Filling and packaging method

Abstract

To reduce heat history of a processed object while enabling processed foods processed by using an extruder to be distributed at a room temperature.SOLUTION: When a processed food processed using an extruder is filled and packaged, a processing condition is adjusted so that water activity of the processed food extruded from the extruder is less than 0.94, the processed food extruded from the extruder is filled and packaged in a sealable container at a temperature of 65 to 99°C and oxygen concentration inside the container in which the processed food is filled and packaged is set to be 1% or less.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a filling and packaging method. [Background technology]

[0002] For example, Patent Document 1 discloses a technology for producing a meat-like processed food as a meat substitute by heating and kneading raw materials containing proteins derived from plants such as soybeans and wheat in an extruder.

[0003] Such meat-like processed foods are preferably shipped in a dried state so that they can be distributed at room temperature. One example of such a distribution format is that they are delivered to a food manufacturer as a food ingredient, reconstituted with water, cooked, and then provided to end consumers. In this case, if distribution at room temperature is required, it is conceivable to fill them into a sealed container, sterilize them by pressurizing and heating, and distribute them as retort foods. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2022-160947 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in such a distribution format, the object to be processed may be subjected to a large amount of heat history in addition to the heat history in the extruder, which may cause the flavor to be impaired. Therefore, the inventors of the present invention have conducted extensive research to enable the distribution of processed foods processed using an extruder at room temperature while reducing the heat history of the object to be processed, and as a result have completed the present invention. [Means for solving the problem]

[0006] The filling and packaging method of the present invention is a method for filling and packaging processed foods processed using an extruder, adjusting processing conditions so that the water activity of the processed food discharged from the extruder is less than 0.94, filling and packaging the processed food discharged from the extruder into a sealable container at a temperature of 65 to 99°C, and setting the oxygen concentration inside the container in which the processed food is filled and packaged to 1% or less.

[0007] Furthermore, the filling and packaging method of the present invention can be a method in which, when filling and packaging a processed food processed using an extruder, processing conditions are adjusted so that the water activity of the processed food discharged from the extruder is less than 0.94, the processed food discharged from the extruder is filled and packaged in a sealable container made of an oxygen-absorbing packaging material at a temperature of 60 to 99°C, and the oxygen concentration in the container in which the processed food is filled and packaged is 1% or less. [Effects of the Invention]

[0008] According to the present invention, it is possible to reduce the thermal history of the object to be processed, while enabling processed foods processed using an extruder to be distributed at room temperature. DETAILED DESCRIPTION OF THE INVENTION

[0009] Preferred embodiments of the present invention will now be described.

[0010] The filling and packaging method according to this embodiment is intended to enable processed foods processed using an extruder to be distributed at room temperature.

[0011] The specific configuration of the extruder is not particularly limited as long as it is configured to process the raw material to be processed by so-called extrusion cooking, in which the raw material to be processed is extruded while being conveyed by compressing, shearing, pulverizing, heating, kneading, etc. The extruder may be either a uniaxial or biaxial type, and in the case of a biaxial type, it may be either a co-rotating or counter-rotating type, or a non-intermeshing type, a partial intermeshing type, or a complete intermeshing type.

[0012] The processed food processed using the extruder is extruded into any desired shape, such as a sheet, through a die attached to the outlet of the barrel, cut at predetermined intervals, and then filled and packaged in a sealable container. This series of steps is preferably carried out in a sterile environment. To achieve this, for example, the die may be installed in an aseptic chamber equipped with filling and packaging equipment such as a fill-seal machine or a form-fill-seal machine, so that the filling and packaging can be carried out in a sterile environment.

[0013] While the water activity at which many food poisoning bacteria can grow is 0.94 or higher, the lower limit of water activity at which mold can grow is 0.60. From this perspective, in this embodiment, the processing conditions are adjusted so that the water activity of the processed food extruded from the extruder is less than 0.94, preferably 0.90 or less, and more preferably 0.85 or less, creating an environment that inhibits the growth of food poisoning bacteria and suppressing the inclusion of mold, making it possible to distribute processed foods processed using an extruder at room temperature.

[0014] Furthermore, mold is sensitive to heat, and most mold is believed to be killed by heating at 60°C for about 10 minutes. From this perspective, in order to prevent mold contamination, when processed foods processed using an extruder are filled and packaged, the processed food extruded from the extruder is filled and packaged in a sealable container at a temperature of 65 to 99°C. This allows the temperature at which mold is killed to be maintained for a predetermined time after the processed food is filled and packaged, more reliably killing the mold and preventing mold from entering the container. Furthermore, by reducing the oxygen concentration inside the container to 1% or less, preferably 0.1% or less, mold growth can be suppressed even if mold has been introduced into the container.

[0015] To reduce the oxygen concentration in a container, gas replacement packaging may be used, in which the air in the container is replaced with an inert gas such as nitrogen while the container is filled and packaged. Using a container made of an oxygen-absorbing packaging material (e.g., OXDEC (registered trademark) manufactured by Toyo Seikan Co., Ltd.) or enclosing an oxygen absorber in the container is also effective in reducing the oxygen concentration in the container.

