Manufacturing methods for processed foods

Abstract

The primary focus is on effectively utilizing ingredients that would otherwise be discarded, by providing them with a texture that meets consumer demand, and on enabling the appropriate processing of even large quantities of discarded ingredients. [Means for solving the problem] We propose a method for manufacturing processed food, comprising a processing step of stirring edible organic fiber with an alkaline solution, a filling step of filling a container with the processed material obtained from the processing step so as to be mixed with a substance of different physical properties, and a heating and standing step of heating the filled processed material to a predetermined temperature and then letting it stand.

Description

Technical Field

[0001] The present invention relates to a method for producing processed foods using organic fibers.

Background Art

[0002] In the process of food processing, some of the raw food materials are removed from the perspective of improving texture, and then processing is carried out. Specifically, by removing organic fibers from the raw materials, the stringy texture and crispy texture peculiar to fibers are reduced.

[0003] The organic fibers removed in the process of such food material processing are often discarded without being used as food, although they are originally edible. Okara removed in the process of food processing using soybeans as raw materials is widely known as an example of such organic fibers.

[0004] Processing these food materials into new foods while reducing the demerits such as the avoidable texture etc. described above not only enables effective utilization of the food materials, but also leads to suitable intake of the nutrients contained in the food materials, thus bringing great utility to general consumers.

[0005] From the above viewpoints, quite a few technologies have been disclosed so far, and the practical application of processed food materials has been attempted. Specifically, Patent Document 1 discloses a technology related to a food processing method including kneading okara with food polysaccharides such as jelly-like tochocolten and konnyaku and then heat-coagulating, and Patent Document 2 discloses a technology related to a food processing method in which those raw materials are mixed into a paste, molded, and then heat-treated by being put into salt water.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

[0007] However, the technology described in Patent Document 1 is unclear as to the specific process by which processed foods can be mass-produced, and the technology described in Patent Document 2 raises doubts as to whether the heat treatment method of immersion in high-temperature saline solution can uniformly sterilize the processed ingredients. Furthermore, the above-mentioned prior art offers no suggestions for correcting the dry texture of organic fibers, which is not necessarily well-received by consumers. Thus, since the present invention aims not only to effectively utilize organic fibers that would otherwise be discarded but also to make them widely accepted by consumers, it is desirable to process the large amount of discarded food ingredients in a suitable manner from various perspectives, including texture. In such processing processes, technical ingenuity that takes mass production into consideration is required. [Means for solving the problem]

[0008] To solve the above problems, the present invention proposes a method for producing processed food, comprising a processing step of stirring edible organic fiber with an alkaline solution, a filling step of filling a container with the processed material obtained from the processing step so as to be mixed with a substance of different physical properties, and a heating and standing step of heating the filled processed material to a predetermined temperature and then letting it stand.

[0009] Furthermore, in connection with the above invention, we also propose a method for producing processed food characterized by allowing the filled processed material to stand for a predetermined time prior to commencing the heating and standing process.

[0010] Furthermore, in relation to the above inventions, we also propose a method for producing processed food characterized by immersing the filled processed material in an alkaline solution after the heating and standing step.

[0011] Furthermore, in relation to the above inventions, we also propose a method for manufacturing processed food, characterized in that the filling step involves filling a container such that the processed material and the material with different physical properties form a layered structure.

[0012] Furthermore, in relation to the above inventions, we also propose a method for manufacturing processed food characterized in that the filling step involves filling a container in a substantially rectangular parallelepiped shape so as to mix the processed material that has undergone the processing step with a material having different physical properties.

[0013] Furthermore, in connection with the above invention, we also propose a method for manufacturing processed food, which further comprises the step of making predetermined cuts at predetermined intervals on at least one surface of the filled processed material after the heating and standing step.

[0014] Furthermore, as an invention that shares the same manufacturing method and challenges to overcome as described above for processed foods, the invention comprises a processing step of stirring edible organic fiber with an alkaline solution, a filling step of filling a container with the processed material after the processing step, forming multiple layered structures from different directions, and a heating and standing step of heating the filled processed material to a predetermined temperature and then letting it stand. We propose a method for manufacturing processed foods that include the following features. [Effects of the Invention]

[0015] With the features described above, the present invention makes it possible to mass-produce products using organic fibers that were previously discarded, while ensuring uniformity and maintaining a texture that is easily accepted by consumers. [Modes for carrying out the invention]

[0016] The embodiments of the present invention will now be described. First, edible organic fiber and an alkaline solution are prepared. In the above description, okara (soy pulp) was used as an example of organic fiber, but it is not limited to this, and other materials such as cabbage cores, pumpkin seeds, sesame seeds, and grains can also be used. In addition, any edible organic fiber that has a certain degree of firmness as a food ingredient, is insoluble or sparingly soluble, and generally has the crumbly or dry texture described above as a problem can be used.

