Secondary molding device for meat substitutes

Abstract

To provide a secondary molding device for meat substitutes capable of more effectively molding large secondary molded products, regardless of the origin of the material or the thermal history of the material.SOLUTION: A secondary molding device SM for meat substitutes obtains a secondary molded product by heating a minced protein material MT in a pressurized state to bond protein components of the minced material MT and mold the same into a desired shape. The secondary molding device SM for meat substitutes includes a sealed pressurizing and heating chamber 1B. The secondary molding device for meat substitutes includes a pressurizing device 3 that pressurizes the minced material MT filled in a mold 8 in the pressurizing and heating chamber 1B at a predetermined pressure, and a high frequency power supply circuit device 2 that, within 300 seconds, supplies a high frequency current to the material MT in the pressurizing and heating chamber 1B in accordance with the type of the material MT to heat the material MT at a temperature of 110°C or higher and 140°C or lower.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an apparatus for secondary molding of artificial meat, and more particularly to an apparatus for secondary molding of artificial meat using an electric current heating method or a saturated steam heating method. [Background technology]

[0002] The technology to produce artificially formed edible meat, so-called artificial meat (alternative meat), is evolving year by year, and the market for artificial meat is expanding. The protein material of artificial meat is finely divided, and the finely divided material is solidified into a desired shape to produce a secondary molded artificial meat product. Twin-screw extruders are known as a device for producing protein materials. Twin-screw extruders are configured to obtain a molded material by extruding a material containing a required amount of moisture at a high temperature of over 100°C while applying pressure. Twin-screw extruders make it possible to continuously produce artificial meat materials.

[0003] A twin-screw extruder is provided with a die on the outlet side. In a twin-screw extruder, the material itself, which is solidified by the flow resistance generated in the die, acts as a seal to prevent the material from leaking out of the die. Therefore, in the case of a material with high fluidity, or depending on the shape or area of ​​the die, the material may not be able to stay at the outlet and may be suddenly extruded, causing the material to fail to be molded and the work to be interrupted. Therefore, in a twin-screw extruder, there are restrictions on the amount of moisture contained in the material, the shape of the die opening, and the area of ​​the die opening.

[0004] In addition, even if the material appears to be successfully converted into a material by a twin-screw extruder, the material may be extruded through a die and the moisture evaporates, causing the internal structure of the material to become spongy, resulting in a poor texture and a loss of shape. For this reason, the material may be cut into granules again as necessary, and then bonded with a secondary material such as egg white as an adhesive to obtain the final secondary processed product.

[0005] For these reasons, there is a demand for a technology that converts protein materials into secondary processed products that exhibit structure and physical properties closer to real meat. For example, Patent Document 1 or Patent Document 2 discloses an artificial meat secondary molding device that fills a mold with one or more types of soy protein materials and makes it possible to heat and pressurize the material filled in the mold while adjusting the heating temperature and heating rate. According to Patent Document 1 or Patent Document 2, there are fewer restrictions on the moisture content, shape, and size of the secondary processed product compared to a twin-screw extruder, and it is possible to obtain a greater variety of textured soy protein foods with different textures. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 5-103593 [Patent Document 2] Patent No. 6649640 Summary of the Invention [Problem to be solved by the invention]

[0007] There is room for improvement in the artificial meat forming equipment to produce better formed products. In particular, regardless of the type of protein used, in order to obtain larger formed products with better quality than ever before, the forming equipment is required to satisfy at least the following conditions:

[0008] First, the finely divided material is compressed more accurately and thoroughly to firmly bond the proteins in the material. Second, the temperature is raised to the specified temperature inside as quickly as possible, even for materials with relatively low thermal conductivity and requiring a relatively long heating time. Third, a high-temperature heat treatment is performed at temperatures well above 100°C, mainly with water coexisting with the material as a plasticizer. Fourth, the secondary molded product after heating and solidification is cooled in a shorter time and removed.

[0009] The main object of the present invention is to provide an artificial meat secondary molding device that can better mold a relatively large secondary molded product using moisture as a plasticizer, regardless of the origin of the material and the thermal history of the material. Here, the origin of the material means, for example, whether the main material is a vegetable food protein or an animal food protein. Also, the thermal history of the material means whether the protein material has already been heat-treated. Some advantages that can be obtained by the secondary molding device of the present invention will be specifically shown in the description of the embodiment. [Means for solving the problem]

[0010] In order to solve the above-mentioned problems, the secondary molding apparatus of the present invention is an artificial meat secondary molding apparatus which heats chopped protein material (MT) under pressure to bond the protein components of the chopped material (MT) and molds it into a desired shape to obtain a secondary molded product, and comprises a pressurizing device (3) which pressurizes the chopped material (MT) filled in a mold (8) at a predetermined pressure in the pressurizing and heating chamber (1B) and a high-frequency power supply circuit device (2) which supplies a high-frequency current to the material (MT) in the pressurizing and heating chamber (1B) for a period of 300 seconds or less corresponding to the type of material (MT) to heat the material (MT) to a temperature of 110°C or more and 140°C or less.

[0011] In the secondary molding device of the present invention, preferably, the high frequency power supply circuit device (2) supplies high frequency AC to the material (MT). In particular, the high frequency power supply circuit device (2) includes a pair of electrodes (20) including an electrode plate (20N) provided on the lower die (8L) of the die (8) into which the material (MT) is charged, and an electrode plate (20P) provided on the upper die (8U) of the die (8) disposed opposite the lower die (20N).

