, and subjected to sensory evaluation. The texture was judged by a panel using the following criteria, with a score of ◯ or higher being considered a pass. ◎: Maintains texture before freezing ○: Inferior to ◎, but maintains texture before freezing ×: The texture before freezing has been lost.

[0067] <9 Results and Discussion> The measurement and evaluation results of Examples 1 to 8 and Comparative Examples 1 and 2 are shown in Table 1.

[0068] [Table 1]

[0069] The difference between the manufacturing conditions of Example 1 (medium protein) and Comparative Example 1 (plain) is the presence or absence of the secondary ingredient soy protein. Also, the difference between the manufacturing conditions of Example 1 (medium protein) and Comparative Example 2 (low protein) is the amount of added secondary ingredient soy protein. As a result, in Comparative Example 1 with no secondary ingredient added and Comparative Example 2 with a small amount added, the texture after freezing and thawing was impaired, whereas in Example 1 this was maintained, and a good quality soy processed product (soy-containing processed food) was obtained. It was estimated that when vegetable protein is used (at least when soy protein is used), the amount of added secondary ingredient should preferably be about 5% or more of the total.

[0070] The difference between the manufacturing conditions of Example 1 (medium protein) and Example 2 (high protein) is the amount of soy protein added as a secondary ingredient. As a result, even in Example 2, where the amount added was increased to about 10% of the total, the texture after freezing and thawing was maintained, and a soybean product of good quality was obtained. Furthermore, in Example 2, the protein content was increased and the lipid content was reduced, resulting in a result that is more in line with the trend for low lipid foods.

[0071] The difference between the manufacturing conditions of Example 2 (high protein) and Example 3 (high protein retort) is the method and temperature of the heat treatment, the former being boiling treatment at 90° C., and the latter being retort treatment at 121° C. As a result, in Example 3, where heat treatment was performed at a higher temperature, the texture of the soybean processed product obtained was extremely good, and furthermore, the texture after freezing and thawing was maintained better than in Example 2, and a soybean processed product of excellent quality was obtained.

[0072] In Example 4 (ultra-high protein), the manufacturing conditions were the same as in Examples 1 and 2, but the amount of soy protein added as a secondary ingredient was increased to over 15% of the total. In this example, the texture after freezing and thawing was maintained, and a good quality soybean product was obtained. In addition, the protein content was further increased and the lipid content was further reduced, resulting in a result that meets the trend for low lipid foods.

[0073] Both Example 5 (Komatsuna spread, low temperature) and Example 6 (Komatsuna terrine, high temperature) are soybean processed foods that use Komatsuna powder and other secondary ingredients as side dishes, but the heating temperatures are different. The former is 65°C, and the latter is 90°C. As a result, Example 5, which was heated at a lower temperature, produced a soybean processed food in the form of a spreadable food (soybean-containing processed food). However, no freezing and thawing tests were conducted on this product.

[0074] On the other hand, in Example 6, which was heated at a higher temperature, a terrine-like soybean product with a high solid content was obtained. The texture was also well maintained after freezing and thawing, and a soybean product of excellent quality was obtained.

[0075] Both Example 7 (boiled matcha terrine) and Example 8 (retorted matcha terrine) are processed soy products in the form of confectionery, using matcha powder and sweeteners as secondary ingredients, but the heat treatment method and temperature are different. The former is boiled at 90°C, and the latter is retorted at 121°C. As a result, both examples showed good texture and the effect of maintaining texture after freezing and thawing, and soy products of good quality were obtained. In particular, Example 8, which was heated at a higher temperature, showed excellent results. [Industrial Applicability]

[0076] According to the soybean-containing processed food production method, soybean-containing processed food production system, and soybean-containing processed food of the present invention, it is possible to provide novel solid soybean-containing processed foods with excellent productivity in terms of texture, taste, flavor, applications, etc. Therefore, this invention is highly industrially applicable in the food production field and all related industrial and technical fields. [Explanation of symbols]

[0077] 01…Soybean-containing processed food ingredients 02…Soy milk 03…Soy flour 04…Coagulum components 06…Water-soluble components 08…Component mixture 09…Homogenized material during dough base preparation 1, 31…Fabric base 2, 22, 32…auxiliary materials 3, 23, 33…auxiliary material mixture 10, 210, 310, 610...Processed foods containing soybeans 21...Dough base (tofu-like emulsion) 35...Homogenized material during post-treatment process 38...Molded product 65…Molding structure p610... Processed foods containing soybeans before removal from the mold structure P10, P210, P310…Dough base preparation process P13…Solidification treatment process P15…Component separation process P16...Selective component mixing process P18…Selective homogenization process P20, P220, P320…auxiliary material mixing process P30, P230, P330…Post-processing process P38, P238, P338...Heat treatment process P335...Selective secondary material mixture homogenization process P336…Molding process S100, S100X…Dough base preparation section S115X…Component separation section S116X…Selective component mixing section S200, S200X…auxiliary material mixing section S300, S300X…Post-processing section S380, S380X…heat treatment section S1000, S1000X...Soy-containing processed food manufacturing system< / f> < / f> < / c> < / c> < / h> < / h>

Claims

1. A method for producing a soy-containing processed food, comprising: a dough base preparation process for preparing a dough base that is the basis of the target soy-containing processed food; a secondary material mixing process for mixing secondary materials with the dough base obtained in the dough base preparation process; and a post-processing process for subjecting the secondary material mixture obtained in the secondary material mixing process to post-processing, said post-processing process including at least a heat treatment process for the secondary material mixture, said dough base having a component composition in which the lipid content is less than the protein content, and said dough base has a solid content of 25% by weight or more in the obtained soy-containing processed food, and said dough base preparation process further including a component separation process for separating coagulated components produced by a coagulation process of soy milk from water-soluble components.