[0017] It is desirable that the organic fibers be pre-processed into a powder. This is to facilitate efficient stirring with the alkaline solution and subsequent mixing with the refined powder, as described later. While it is desirable to grind them as finely as possible, it is not necessarily required to be in a specific granular shape. In this embodiment, we will describe the case in which okara (soy pulp) is used as the organic fiber and is ground into a powder before use. Again, it should be noted that okara is merely one example of an organic fiber, and the process described below is equally applicable to other edible organic fibers.

[0018] The alkaline solution can be an aqueous solution using, for example, calcium hydroxide, calcium carbonate, calcium bicarbonate, calcium oxide, magnesium oxide, magnesium carbonate, sodium hydroxide, sodium carbonate, or sodium bicarbonate. In addition, various substances can be used as solutes, as long as they are not alkaline substances that are harmful to the human body if ingested. In this embodiment, the explanation will be based on the premise of an aqueous solution using calcium hydroxide.

[0019] As an example of a method for producing an alkaline solution using calcium hydroxide as the solute, first, a predetermined amount of water is placed in a container, then lime is added and stirred for a predetermined time, and then the mixture is circulated. By circulating the mixture after it has been stirred to produce the alkaline solution, the alkaline concentration can be kept uniform, and consequently, the burden of the mixing process in the post-settlement mixing process described later can be reduced.

[0020] Incidentally, the hydrogen ion concentration (pH) of the alkaline solution generated at this time is preferably in the range of 10.75 to 12. If the concentration is higher than this, due to the strong alkalinity, the okara will decompose over time during the stirring or mixing process, making it difficult to ensure the homogeneity of the processed food. In any case, by using an alkaline solution of the above-mentioned concentration to stir the okara and further mix it with refined flour, food processing with a good texture becomes possible.

[0021] Also, the temperature of the alkaline solution is preferably lukewarm water at least around 45 to 65 degrees when mixing and stirring with the okara in the processing step. By maintaining the temperature at a certain level, the stirring process with the okara can be carried out efficiently.

[0022] The stirring of the okara and the alkaline solution may be carried out by any method as long as it is the optimal method to achieve uniform alkalization of the processed material through the stirring (processing step). As an example, it can be considered to be carried out by continuously spraying the alkaline solution onto a predetermined amount of okara. In this embodiment, when irregularly mixing an aqueous calcium hydroxide solution with powdered okara, not only will the okara be inefficiently stirred, such as forming partial lumps, but it may also result in a lower yield as a processed food ingredient. In this regard, for example, by passing through a process of continuously spraying a certain amount of the alkaline solution from the upper part of the container where the powdered okara is stored in advance as described above, it becomes easier to uniformly mix the alkaline solution with the okara.

[0023] Also, as another method, a method of injecting an alkaline solution into the container storing the powdered okara while applying pressure to the okara can also be considered. By adopting this configuration, the alkalization of the processed material can be promoted, and labor saving or efficiency improvement during the generation of the processed material can be realized.

[0024] Furthermore, it is also conceivable to adopt a process in which the alkali solution is continuously ejected in the above-described manner while vibrating the container during the processing step. By vibrating the container, the powdery okara stored therein also vibrates, and the alkali solution ejected thereinto is evenly agitated. As a result, it becomes easier to avoid the above-described drawback of air pockets forming in the processed substance, and the vibration can reduce or suppress the drawback such as the okara sticking to the container wall due to the viscosity caused by containing the alkaline aqueous solution.

[0025] Incidentally, it is desirable that the temperature of the processed substance generated from the powdery okara and the alkali solution be temperature-controlled or temperature-regulated to maintain a temperature of 20 degrees to 50 degrees throughout the processing step.

[0026] Also, it is desirable that the hydrogen ion concentration of the processed substance be maintained at about pH 10 to 12, and more preferably about pH 11. By mixing substances with different physical properties such as refined flour after maintaining the concentration, the processed food produced can maintain a rich elastic feel in the structure of the substances with different physical properties.

[0027] The processed substance after the processing step is then filled into a container so as to be mixed with substances having different physical properties (filling step). In view of the fact that the present invention relates to a method for manufacturing processed foods, it is necessary that the different physical properties referred to here are physical properties related to the manufacture of processed foods. That is, it is conceivable to mix substances having different physical properties such as elasticity, viscosity, swelling property, expansibility, density, and temperature. As described above, organic fibers originally have a texture peculiar to fibrous materials, such as a dull texture and a crispy texture, which are shunned as processed foods and have become targets for disposal and the like. By mixing with substances having different physical properties that compensate for the physical properties that are often negatively evaluated in relation to such textures, it becomes possible to effectively utilize organic fibers as food ingredients and provide processed foods that are acceptable to consumers.

