Method of manufacturing olive food products

Abstract

To enable consumers to purchase olive products with greater confidence, this invention provides a method for producing olive products under temperature conditions that prevent syneresis, resulting in products that are visually appealing and have a long shelf life. [Solution] The method for manufacturing olive food includes: a first sterilization step (steps S11-S16) in which unpasteurized olives are divided into portions of 250g or more, individually packaged, and sterilized by pressurizing and heating under temperature conditions equivalent to a core temperature of 75°C for 1 minute or more; a storage step (step S21) in which the olives sterilized in the first sterilization step are stored; and a second sterilization step (steps S31-S35) in which the olives stored in the storage step are divided into portions of less than 250g, individually packaged, and sterilized by pressurizing and heating under temperature conditions equivalent to a core temperature of 75°C for 1 minute or less.

Description

Technical Field

[0005] , , ,

[0001] The present invention relates to a method for manufacturing olive foods.

Background Art

[0002] Olives (olive fruits) contain oleic acid, which has a preventive effect on heart disease and diabetes, and polyphenols and vitamin E that have an antioxidant effect. Olives also contain minerals such as calcium and iron, and dietary fiber. Therefore, conventionally, olives have been attracting attention as healthy foods.

[0003] However, since olive fruits have a strong astringency, it is difficult to eat them raw as they are. Generally, they are desalted by lactic acid fermentation and processed into pickled, pickled, or grassy foods for consumption. As a technology related to foods processed from olives, for example, there is one described in Patent Document 1. Patent Document 1 describes an olive food composed of a packaging container, olive fruits held in this packaging container, and brine in which the olive fruits are immersed. In addition, the olive fruits are attached with a fruit stalk of a predetermined length, and consumers of this olive food can easily eat the olive fruits by pinching this fruit stalk when eating the olive fruits in the packaging container.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] As with the olive food described in Patent Document 1, there is a need for technologies that make olives more delicious and easier to eat for consumers, as well as technologies that allow consumers to purchase olive food with greater peace of mind. For example, olive food undergoes sterilization (pressure and heat sterilization) during the manufacturing process, but because the olives are pressurized and heated in a pressure vessel, water may seep out of the olives (synchronization). Furthermore, the water that seeps out of the olives darkens over time, causing an unsightly problem. As a result, even if there is no problem with the quality, the appeal to general consumers weakens. This problem is particularly noticeable when olive food is sealed in a transparent bag and has a long shelf life of more than one month.

[0006] Therefore, the present invention aims to provide a method for producing olive products that are visually appealing and have a long shelf life, enabling consumers to purchase olive products with greater peace of mind. This is achieved by producing olive products under temperature conditions that do not cause syneresis (water separation), resulting in olive products with a good shelf life. [Means for solving the problem]

[0007] The method for producing olive food according to the present invention includes: a first sterilization step in which unpasteurized olives are divided into portions of 250g or more, individually packaged, and sterilized by pressurizing and heating under temperature conditions equivalent to a core temperature of 75°C for 1 minute or more; a storage step in which the olives sterilized in the first sterilization step are stored; and a second sterilization step in which the olives stored in the storage step are divided into portions of less than 250g, individually packaged, and sterilized by pressurizing and heating under temperature conditions equivalent to a core temperature of 75°C for less than 1 minute.

[0008] As a result, the unpasteurized olives are divided into portions of 250g or more and individually packaged, and then in the first sterilization process, they are pressurized and heated under temperature conditions equivalent to a core temperature of 75°C for more than one minute (hereinafter sometimes referred to as the "first temperature condition"). After being stored in the storage process and removed at any time, they are pressurized and heated in the second sterilization process under temperature conditions equivalent to a core temperature of 75°C for less than one minute (hereinafter sometimes referred to as the "second temperature condition").

[0009] In the first sterilization step, it is preferable to sterilize the brine-pickled olives under pressure and heat along with the brine. In the storage step, it is preferable to cool the brine-pickled olives and store them in a refrigerator. Furthermore, it is preferable that the olives that have been portioned in the second sterilization step be dry-packed in transparent packaging containers.