[0012] The secondary molding apparatus of the present invention includes a sealed post-treatment chamber (1C) connected to the pressurizing and heating chamber (1B) and a cooling device (4) for cooling the secondary molded product molded into a desired shape in the pressurizing and heating chamber (1B) in the post-treatment chamber (1C). In particular, the cooling device (4) supplies cold air into the post-treatment chamber (1C) to cool the secondary molded product. Alternatively, the cooling device (4) cools the secondary molded product in the post-treatment chamber (1C) by bringing a cooling plate into contact with the secondary molded product. Alternatively, the cooling device (4) cools the secondary molded product in the post-treatment chamber (1C) by bringing cooling water into contact with the secondary molded product.

[0013] In addition, in the secondary molding device of the present invention, the lower die (8L) of the die (8) into which the divided material (MT) is charged is made of resin.

[0014] In order to solve the above-mentioned problems, the secondary molding apparatus of the present invention is an artificial meat secondary molding apparatus for heating a comminuted protein material (MT) under pressure to bond the protein components of the comminuted material (MT) and molding it into a desired shape to obtain a secondary molded product, the secondary molding apparatus comprising a sealed pre-treatment chamber (1A) and a sealed pressurized heating chamber (1B), and in the pre-treatment chamber (1A), the material (MT) filled in the lower die (8L) of a mold (8) is heated in an upper die (8L) of the mold (8) that is arranged opposite the lower die (8L). 8U), a pressurizing device (3) that pressurizes the material (MT) at a predetermined pressure in the sealed pressurized heating chamber (1B), and a saturated steam treatment device (9) that supplies saturated steam into the pressurized heating chamber (1B) and heats the material (MT) to a temperature of 110° C. or more and 140° C. or less in a short period of time of 300 seconds or less according to the type of the material (MT) while pressurized by the pressurizing device (3).

[0015] In the secondary forming apparatus of the present invention, the pressurizing device (3) preferably obtains a pressurizing force for pressurizing the material (MT) by a pressure that depends on the mass of the upper die (8U) of the mold (8) and the pressure of high-pressure saturated steam supplied from the saturated steam treatment device (9). Also, in the secondary forming apparatus of the present invention, the saturated steam treatment device (9) supplies a pressure required to increase the internal pressure of the pressurized heating chamber (1B) to a pressure necessary for the saturated steam to maintain a predetermined temperature.

[0016] The secondary molding apparatus of the present invention includes a sealed post-treatment chamber (1C) connected to the pressurizing and heating chamber (1B) and a cooling device (4) for cooling the secondary molded product molded into a desired shape in the pressurizing and heating chamber (1B) in the post-treatment chamber (1C). In particular, the cooling device (4) supplies cold air into the post-treatment chamber (1C) to cool the secondary molded product. The cooling device (4) cools the secondary molded product in the post-treatment chamber (1C) by bringing cooling water into contact with the secondary molded product.

[0017] In the secondary molding apparatus of the present invention, the upper die (8U) of the die (8) is provided with an air release valve (80D). Effect of the Invention

[0018] The artificial meat secondary molding device of the present invention is capable of producing relatively large secondary molded products using moisture as a plasticizer, regardless of the origin of the material and the thermal history of the material. [Brief description of the drawings]

[0019] [Figure 1] FIG. 1 is a schematic diagram showing a first embodiment of a secondary forming device of the present invention. [Diagram 2] FIG. 2 is a diagram showing a cross section of a mold in the first embodiment. [Diagram 3] FIG. 4 is a schematic diagram showing a second embodiment of a secondary forming device of the present invention. [Figure 4] FIG. 11 is a diagram showing a cross section of a mold in the second embodiment. [Diagram 5] FIG. 2 is a perspective view showing an entire mold in the secondary molding apparatus of the present invention. [Figure 6] 1 is a perspective view showing a shape of a secondary formed product formed by the secondary forming device of the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Fig. 1 is a schematic diagram showing a first embodiment of the artificial meat molding apparatus of the present invention. Fig. 2 shows a side view of a mold used in the molding apparatus shown in Fig. 1. The molding apparatus and mold shown in Fig. 1 and Fig. 2 are models and do not accurately reflect the real molding apparatus and mold, and the relative positions and sizes of multiple devices and members are not the same as those of the real ones.

[0021] The secondary molding device for artificial meat shown in Fig. 1 pressurizes and compresses the protein material of the artificial meat filled in a mold, and heats it by electrical heating to secondary mold the material. The protein material may contain multiple additives. The secondary molding device SM shown in Fig. 1 includes a secondary molding device main body 1, a high-frequency power supply circuit device 2, a pressurizing device 3, a cooling device 4, a door opening and closing device 5, a driving device 6, and a control device 7. The secondary molding device main body 1 in the embodiment includes a pre-treatment chamber 1A, a pressurizing and heating chamber 1B, and a post-treatment chamber 1C.

[0022] The pretreatment chamber 1A of the secondary molding device main body 1 can be sealed by closing the door 50A. In the pretreatment chamber 1A, one or more types of artificial meat protein materials MT are filled into the concave portion of the lower mold 8L of the mold 8. In Figs. 1 and 2, multiple types, for example, three types of protein materials are filled in layers. In the secondary molding device SM of the embodiment, the upper mold 8U of the mold 8 has a convex shape that is the inverse of the concave shape of the lower mold 8L.

[0023] The pressurizing and heating chamber 1B in the secondary molding device main body 1 has a structure that blocks high-frequency current and electromagnetic waves. In the pressurizing and heating chamber 1B, a lower die 8L filled with material fits into an upper die 8U of a die 8 attached to a pressurizing device 3. The lower die 8L is positioned at a predetermined position where one electrode plate 20P of a pair of electrodes 20 provided on the upper die 8U and the other electrode plate 20N provided on the lower die 8L are relatively aligned. At the predetermined position, the material MT filled in the lower die 8L is heated by the high-frequency power supply circuit device 2 while being pressurized by the upper die 8U.