2. The method for producing soy-containing processed foods as described in claim 1, characterized in that the dough base preparation process comprises a selective component mixing process in which, if necessary, a water-soluble component is mixed with the coagulated component separated in the component separation process to obtain a component mixture, and a selective homogenization process in which, if necessary, a homogenization treatment is performed on the coagulated component or, if the selective component mixing process has been performed, on the component mixture obtained thereby.

3. The method for producing soy-containing processed foods described in claim 2, characterized in that in the selective component mixing process, the processing is carried out at a mixing ratio of 25% by weight or more and 100% by weight or less of the coagulated component and 0% by weight or more and 75% by weight or less of the water-soluble component so that the concentration of the coagulated component is a concentration suitable for obtaining the target soy-containing processed food.

4. The method for producing a soy-containing processed food comprises a dough base preparation process for preparing a dough base that is the basis of the target soy-containing processed food, a secondary material mixing process for mixing secondary materials with the dough base obtained in the dough base preparation process, and a post-processing process for post-processing the secondary material mixture obtained in the secondary material mixing process, the post-processing process including at least a heat treatment step for the secondary material mixture, the dough base has a component composition in which the lipid content is less than the protein content, and the obtained soy-containing processed food contains 25% by weight or more of solids derived from the dough base, and the dough base preparation process obtains a tofu-like emulsion by water extraction of soy flour as the dough base.

5. 5. A method for producing a soybean-containing processed food according to claim 1, 2, 3 or 4, characterized in that the heat treatment in the heat treatment step is any of the heat treatments listed in <H> below. <H> Baking in an oven, baking in a convection oven, baking in a steam oven, heat treatment in a drum dryer, boiling treatment after filling into a container or package, retort treatment after filling into a container or package, and other heat treatments (excluding baking in an oven, baking in a convection oven, baking in a steam oven, heat treatment in a drum dryer, boiling treatment after filling into a container or package, and retort treatment after filling into a container or package)

6. 6. The method for producing a soybean-containing processed food according to claim 5, characterized in that the post-processing step includes a molding step of molding the secondary material mixture, and the molded product obtained by the molding step is subjected to a heat treatment in the heat treatment step.

7. 7. The method for producing a soybean-containing processed food according to claim 6, wherein the post-treatment step includes a selective secondary ingredient mixture homogenization step of homogenizing the secondary ingredient mixture as necessary, and when the selective secondary ingredient mixture homogenization step is performed, the homogenized product obtained thereby is subjected to a molding step in the molding step.

8. 8. The method for producing a soybean-containing processed food according to claim 6 or 7, wherein the secondary ingredients are any one or more of the ingredients listed in <C> below. <C> Soy protein, vegetable protein (excluding soy protein), seasonings, food polysaccharides, vegetable powder, fruit powder, confectionery powder, fish meal, dairy products, oils and fats

9. A soy-containing processed food manufacturing system comprising a dough base preparation section which prepares a dough base that is the basis of the target soy-containing processed food, a secondary material mixing section which mixes secondary materials with the dough base obtained in the dough base preparation section, and a post-treatment section which applies post-treatment to the secondary material mixture obtained in the secondary material mixing section, the post-treatment section including at least a heat treatment section for the secondary material mixture, wherein the dough base preparation section obtains a dough base having a lipid content less than its protein content, and the resulting soy-containing processed food contains 25% by weight or more of solids derived from the dough base.

10. The dough base preparation unit includes:

10. The soybean-containing processed food production system according to claim 9, further comprising a component separation section for separating coagulated components produced by the coagulation treatment of soy milk from water-soluble components.

11. The soy-containing processed food manufacturing system of claim 10, characterized in that the dough base preparation section is provided with a selective component mixing section which, if necessary, mixes a water-soluble component with the coagulated component separated in the component separation section to obtain a component mixture.

12. A soybean-containing processed food produced by the soybean processed product production system according to any one of claims 9, 10 and 11.

13. This soy-containing processed food is characterized in that a secondary ingredient is mixed into a dough base made from soybeans, the dough base has a component composition in which the lipid content is less than the protein content, and the solid content derived from the dough base in the obtained soy-containing processed food is 25% by weight or more, and the soy-containing processed food is formed through a heat treatment.

14. 14. The soybean-containing processed food according to claim 12 or 13, characterized in that it is formed into a specific shape like a pate for a terrine de pate.

15. The soybean-containing processed food according to claim 14, characterized in that it is any one of the foods listed in <F> below. <F> High protein foods, side dishes, confectioneries, spreads

16. 16. The soybean-containing processed food according to claim 15, which is a frozen food.

Images