[0010] Furthermore, it is desirable that the manufacturing method for olive products produces olive products with a hydrogen ion concentration (pH) of over 4.6 and a shelf life of one month or more. [Effects of the Invention]

[0011] The method for producing olive food according to the present invention, with the above configuration, involves thoroughly pressurizing and heating the olives under first temperature conditions in the first sterilization step (for example, inactivating botulinum toxin), storing the pressurized and heat-sterilized olives in a storage step so that they can be removed at any time, and further pressurizing and heating the olives under second temperature conditions in the second sterilization step, thereby producing olive food that does not undergo syneresis and is highly safe. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic flowchart of the method for producing olive food according to an embodiment of the present invention. [Figure 2] This figure shows an example of an olive food product produced by the method for producing olive food products according to an embodiment of the present invention. [Modes for carrying out the invention]

[0013] The embodiments of the present invention will be described in detail below, but the description of the constituent elements described below is an example (representative example) of an embodiment of the present invention, and the present invention is not limited to the following unless its gist is changed. In addition, "temperature conditions" in this description is synonymous with "sterilization conditions" or "heat sterilization conditions".

[0014] [Manufacturing method for olive food products] The method for producing olive food products according to the present invention is a method for producing olive food products, including olives alone and olives that have been processed with flavorings such as marinades. Furthermore, olive food products can be processed in various ways to suit consumer preferences, such as roasting, crushing, or pitting.

[0015] Figure 1 shows a schematic flow of the method for producing olive food according to an embodiment of the present invention. Of course, the method for producing olive food according to the present invention also includes various other processes besides those shown in Figure 1, such as receiving and storing raw materials (olives, salt, cheese, herbs, etc.), X-ray inspection, labeling, inspection, and packaging.

[0016] The method for producing olive food according to an embodiment of the present invention mainly includes the following steps. (A) First sterilization process (steps S11-S16) (B) Storage process (Step S21) (C) Second sterilization process (steps S31-S35)

[0017] [First sterilization process] First, the manufacturer procures and delivers raw materials (primary ingredients), auxiliary ingredients, and additives (Step S11). The primary ingredients procured and delivered will differ for each olive food product being manufactured. In this embodiment, the manufacturing method of olives that have been debittered without fermentation (see Figure 2(A)) will be used as an example to explain the olive food product. In this embodiment, the primary raw materials procured and delivered are green olives or ripe olives, but in this explanation, they will simply be referred to as olives.

[0018] The olives procured and delivered in step S11 are, for example, unpasteurized olives in brine. Therefore, the procured and delivered olives are then desalted in a dedicated desalting tank (step S12).

[0019] Then, the desalted olives are weighed and packed into containers (step S13). Here, the olives are individually packaged after being divided into portions of 250 g or more. For example, the olives are divided into portions of 1.0 kg to 1.5 kg and then individually packaged into each container.

[0020] Next, each container is filled with brine and sealed (step S14).

[0021] After that, the olives individually packaged in containers and further filled and sealed with brine are subjected to pressure and heat sterilization under the first temperature condition (step S15). Here, the first temperature condition is a temperature condition corresponding to a central temperature of 75 °C for 1 minute or more. For example, "the central temperature of the olives is 80 °C for 20 minutes or more" corresponds to this first temperature condition. The central temperature is the temperature measured by inserting a probe (the probe of a thermometer) into the center of the food (olives).

[0022] As a result, since the pressure and heat sterilization treatment can be sufficiently performed on the olives under the first temperature condition, for example, even if Clostridium botulinum with extremely strong heat resistance is producing botulinum toxin, it can be inactivated by heating at a central temperature of 80 °C for 20 minutes.

[0023] In fact, in Japan too, there have been multiple cases of food poisoning caused by Clostridium botulinum in the past. In particular, in August 1998, there was a case in Tokyo where multiple food poisoning patients occurred due to canned Italian green pickled olives. Due to this case and others, it is known that foods such as vegetables and fruits including olives that are packaged and cannot be sufficiently heated may have Clostridium botulinum surviving and, if the bacteria grow, may be contaminated by the toxin.