[0024] In the pressurizing and heating chamber 1B, the control device 7 operates the pressurizing device 3 to lower the upper mold 8U to a predetermined position where the material MT filled in the lower mold 8L is compressed with a predetermined pressure so that the material MT is tightly attached to the mold 8 and the moisture contained in the material MT does not leak out of the mold 8. At this time, air is pushed out of the material MT, making it possible to sufficiently increase the thermal conductivity. The moisture contained in the material MT varies depending on the type, but is, for example, 60 g weight %.

[0025] When the upper die 8U compresses the material MT with a predetermined pressure, the electrode plate 20P provided on the upper die 8U comes into even contact with the surface of the material MT. The control device 7 operates the high frequency power supply circuit device 2 to supply a high frequency current to the material filled in the lower die 8L, and heats the material MT from the inside by Joule heat to a temperature well above 100°C, preferably a high temperature of 110°C or higher. In the fragmented material MT that has been pressurized and heated, the protein components of adjacent pieces of material MT bond and become integrated.

[0026] The heating time is short, within 300 seconds, to prevent deterioration of the material MT, such as liquefaction of the material MT. A short heating time also shortens the time required for cooling to 100°C or below after heating. Preferably, steam generated between the upper mold 8U and the lower mold 8L during heating is exhausted to the outside of the mold 8 through an exhaust pipe EH provided in the upper mold 8U. If the upper mold 8U is provided with an exhaust pipe EH, it is possible to prevent moisture from overflowing from the gap between the upper mold 8U and the lower mold 8L during heating.

[0027] The post-treatment chamber 30 of the secondary molding device main body 1 of the embodiment protects the material MT from contact with the outside air, thereby delaying deterioration of the secondary molded product. The post-treatment chamber 30 also serves as a cooling chamber. The control device 7, for example, operates the cooling device 4 to cool the material to less than 30°C in a short time to prevent the growth of bacteria. In the post-treatment chamber 30, the lower die 8L can be inverted to remove the secondary molded product from the lower die 8L. The secondary molded product released from the lower die 8L is collected in a collection box (not shown) installed below the post-treatment chamber 1C, or by free falling onto a conveyor (not shown).

[0028] The high frequency power supply circuit device 2 supplies a high frequency current between an electrode plate 20N provided on the lower die 8A of the die 8 shown in FIG. 2 and an electrode plate 20P provided on the upper die 8U. The high frequency power supply circuit device 2 preferably supplies a high frequency AC current of 1 kHz or more. The high frequency power supply circuit device 2 of the embodiment can supply a high frequency AC current of 20 kHz. However, the high frequency power supply circuit device 2 of the embodiment can supply an AC current of a lower frequency depending on the type of the material MT, and for example, it is also possible to perform electrical heating at a household power frequency of about 50 Hz. The frequency of the high frequency power supply circuit device 2 can be controlled by the control device 7.

[0029] The high frequency power supply circuit device 2 includes a 100V or 200V DC power supply. The DC is converted to high frequency AC through a converter (not shown). The converter includes a bridge circuit of multiple switching elements such as MOSFETs (field effect transistors). Alternatively, the converter includes multiple switching elements and a ferrite ring core.

[0030] The current is adjusted according to the material MT. In resistive heating, Joule heat is used for heating, so the current that can complete heating to 110°C or higher within 300 seconds can be calculated from the power, voltage, and resistance in the current circuit including the material MT. Specifically, the current value can be determined by conducting a test using a sample in advance according to the type of material MT and the shape and size of the secondary molded product, which are factors that affect the resistance. The voltage and current in the high-frequency power supply circuit device 2 can be controlled by the control device 7.

[0031] The high frequency power supply circuit device 2 in the secondary forming device SM of the embodiment supplies high frequency alternating current. Compared with direct current heating, electrical heating using high frequency alternating current can reduce electrolytic corrosion of the pair of electrodes 20, and therefore prevents the metal contained in the electrodes 20 from eluting and being mixed into the material MT. In the high frequency power supply circuit device 2, a metal that is resistant to electrolytic corrosion and has little effect on the human body, such as a titanium alloy, is selected as the material for the electrodes 20. Alternatively, a metal that is relatively less susceptible to electrolytic corrosion and has little effect on the human body, such as a nickel alloy, is selected. The secondary forming device of the embodiment promotes the spread of secondary forming of larger materials by electrical heating, which has been difficult to put into practical use.

[0032] In the embodiment, the lower mold 8L of the mold 8 is made of a heat-resistant resin suitable for food containers. When the lower mold 8L is made of resin, the loss of electric current can be reduced and the heating efficiency can be improved. In addition, the resin lower mold 8L has the advantage that the mold material is less contaminated by electrolytic corrosion than a metal mold, and can be easily manufactured into any shape.

[0033] In the secondary molding device SM of the embodiment, the lower mold 8L is formed of a hard and durable resin having heat resistance that can maintain its outer shape when pressure is applied. However, this does not mean that a relatively soft resin such as silicone resin cannot be used as the material of the lower mold 8L. When the material of the lower mold 8L is a relatively soft resin, the outer periphery of the lower mold 8L can be reinforced with a stainless steel wall so that the lower mold 8L does not deform and spread outward when pressure is applied at the pressurizing and heating position. When the lower mold 8L is a relatively soft resin, the deformation of the lower mold 8L can be expected to have the effect of making it easier to release the secondary molded product.