[0016] Furthermore, by using a container made of oxygen-absorbing packaging material, the oxygen remaining in the container after the processed food has been filled and packaged is absorbed, further reducing the oxygen concentration inside the container over time. This inhibits mold growth in an environment with a lower oxygen concentration, so mold growth can be suppressed even if the temperature of the processed food discharged from the extruder is set to 60 to 99°C when it is filled and packaged in the container.

[0017] According to this embodiment, processed foods processed using an extruder can be distributed at room temperature, which makes it possible to omit the drying process in the distribution system described above as an example of the background art, thereby reducing the thermal history of the processed food. [Example]

[0018] The present invention will be described in more detail below with reference to specific examples.

[0019] [Example 1] A soybean processed food was processed using a twin-screw extruder while adjusting the processing conditions so that the water activity was 0.85, and the soybean processed food extruded from the extruder was filled into an aluminum-laminated pouch at a product temperature of 65°C. The pouch was then sealed while replacing the gas with nitrogen gas so that the oxygen concentration inside the pouch was 1%, and a sample filled and packaged with the soybean processed food was prepared. The sample prepared in this way was stored at room temperature (25°C), and when the filled and packaged soybean processed food was observed after one month, no mold growth was observed.

[0020] [Example 2] A soybean processed food was processed using a twin-screw extruder while adjusting the processing conditions so that the water activity was 0.85, and the soybean processed food extruded from the extruder was filled into an oxygen-absorbing pouch made of an oxygen-absorbing packaging material at a product temperature of 60°C. The pouch was then sealed while replacing the gas with nitrogen gas so that the oxygen concentration inside the pouch was 1%, and a sample filled and packaged with the soybean processed food was prepared. The sample prepared in this way was stored at room temperature (25°C), and when the filled and packaged soybean processed food was observed after one month, no mold growth was observed.

[0021] [Example 3] A soybean processed food was processed using a twin-screw extruder while adjusting the processing conditions so that the water activity was 0.85, and the soybean processed food extruded from the extruder was filled into an aluminum-laminated pouch at a product temperature of 65°C in a sterile environment in a clean bench. The pouch was then sealed while replacing the gas with nitrogen gas so that the oxygen concentration inside the pouch was 1%, and a sample filled and packaged with the soybean processed food was prepared. The sample prepared in this way was stored at room temperature (25°C), and when the filled and packaged soybean processed food was observed after one month, no mold growth was observed.

[0022] [Comparative Example 1] A soybean processed food was processed using a twin-screw extruder while adjusting the processing conditions so that the water activity was 0.85, and the soybean processed food extruded from the extruder was filled into an aluminum-laminated pouch at a product temperature of 25°C. The pouch was then sealed without adjusting the oxygen concentration by gas replacement to prepare a sample filled with the soybean processed food. The sample prepared in this way was stored at room temperature (25°C), and when the filled and packaged soybean processed food was observed after one month, mold growth was observed.

[0023] Comparative Example 2 A soybean processed food was processed using a twin-screw extruder while adjusting the processing conditions so that the water activity was 0.85, and the soybean processed food extruded from the extruder was filled into an aluminum-laminated pouch at a product temperature of 60°C. The pouch was then sealed while replacing the gas with nitrogen gas so that the oxygen concentration inside the pouch was 1%, and a sample filled and packaged with the soybean processed food was prepared. The sample prepared in this way was stored at room temperature (25°C), and when the filled and packaged soybean processed food was observed after one month, mold growth was observed.

[0024] The present invention has been described above by showing preferred embodiments, but it goes without saying that the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention.

[0025] The present invention is suitable for, but not limited to, meat-like processed foods made from plant-derived proteins, and can be applied to various processed foods that are processed by extrusion cooking.

Claims

1. When filling and packaging processed foods processed using an extruder, Adjusting processing conditions so that the water activity of the processed food extruded from the extruder is less than 0.94; The processed food extruded from the extruder is filled and packaged in a sealable container at a temperature of 65 to 99°C, A method for filling and packaging a processed food, characterized in that the oxygen concentration inside the container in which the processed food is filled and packaged is set to 1% or less.

2. 2. The method of claim 1, wherein the container is made of an oxygen-absorbing packaging material.

3. When filling and packaging processed foods processed using an extruder, Adjusting processing conditions so that the water activity of the processed food extruded from the extruder is less than 0.94; The processed food extruded from the extruder is filled and packaged in a sealable container made of an oxygen-absorbing packaging material at a temperature of 60 to 99°C, A method for filling and packaging a processed food, characterized in that the oxygen concentration inside the container in which the processed food is filled and packaged is set to 1% or less.

4. The filling and packaging method according to any one of claims 1 to 3, wherein the processed food extruded from the extruder is filled and packaged in the container in a sterile environment.