[0024] Therefore, the purpose desired in the first sterilization step is to perform sufficient pressure and heat sterilization treatment on the unsterilized olives to inactivate botulinum toxin.

[0025] In addition, while the first temperature condition in the first sterilization step should preferably be one that inactivates botulinum toxin, the core temperature and pressurization / heating time can be arbitrarily determined by the manufacturer as long as a temperature of 75°C for 1 minute or more, which is sufficient to kill non-spore-forming food poisoning bacteria, can be achieved.

[0026] In the first sterilization step, it is preferable to fill the packaging with brine (step S14) and then sterilize the brine-soaked olives under pressure and heat together with the brine (step S15). This is because brine conducts heat better than gas, allowing for sterilization under pressure and heat in a shorter time. Furthermore, while water seeps out of the olives when dry-packed and then sterilized under pressure and heat, if the packaging is filled with brine before sterilization under pressure and heat, as described in the first sterilization step, syneresis will not be a problem. Note that dry packing is a method of heating via air, so it requires pressurization for a longer period than when using brine. Therefore, in the case of dry packing, the amount of syneresis due to the phenomenon will be greater than when brine is filled.

[0027] As mentioned above, the first sterilization step is a sterilization step aimed at killing non-spore-forming food poisoning bacteria. However, under temperature conditions of 75°C for more than one minute, if Clostridium botulinum survives and produces toxin, this toxin cannot be inactivated. Therefore, it is desirable to immerse the samples in salt water (step S14) and perform sterilization efficiently in a short time under higher temperature conditions (for example, a core temperature of 80°C as illustrated).

[0028] Finally, the olives, which have been sterilized by pressurization and heat under the first temperature conditions, are rapidly cooled (step S16). Since many spore-forming bacteria, such as Clostridium botulinum, actively proliferate at temperatures around 50°C, slowly cooling the pressurized and heat-sterilized olives increases the risk of spore-forming bacteria germinating and proliferating. Therefore, the pressurization and heat sterilization process (step S15) and the cooling process (step S16) are performed together.

[0029] [Storage process] Next, the cooled olives are stored in a refrigerator (step S22). The storage temperature should preferably be 10°C or below, because Clostridium botulinum does not germinate or multiply at temperatures below 10°C.

[0030] The temperature conditions required to kill botulinum spores are defined in the Food Sanitation Act as "a core temperature of 120°C for 4 minutes." The first temperature condition exemplified is lower than this, so while it may kill the vegetative cells of Clostridium botulinum, heat-resistant botulinum spores may survive. However, even if botulinum spores are present in olives preserved in brine, the danger can be prevented by storing them at a temperature that prevents germination.

[0031] In this way, during the storage process, the brine-pickled olives can be refrigerated for a long period of time in small portions of 1.0 kg to 1.5 kg, individually packaged.

[0032] [Second sterilization process] The stored olives can be taken out at any time. Therefore, the manufacturer first removes the amount of olives to be sold and discards the brine in the container (step S31).

[0033] Next, the removed olives are weighed and packed into packaging containers for sale (step S32). Here, the olives are divided into portions of less than 250g before being individually packaged. For example, the olives are divided into portions of about 100g before being individually packaged in each container. The packaging containers for sale are transparent plastic trays or bags (three-sided pouches) that are partially or entirely transparent, allowing the contents (olives) to be seen from the outside.

[0034] Then, the olives packed in transparent packaging containers are dry-packed (gas-filled packaging) (step S33). Specifically, an inert gas is filled into the packaging container using a dedicated packaging machine, and the container is sealed.

[0035] The inert gas is, for example, "70% nitrogen gas and 30% carbon dioxide gas," but is not limited to the example given, and carbon dioxide gas, nitrogen gas, argon gas, etc., can be used. Furthermore, the concentration of the inert gas filled in the packaging container is appropriately set (adjusted) depending on the type, size, freshness, and processing of the olive fruit, as well as the type and size of the packaging container and various other factors.