[0034] The bottom surface of the lower mold 8L is provided with an electrode plate 20N of a pair of electrodes 20. In the secondary molding device SM of the embodiment, a plurality of conductive members 20E are provided on the bottom surface of the lower mold 8L, and at a predetermined heating and pressurizing position in the pressurizing and heating chamber 1B, a current is passed between the power supply plate 20B and the electrode plate 20N fixed at the pressurizing and heating position of the pressurizing and heating chamber 1B through the conductive members 20E, and high-frequency AC is supplied from the high-frequency power supply circuit device 2. At the pressurizing and heating position, the material MT filled in the mold 8L is electrically heated by the high-frequency AC while being pressurized by the upper mold 8U.

[0035] The pressurizing device 3 includes a drive device (not shown) whose positioning can be controlled by a control device 7 that is a hydraulic cylinder or a linear motor. Therefore, the material MT is pressed with a more appropriate pressure. The delicate control of the movement of the upper mold 8U effectively prevents the material MT from losing more moisture than necessary.

[0036] The upper die 8U is replaceably attached to a movable body that is moved by a driving body in accordance with the outer shape and size of the desired secondary molded product. In the pressurizing device 3, after pressurization, the upper die 8U rises together with the movable body. In the pressurizing device 3, if delicate pressurizing force and minute positioning in the height direction are not required for the upper die 8U, for example, the material MT may be pressed by the weight of the upper die 8U alone. When the material MT is pressed by only the upper die 8U, the upper die 8U essentially constitutes the pressurizing device 3.

[0037] In the pressurizing device 3 of the embodiment, after pressurization, the upper die 8U can be deformed so as to be detached from the movable body of the pressurizing device 3. When the upper die 8U is detached from the movable body, as shown by the dotted line in Fig. 1, the secondary molded product can be cooled in the post-treatment chamber 1C while compressing the secondary molded product in the lower die 8L with a pressing force corresponding to the upper die 8U's own weight, so that the expansion of the secondary molded product can be better prevented.

[0038] However, the next upper die 8U must be collected from the post-treatment chamber 1C and reused, or the next upper die 8U must be prepared near the pressurizing and heating chamber 1B. In the present invention, the swelling phenomenon can be prevented by applying pressure to the die 8 by appropriately treating the steam or air generated from the die 8 during pressurization, or by keeping the internal pressure of the pressurizing and heating chamber 1B slightly higher than atmospheric pressure. The upper die 8U is made of a material that is highly corrosion-resistant and safe, is relatively heavy, and is easy to mold. Specifically, the upper die 8U is made of, for example, iron with a surface coated with a nickel alloy.

[0039] The pressurizing device 3 can pressurize the material MT by changing the pressure to be applied in accordance with the type of material MT using the control device 7. The pressurizing device 3 in the secondary processing apparatus SM according to the embodiment can pressurize the material MT by, for example, applying a maximum pressure of 0.5 MPa (approximately 5.1 kgf / cm 2 The required pressure is equal to or lower than the pressure at which the material MT adheres sufficiently to the lower mold 8 so that the moisture contained in the material MT does not flow out of the lower mold 8.

[0040] The cooling device 4 supplies cold air that has been cooled to a predetermined temperature or lower to the post-treatment chamber 1C to maintain the room temperature at a predetermined temperature or lower. The cooling device 4 also forcibly cools the material MT in a short time by directly jetting and supplying cold air near the lower die 8L. Alternatively, the cooling device 4 cools the secondary processed product in the lower die 8L by jetting and supplying cold air directly.

[0041] The cooling device 4 can be configured to directly cool the material MT filled in the lower mold 8L by contacting a cooling plate (not shown). The cooling plate is, for example, configured to have multiple cooling pipes formed therein to supply a refrigerant, or configured to have multiple Peltier elements. The cooling device 4 can also be configured to directly spray the cooling water onto the lower mold 8L or the secondary molded product, or to immerse the lower mold 8L together with the secondary molded product in cooling water stored in a cooling tank to directly cool the secondary molded product. The temperature of the water supplied from the cooling device 4 is equal to or lower than room temperature. When the secondary molded product is cooled with cooling water, the cooling time can be shortened.

[0042] The door opening and closing device 5 operates the doors 50A, 50B, 50C, and 50D that open and close the entrances to each of the pre-treatment chamber 1A, the pressurizing and heating chamber 1B, and the post-treatment chamber 1C of the secondary molding device main body 1. The door opening and closing device 5 can be remotely operated by the control device 7. In addition, the control device 7 can sequence the door opening and closing device 5 to automatically and continuously mold a plurality of materials MT.

[0043] The conveying device 6 includes conveyors 60A, 60B, 60D, and a plurality of electric motors (not shown) that drive each conveyor independently. The conveyors are, for example, belt conveyors or roller conveyors. The conveying device 6 is controlled by a control device 7. The control device 7 controls the driving of the electric motors to automatically and continuously heat and pressurize the material MT, and remotely and arbitrarily operates each conveyor.

[0044] The control device 7 can independently operate the high frequency power supply circuit device 2, the pressurizing device 3, the cooling device 4, the door opening / closing device 5, and the transport device 6 in sequence. The control device 7 can control the operation of the high frequency power supply circuit device 2, the pressurizing device 3, the cooling device 4, the door opening / closing device 5, and the transport device 6 in a linked manner, and can automatically and continuously fill a plurality of materials MT into a mold 8, heat and pressurize it, cool it, and collect it.

[0045] The secondary molding device SM of the embodiment is equipped with a pressurizing device 3 that can apply a pressure to the material at any pressure using a control device 7, so that the material MT that has been fragmented before heating can be sufficiently compressed. This allows the protein components of the material MT to be firmly and effectively bonded, and a secondary molded artificial meat product with a good texture and good bite can be obtained.