[0036] Subsequently, the olives, dry-packed in packaging containers, are pressurized and heat-sterilized under a second temperature condition (step S34). Here, the second temperature condition is a temperature condition equivalent to a core temperature of 75°C for 1 minute. Depending on the product being manufactured and its purpose, "a core temperature of 75°C for 1 minute" also corresponds to this second temperature condition. Similarly, "a core temperature of 70°C for 3 minutes" or "a core temperature of 65°C for 10 minutes" also correspond to this second temperature condition.

[0037] Here, the olives that are packed into the packaging containers have been sterilized by pressurization and heat in the first sterilization process (step S15), but there is a possibility of bacterial contamination during the refilling and packaging process (steps S31-S33).

[0038] The primary purpose of the second sterilization process is to thoroughly sterilize the olives so that they can have a long shelf life even after being repackaged. For example, if the olives are contaminated with bacteria after being repackaged and the second sterilization process is not performed, mold may begin to grow in about 30 days, even if gas-purged packaging is used to reduce the amount of oxygen and the olives are stored in the refrigerator. Once mold begins to grow inside the packaging container, it is impossible to stop its growth.

[0039] However, since the pressurized and heat sterilization in the second sterilization step is to sterilize olives that may have been contaminated during repackaging, etc., the second temperature condition is lower in temperature and / or shorter in duration than the first temperature condition (so-called pasteurization). In short, the second temperature condition only needs to be sufficient to kill any bacteria that may be present around the olives. Therefore, in the second sterilization process, there is no problem of water seeping out of the olives, or of the seeping water turning black over time and becoming unsightly.

[0040] Furthermore, the problem of water separation is particularly noticeable when the packaging container for dry-packed olive products is transparent or when a long shelf life of more than one month is set. However, the olive product manufacturing method according to the present invention makes it possible to manufacture olive products that do not have such problems, so transparent trays or bags can be used. Therefore, consumers and retailers can see the olives inside the packaging container when purchasing, and can sell and buy olive products with confidence.

[0041] Furthermore, if syneresis occurs, if the packaging container is a flat tray, the water spreads thinly across the bottom of the tray and is not very noticeable. However, if the packaging container is a vertical bag, the water collects at the bottom of the bag, and this becomes more noticeable if the bag is tilted. However, the olive food manufacturing method according to the present invention prevents the occurrence of problems related to syneresis, so the type of packaging container is not limited, and vertically long packaging containers can also be used.

[0042] Finally, for the same reasons as in the cooling step S16, the olives that have been pressurized and heat-sterilized under the second temperature conditions are rapidly cooled (step S35).

[0043] [Other processes] The olives, after undergoing the second sterilization process, are labeled and stored in the refrigerator (Step S41), then packaged and shipped as appropriate (Step S42).

[0044] Olive food is produced by the method for producing olive food according to the present invention through the following process. The olive food produced by the method for producing olive food according to the present invention has a pH of over 4.6 and can have a shelf life of one month or more.

[0045] In short, the olive food produced by the olive food production method according to the present invention contains unfermented olives with a pH of over 4.6 and is distributed to the market under refrigeration. Unfermented olives preserve olive oil and olive juice in a fresh state, maintaining a good texture and a vibrant green color. Therefore, unfermented olives can bring out the original flavor of the ingredients to the fullest, and suit the preferences of consumers who prefer the natural taste of ingredients.

[0046] Here, even if the pH exceeds 4.6, retort sterilization (120°C for 4 minutes) makes it possible to distribute at room temperature. However, retort sterilization inevitably softens the olive flesh and causes a loss of flavor. Therefore, the olive food manufacturing method according to the present invention makes it possible to produce olive food with good olive flavor and taste without adding the temperature conditions required for retort sterilization.

[0047] Most olive products on the market are either fermented or have organic acids added to maintain a pH of 4.6 or lower, allowing them to be distributed at room temperature. However, some types of olives, such as certain black olives, cannot have their pH lowered to 4.6 or lower. However, with the olive food manufacturing method of the present invention, it is not necessary to maintain a pH of 4.6 or lower, so various types of olives can be used as the first raw material.

[0048] For example, the first ingredient, olives, can be of various origins, including those produced abroad or in Japan, and there are no particular restrictions on the type of olive used. However, green Castelvetrano, green Cerignola, Leccino, Gaeta, Kalamata, and black ohiblanca are preferred.

[0049] Furthermore, as mentioned above, the olive food produced by the olive food production method according to the present invention can have a shelf life of more than one month due to the first and second sterilization steps.

[0050] Specifically, by setting the second temperature condition to an olive core temperature of 65°C for 10 minutes, it is possible to manufacture olive food with a shelf life of 4 months. In fact, the applicant is selling olive food manufactured using the olive food manufacturing method according to the present invention with a shelf life of 4 months. This temperature condition of "core temperature of 65°C for 10 minutes" was a condition stipulated in the "Hygienic Standards for Pickles," which was abolished with the revision of the Food Sanitation Act in 2021. Although it does not meet the core temperature conditions stipulated in the Food Sanitation Act, it already clears the first temperature condition of "core temperature of 75°C for 1 minute or more," so it can be adopted as the second temperature condition for food that conforms to the revised Food Sanitation Act.

[0051] Most olive products distributed in Japan are canned or bottled in brine, making them heavy and inconvenient to shop for. However, olive products manufactured using the olive food manufacturing method according to the present invention are packaged in trays or bags during the second sterilization process, making them lighter and more convenient not only for shopping but also for transportation and distribution. Furthermore, while canned and bottled olive products have three-dimensional packaging, making it difficult to see the fruit inside, the olive food manufacturing method according to the present invention allows olives to be sealed in a single layer (one layer) in a transparent tray or bag. This makes it possible to see the front and back of the olive fruit, allowing for visual inspection of small defects such as insect damage during manufacturing and purchase.

[0052] Furthermore, while canned and bottled olive products require specialized seamers and cappers, limiting the range of available capacities, the olive food manufacturing method according to the present invention allows for the arbitrary selection of bag sizes for bagged olives (see Figure 2(B)), thus meeting diverse customer needs.

[0053] The method for producing olive food described above is merely one example of the present invention, and the method for producing olive food according to the present invention can be modified as appropriate without changing its essence.

[0054] For example, to kill Clostridium botulinum, the first temperature condition could be set to "an olive core temperature of 120°C for 4 minutes" or "an olive core temperature of 100°C for 6 hours." Furthermore, if the olive food product is flavored and processed with other ingredients such as vegetables, fruits, or seafood, the first and second temperature conditions can be determined according to the type of these additional ingredients.

[0055] Furthermore, the temperature at which olives are refrigerated (steps S21, S41) can be determined by the manufacturer as appropriate, such as 4°C to 7°C or 3°C or below. [Industrial applicability]

[0056] This invention provides a method for producing olive food products under temperature conditions that do not cause syneresis, resulting in olive food products that are visually appealing and have a long shelf life. This method is industrially useful because consumers can confidently purchase olive food products produced by this invention in retail markets for general households (general consumers) as well as in the food service industry, such as restaurants. [Explanation of symbols]

[0057] 10,20 Olive Foods

Claims

1. The first sterilization step involves dividing unpasteurized olives into portions of 250g or more, individually packaging them, and then pressurizing and heating them under temperature conditions equivalent to a core temperature of 75°C for at least one minute. A storage step for storing olives sterilized by the first sterilization step, The olives stored in the aforementioned storage process are divided into portions of less than 250g each, individually packaged, and then subjected to a second sterilization process in which they are pressurized and heated under temperature conditions equivalent to less than 1 minute at a core temperature of 75°C. A method for producing olive food products.

2. The first sterilization step involves pressurizing and heating the brine-soaked olives together with the brine, The aforementioned storage process involves cooling the brine-pickled olives and storing them in a refrigerator. A method for producing olive food according to claim 1.

3. The olives that were portioned in the second sterilization step are dry-packed in transparent packaging containers. A method for producing olive food according to claim 1.

4. A company that manufactures olive products with a pH above 4.6 and a shelf life of one month or more. A method for producing olive food according to any one of claims 1 to 3.

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