[0046] The secondary molding device SM is equipped with a high-frequency power supply circuit device 2 that heats the material MT by current heating using high-frequency AC, so that even if the material MT is a type that has a relatively low thermal conductivity and requires a long time to heat, it can heat the material MT almost uniformly to the inside at a high temperature of 110°C or higher in a short time of less than 300 seconds. Therefore, even if the protein material MT is larger in size than before, regardless of the origin of the material and the thermal history of the material, the material MT can be firmly and well bonded without any deterioration such as liquefaction, and a secondary molded artificial meat product with excellent quality can be obtained.

[0047] In the secondary molding device SM, the material MT is not kept at a high temperature for a long time due to the electrical heating by the high frequency power supply circuit device 2, so the time required for cooling is shorter than in the past. Therefore, a high quality secondary molded product can be obtained even with a relatively large material MT. In particular, since the secondary molding device SM is equipped with the cooling device 4, the secondary molded product can be rapidly cooled and removed in a shorter time.

[0048] FIG. 3 is a schematic diagram showing a second embodiment of the artificial meat molding apparatus of the present invention. FIG. 4 shows a side view of a mold used in the molding apparatus shown in FIG. 3. The molding apparatus and mold shown in FIG. 3 and FIG. 4 are models and do not accurately reflect the real molding apparatus and mold, and the relative positions and sizes of multiple devices and members are not the same as those of the real ones. In FIG. 3 and FIG. 4, when the same names as those of the molding apparatus and mold shown in FIG. 1 and FIG. 2 are used, they are described by using the same reference numerals even if the configuration or function is different.

[0049] The secondary molding device for artificial meat shown in FIG. 3 pressurizes and compresses the protein material of the artificial meat filled in a mold, and heats it by a saturated steam heating method to secondary mold the material. The protein material may contain a plurality of additives. The secondary molding device SM shown in FIG. 1 includes at least a secondary molding device main body 1, a pressurizing device 3, a door opening and closing device 5, a driving device 6, a control device 7, a saturated steam processing device 9, and a decompression device 10. The secondary molding device main body 1 in the embodiment includes a pre-treatment 1A, a pressurizing and heating chamber 1B, and a post-treatment chamber 1C. The secondary molding device main body 1 also includes a material filling stage 1D and a mold recovery stage 1E.

[0050] The pretreatment chamber 1A of the secondary molding device main body 1 has a structure that allows the interior to be sealed by closing the doors 50A and 50B. In the secondary molding device SM of this embodiment, the pretreatment chamber 1A is a decompression chamber. The pretreatment chamber 1A has a plurality of sub-chambers corresponding to the required air pressure value, and can be decompressed stepwise to an air pressure closer to a vacuum, for example, about 0.05 Pa. In addition, the pretreatment chamber 1A can be restored to atmospheric pressure by providing a pressure-recovery chamber in a sub-chamber adjacent to the pressurizing and heating chamber 1B among the plurality of sub-chambers so that the pressure in the pressurizing and heating chamber 1B does not rise suddenly from a low-pressure environment.

[0051] Air has a greater specific gravity than steam, so when steam flows into the chamber, the air is difficult to expel outside and tends to accumulate at the bottom of the chamber. Air acts as an insulator when heating the material MT, so it becomes an obstacle to raising the temperature to a specified temperature in a short period of time. By reducing the pressure inside the pretreatment chamber 1A, it is possible to remove as much air as possible outside the chamber, which helps to heat the relatively large material MT in the required short period of time.

[0052] The pressurized heating chamber 1B can be sealed by closing the doors 50B and 50C. When the material MT is pressurized and heated, compressed and highly pressurized steam is rapidly supplied from the saturated steam processing device 9 with the pressurized heating chamber 1B sealed. If the material MT is exposed to high-temperature saturated steam for a long period of time, the proteins are hydrolyzed and liquefied. For this reason, it is required to heat the material MT to a predetermined temperature in a short time before it liquefies. Specifically, the saturated steam processing device 9 supplies saturated steam at a temperature of 120°C or higher and 140°C or lower, and the heating time is within 300 seconds.

[0053] The pressurizing device 3 is a device that can operate without failure in a hot and humid room. The pressurizing device 3 of the embodiment is configured to perform pressurization by a force that is a sum of a pressure that depends on the weight of the upper mold 8U of the mold 8 plus the weight of the weight 80A attached to the upper mold 8U, and the steam pressure of the high-pressure steam supplied into the pressurizing and heating chamber 1C acting in the direction of gravity, without providing a driving device. Therefore, in the embodiment, the pressurizing device 3 is substantially composed of the saturated steam processing device 9 that supplies high-pressure saturated steam and the upper mold 8U including the weight 80A.

[0054] The pressurizing device 3, which does not have a drive device, can obtain sufficient pressure for most types of material MT. However, depending on the type of material MT and the size of the mold, such as a material MT that has a strong repulsive force, a high moisture content, and is relatively large, the pressure may not be sufficient using only the upper mold 8U including the weight 8A and the steam pressure. The pressurizing device 3 can be configured to include a pressing device such as a pusher (not shown) that can operate in a high-temperature room, and the pusher can be used as an auxiliary when the pressure is insufficient.

[0055] The temperature and time of the saturated steam to be supplied can be set by the operator on the operation panel of the control device 7. The saturated steam processing device 9 supplies high-temperature saturated steam at 120°C to 140°C for an appropriate time of 300 seconds or less, depending on the type of material MT and the size of the secondary molded product. The material MT in the lower die 8L of the mold 8 receives the thermal energy of the condensation latent heat and sensible heat of the steam generated on the surfaces of the upper die 8U and lower die 8L through the mold 8, and is heated to the temperature of the saturated steam in an extremely short time of less than one second.

[0056] The pressurized material MT is molded by obtaining thermoplasticity through thermal energy, with the moisture contained in the material MT and the steam condensed water generated on the surface of the material MT acting as a plasticizer. When there is sufficient moisture, the material MT bonds better due to the overall plasticity of the secondary molded product in which the material MT is solidified. Also, when the moisture is limited to the condensed water on the surface of the secondary molded product, better molding is possible due to the bonding of the material MT on the outer surface of the material MT and deformation due to the softening of the material MT.

[0057] In this way, when the material MT is heated by the saturated steam heating method, the material MT exhibits some fluidity depending on the amount of moisture provided. The fluidity of the material MT may cause the material MT to flow out from the gap between the upper mold 8U and the lower mold 8L. However, when the material MT is heated at an appropriate temperature for an appropriate time, it has sufficient viscoelasticity and will not leak out from the gap between the upper mold 8U and the lower mold 8L.

[0058] The post-treatment chamber 1C is a pressure recovery chamber that recovers the pressure of the upper mold 8U and the lower mold 8L to atmospheric pressure, while the interior of the pressurizing and heating chamber 1B becomes highly pressurized during the pressurizing and heating process. The post-treatment chamber 1C also serves as a cooling chamber. When the pressure is recovered in the pressure recovery chamber 1C, the air and steam inside the chamber are discharged and outside air or cold air is introduced into the post-treatment chamber 1C, so that the secondary molded product is rapidly cooled through the upper mold 8U and the lower mold 8L, which are molds with a relatively high thermal conductivity.

[0059] The material filling stage 1D is a workbench where the segmented material MT is filled into the concave portion of the lower mold 8L from a material filling device 11 such as a hopper. In the material filling stage 1D, water can be added as a plasticizer as necessary. The amount of water contained in the material MT is accurately adjusted when water is added, so that there is no variation in quality among the multiple secondary molded products that are continuously produced.

[0060] In the material filling stage 1D, the upper mold 8U including the weight 80A is placed on the lower mold 8L while being aligned with the concave portion filled with the hydrated material MT. At this time, the material MT may sink to a certain height due to the weight of the mold, which is the sum of the weight of the upper mold 8U and the weight of the weight 80A. However, since there is almost no gap between the upper mold 8U and the lower mold 8L and the amount of moisture contained in the material MT is adjusted, the material MT does not flow out from the gap.

[0061] The mold recovery stage 1E is a workbench for recovering the mold 8. In the mold recovery stage 1E, the upper mold 8U is removed and recovered outside the secondary molding device 1 by a mold lifting device (not shown). The lower mold 8L left on the table is turned over by an inversion device (not shown) so that the bottom surface is positioned upward. At this time, a pin pressing device (not shown) pushes out multiple pins 80B protruding from the bottom of the lower mold 8L, causing the movable plate 80C to move downward. As the movable plate 80C moves, the secondary molded product is released from the mold and falls freely, and is recovered by an appropriate method.

[0062] The door opening and closing device 5 operates the doors 50A, 50B, 50C, and 50D that open and close the entrances to each of the pre-treatment chamber 1A, the pressurizing and heating chamber 1B, and the post-treatment chamber 1C of the secondary molding device main body 1. The door opening and closing device 5 can be remotely operated by the control device 7. In addition, the control device 7 can sequence the door opening and closing device 5 to automatically and continuously mold a plurality of materials MT.

[0063] The conveying device 6 includes conveyors 60A, 60B, 60D, and 60E, and a plurality of electric motors (not shown) that drive each conveyor independently. The conveyors are, for example, belt conveyors or roller conveyors. The conveying device 6 is controlled by a control device 7. The control device 7 controls the driving of the electric motors to automatically and continuously heat and pressurize the material MT, and remotely and arbitrarily operates each conveyor.

[0064] The saturated steam processing device 9 includes a boiler and a compressor, not shown, and a plurality of supply lines, and can supply high-pressure saturated steam compressed to a predetermined pressure to the pressurized heating chamber 1B. The saturated steam processing device 9 can supply saturated steam at 120°C or higher and 140°C or lower.

[0065] The pressure reducing device 10 includes a vacuum pump. When the pressure reducing device 10 has a plurality of sub-chambers corresponding to the pressure value required in the pre-treatment chamber 1A, a vacuum pump is provided for each sub-chamber, and the pressure can be reduced stepwise to a low pressure close to vacuum. The pressure reducing device 10 in the secondary molding apparatus SM of the embodiment can reduce the pressure in the pre-treatment chamber 1A to any pressure up to 0.05 Pa. Also, if necessary, the pressure can be restored to atmospheric pressure in the sub-chamber adjacent to the pressurizing and heating chamber 1B.

[0066] 3, the cooling device 4 also serves as a pressure recovery device. The pressure recovery device opens a safety valve provided in the post-treatment chamber 3 to open the exhaust port, and recovers the air pressure in the pressurized and heated chamber 1B, which has been increased by the high-pressure saturated steam, in the post-treatment chamber 3. The cooling device 4 supplies cold air ranging from room temperature air to about -10°C to the post-treatment chamber 1C, so that the post-treatment chamber 3 can be constantly maintained at a predetermined temperature.

[0067] The cooling device 4 can directly inject cold air or cooling water into the mold 8, and can rapidly cool the secondary processed product molded in the pressurized and heated chamber 1B. The cooling device 4 can be modified so as to directly cool the secondary processed product by immersing the secondary processed product together with the mold 8 in cooling water stored in a cooling tank. When the secondary processed product is directly cooled by cooling water, the secondary processed product can be cooled in a shorter time.

[0068] The control device 7 can independently operate the pressurizing device 3, the cooling device 4, the door opening / closing device 5, the transport device 6, the saturated steam treatment device 9, and the decompression device 10 in sequence. The control device 7 can control the operation of the pressurizing device 3, the cooling device 4, the door opening / closing device 5, the transport device 6, the saturated steam treatment device 9, and the decompression device 10 in a linked manner, and can automatically and continuously fill a plurality of materials MT into a mold 8, heat and pressurize it, cool it, and recover it.

[0069] In the secondary molding device SM of the saturated steam heating type, the mold 8 is a metal mold. In particular, when the size of the mold 8 is large, in order to heat the material MT to a high temperature of 110°C to 140°C in a short time of 300 seconds or less, it is desirable for the mold 8 to have high thermal conductivity.

[0070] The lower part 8 of the mold 8 has a plurality of concave portions as shown in Fig. 4. For example, the concave portions of the lower part 8L shown in Fig. 5 all have the same shape. At least the surface of the concave portions of the lower part 8L is covered with a material that does not easily dissolve in the material MT in order to prevent contamination caused by dissolving metal components contained in the die.

[0071] For example, the concave portion is coated with a fluororesin. Coating the concave portion with a fluororesin suppresses contamination and prevents deterioration of the quality and safety of the secondary molded product, and coating the concave portion with a fluororesin improves the releasability of the secondary molded product and improves the efficiency of cleaning the lower die 8L. For example, the concave portion is plated with a nickel alloy. Plating with a nickel alloy suppresses contamination and prevents deterioration of the quality and safety of the secondary molded product, and prevents a decrease in thermal conductivity.

[0072] The lower die 8L is provided with a plurality of mold-releasing push-out pins 80B. The mold-releasing push-out pins 80B push out a metallic movable plate 80C arranged on the bottom surface of the concave portion of the lower die 8, thereby facilitating the release of the secondary molded product. Originally, when the material MT is pressurized and heated in the pressurizing and heating chamber 1B of the main secondary molding device 1, the moisture present between the lower die 8L and the material MT evaporates, resulting in the release of the secondary molded product. When the movable plate 80C is moved by the mold-releasing push-out pins 80B, the material MT solidifies and the molded secondary molded product can be lifted up, so that the secondary molded product can be easily released from the lower die 8L.

[0073] In the secondary molding device SM of the embodiment, the lower die 8L is inverted at the die recovery stage 1E to recover the secondary molded product. Therefore, after the upper die 8U moves to a position away from the die recovery stage 1E, the releasing push pin 80B is moved downward by a pusher (not shown) provided above the releasing push pin 80B. As a result, the secondary molded product is pushed out by the movable plate 80C and falls freely below the die recovery stage 1E to be recovered. Note that, when the lower die 8 has the push pin 80B and the movable plate 80C, the secondary molded product can be recovered without inverting the die 8.

[0074] The upper die 8U of the die 8 has a convex shape that is the inverse of the concave shape of the lower die 8L. The convex portion of the upper die 8U fits into the concave portion of the lower die 8L with a small gap. At least the surface of the convex portion of the upper die 8U that comes into contact with the material MT is coated with, for example, a fluororesin or a nickel alloy.

[0075] The upper die 8U in the embodiment is provided with one or more weights 80A for pressurization. The upper die 8U provided with the weights 80A is advantageous in that the mass of the weights 80A can be changed according to the required pressurizing force. However, when the magnitude of the required pressurizing force is fixed, the required pressurizing force can be obtained by increasing the mass of the upper die 8U by increasing the thickness of the convex portion of the upper die 8U.

[0076] An air release valve 80D is provided at the convex portion of the upper mold 8U. When one upper mold 8U has multiple convex portions, an air release valve 80D is provided at each convex portion. When the pressure is reduced in the pre-treatment chamber 1A of the main secondary molding device 1 in a state where the concave portion of the lower mold 8L and the convex portion of the upper mold 8U are engaged with each other and the upper mold 8U is placed on the lower mold 8L, the air release valve 80D exhausts the air present in the concave portion of the lower mold 8L from the concave portion. As a result, when the material MT is pressurized and heated in the pressurized and heated chamber 1B, the material MT can be heated in a state where the air having a heat insulating effect has been removed, making it possible to heat the material MT at a high temperature in a shorter time.

[0077] The artificial meat molding device of the present invention can produce a secondary molded product using a mold 8 having a plurality of relatively large concave portions, for example, as shown in Fig. 5. This is advantageous in that more secondary molded products can be produced at once. In addition, it is possible to produce secondary molded products that are larger in size, even if they have a disk shape as shown in Fig. 6A or a square shape as shown in Fig. 6B, which have previously been possible to mold. It is also possible to mold a secondary molded product with a complex outer shape as shown in Fig. 6C, which has previously been difficult to mold.

[0078] Using a relatively large mold having one circular recessed area measuring 30 cm in diameter and 10 cm in depth, the soy protein material was heated at 120°C to 130°C for 120 seconds using the secondary molding device SM shown in Figure 3 to obtain a secondary molded product in the shape of a disk measuring 30 cm in diameter and 10 cm in thickness.The protein in the secondary molded product had an adjusted fiber orientation and was able to maintain a dense fiber structure with the required strength, and an artificial meat with a chewy texture and less of a spongy feel than conventional products was obtained.

[0079] The saturated steam secondary molding device SM vacuum-consolidates the material in the mold by reducing pressure in the pre-treatment chamber 1A, then heats it with saturated steam at a high pressure that can maintain the saturated steam at 110°C to 140°C, and utilizes the thermoplasticity at the glass transition point using moisture as a plasticizer. The short-term supply of thermal energy to reach the glass transition point is provided by the latent heat of steam condensation and the sensible heat of steam in the mold in the relatively large concave portion. The consolidated state of the finely divided material is maintained by the densification by reduced pressure or vacuum treatment in the pre-treatment chamber and the pressure difference of the saturated steam in the pressurized heating chamber.

[0080] Glass transition pointThe fragmented materials are in close contact with each other while the thermoplastic properties are maintained, in other words, the protein regions come into contact, and the structure of the fragmented materials is modified and integrated into a molded product. Protein components undergo hydrolysis and become liquefied under high temperature conditions, but the secondary molding device SM can heat the material at a high temperature of 110°C or higher and 140°C or lower for a short period of time of less than 300 seconds, so hydrolysis or liquefaction of the protein components does not occur.

[0081] The present invention is not limited to the specific configuration of the secondary molding device of the embodiment within the scope of the technical concept of the present invention. Although several examples of the secondary molding device of the present invention have already been shown, the secondary molding device of the embodiment may be modified, replaced, or combined in whole or in part. [Explanation of symbols]

[0082] 1 Secondary forming equipment 1A Pre-treatment chamber 1B Pressurized heating chamber 1C Post-processing room 2 High frequency power supply circuit equipment 3. Pressurizing device 4 Cooling device 5 Door opening and closing device 6. Conveyor 7 Control device Type 8 8L lower mold 8U upper type 9. Saturated steam treatment equipment 10 Pressure reducing device 11 Material filling device 20 electrodes 20N electrode plate 20P electrode plate 20B power supply board 50A, 50B, 50C, 50D Door 60A, 60B, 60C, 60D Conveyor SM secondary forming equipment MT Material

Claims

1. This artificial meat secondary molding device heats chopped protein material under pressure to bond the protein components of the chopped material and mold it into a desired shape to obtain a secondary molded product, and comprises: a pressure device which is equipped with a sealed pressurized and heated chamber and which pressurizes the chopped material filled into a mold in the pressurized and heated chamber at a predetermined pressure; and a high-frequency power supply circuit device which supplies a high-frequency current to the material in the pressurized and heated chamber for a period of 300 seconds or less corresponding to the type of material, thereby heating the material to a temperature of 110°C or higher and 140°C or lower.

2. 2. The artificial meat secondary molding apparatus according to claim 1, wherein the high frequency power supply circuit device supplies high frequency alternating current to the material.

3. 2. The secondary molding apparatus according to claim 1, wherein the high-frequency power supply circuit device includes a pair of electrodes: an electrode plate provided on a lower die of the mold into which the material is filled, and an electrode plate provided on an upper die of the mold arranged opposite the lower die.

4. The artificial meat secondary molding apparatus as described in claim 1, further comprising a sealed post-processing chamber connected to the pressurized heating chamber, and a cooling device for cooling the secondary molded product molded into a desired shape in the pressurized heating chamber within the post-processing chamber.

5. 5. The artificial meat molding apparatus according to claim 4, wherein the cooling device supplies cold air into the post-treatment chamber to cool the molded product.

6. 5. The artificial meat molding apparatus according to claim 4, wherein the cooling device cools the secondary formed product by bringing a cooling plate into contact with the secondary formed product in the post-treatment chamber.

7. 5. The artificial meat molding apparatus according to claim 4, wherein the cooling device cools the secondary molded product by bringing cooling water into contact with the secondary molded product in the post-treatment chamber.

8. 2. The secondary molding device for artificial meat according to claim 1, wherein the lower part of the mold into which the divided material is charged is made of resin.

9. This artificial meat secondary molding device heats a fragmented protein material under pressure to bond the protein components of the fragmented material and mold it into a desired shape to obtain a secondary molded product, and comprises: a sealed pre-treatment chamber and a sealed pressurized and heated chamber, a pressure reducing device which reduces the pressure inside the pre-treatment chamber while pressing the material filled in the lower part of a mold in the pre-treatment chamber with an upper part (8U) of the mold which is arranged opposite the lower part, a pressurizing device which pressurizes the material to a predetermined pressure in the sealed pressurized and heated chamber, and a saturated steam treatment device which supplies saturated steam into the pressurized and heated chamber and heats the material to a temperature of 110°C or higher and 140°C or lower in a short period of time of 300 seconds or less according to the type of material while pressurized by the pressurizing device.

10. The artificial meat secondary molding apparatus according to claim 9, wherein the pressurizing device obtains a pressure for pressurizing the material by a pressure dependent on the mass of the upper part of the mold and the pressure of high-pressure saturated steam supplied from the saturated steam treatment device.

11. The secondary production apparatus for artificial meat according to claim 10, wherein the saturated steam treatment device supplies a pressure required to increase the internal pressure of the pressurized heating chamber to a pressure necessary for the saturated steam to maintain a predetermined temperature.

12. The artificial meat secondary molding apparatus of claim 9, further comprising a sealed post-processing chamber connected to the pressurized heating chamber, and a cooling device for cooling the secondary molded product molded into a desired shape in the pressurized heating chamber within the post-processing chamber.

13. The artificial meat molding apparatus according to claim 12, wherein the cooling device supplies cold air into the post-treatment chamber to cool the molded product.

14. The artificial meat molding apparatus according to claim 12, wherein the cooling device cools the secondary-formed product by bringing cooling water into contact with the secondary-formed product in the post-treatment chamber.

15. The secondary production apparatus for artificial meat according to claim 9, wherein the upper part of the mold is provided with an air release valve.

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