[0028] Here, as a substance with different physical properties from the processed substance, it is conceivable to select an ingredient rich in at least one of the following properties: elasticity or viscosity, swelling, or expansion, such as konjac containing glucomannan. Furthermore, in order to more suitably blend these substances with different physical properties and compensate for the negative physical properties of the organic fibers mentioned above, it is desirable to further include a step of heating the blended and filled processed substance at a predetermined temperature and then letting it stand. This is because, after the heating step and then letting it stand for a certain period of time, the above physical properties are neutralized, and it is possible to provide physical properties that are particularly suitable from the viewpoint of texture.

[0029] Incidentally, when filling the above container, it is conceivable to adopt a configuration in which the processed substance and the substances with different physical properties are filled into the container in a layered structure. This could be a so-called mille-feuille-like, lattice-like, or well-shaped structure. By providing processed food in a layered structure of substances with different physical properties, consumers can experience the textures of substances with different physical properties when they eat it. This makes the unpleasant texture of the organic fibers mentioned above less noticeable, and makes it easier to perceive a texture similar to other processed foods on the market.

[0030] Furthermore, the layered structure can be achieved through a variety of processes. For example, a mille-feuille-like structure may be formed by coating or placing a substance with different physical properties on all or part of the top surface of the stirred processed material which is placed in a planar manner, and then mixing them together to form a layered structure, and then coating or placing the stirred processed material on top of that. Alternatively, instead of coating substances with different physical properties in a planar manner, a structure may be formed by decorating and coating or placing them in a grid or well-shaped pattern, and of course, other similar structures are not excluded. In any case, by combining substances with different physical properties to provide a variety of textures, it is possible to reduce consumer discomfort and increase acceptance.

[0031] Furthermore, in the filling process, it is conceivable to fill the container in a roughly rectangular parallelepiped shape so as to mix the processed material that has undergone the processing process with a material having different physical properties. Given the reality that large quantities of edible organic fibers have been discarded until now, it is relatively easy to imagine that the processed food that can be provided by the present invention can also be mass-produced. In such a case, by filling the container in a roughly rectangular parallelepiped shape and then solidifying it, it becomes possible to mass-produce and provide homogeneous or stable processed food to consumers.

[0032] The processed material, filled into the container as described above, is heated to a predetermined temperature and then left to stand (heating and standing process). It is desirable that the heating temperature at this predetermined temperature be around 45 degrees Celsius. Since the processed material is likely to reach a higher temperature than konjac powder during its production process, a temperature difference of at least 45 degrees Celsius is sufficient to prevent unstable changes in hydrogen ion concentration during the stirring process, making it easier to achieve homogenization of the processed food.

[0033] Incidentally, it is also possible to immerse the processed substance filled in the container in an alkaline solution after the heating and standing process. Immersion in an alkaline solution adjusts the pH that has decreased during the heating and standing process, thereby suppressing oxidation and, consequently, inhibiting the attachment or growth of harmful bacteria. There are no particular restrictions on the concentration of the alkaline solution used for immersion or the immersion time; basically, these can be adjusted as appropriate as long as the packaging process for the processed substance as a processed food can be carried out smoothly. However, it is desirable to avoid prolonged immersion, such as for a day, as this will cause nutrients in the processed food to leach into the alkaline solution.

[0034] Furthermore, after the heating and settling process, a step may be added in which predetermined cuts are made at predetermined intervals on at least one surface of the filled processed material. These cuts increase the specific surface area that allows the seasoning ingredients to penetrate when seasoning the processed food, resulting in stable and rapid flavor penetration. By providing the processed food in a state with these technical characteristics, it becomes possible to perform seasoning treatments similar to those used for other commonly used ingredients, making it easier to use as an ingredient.

[0035] Incidentally, the incisions referred to here can be made in a variety of ways, for example, linearly or in a dotted pattern. The configuration allows for incisions in various patterns, making it possible or easy to create a variety of textures. Furthermore, by creating a texture similar to other foods (for example, meat, fish, noodles, and cooked foods made from them), it becomes possible to position processed foods produced using this invention as substitute foods for those other foods.

[0036] The present invention will be described in more detail below with reference to examples. These examples are not intended to limit the scope of the present invention in any way.

[0037] First, the applicant mixed konjac powder with the processed material, filled it into a container, and then heated the processed material in stages from 30 to 70 degrees Celsius to verify the finished product as a processed food. Example 1 was the result of continuous heating for 3 hours, and Example 2 was the result of continuous heating for 5 hours, but all other conditions (quantity, size, humidity, pH, ambient temperature, humidity, etc. of each material constituting the processed material) were the same in both cases.

[0038] (Example 1-1) Initially, the applicant manufactured a processed food by heating the processed material at 30 degrees Celsius for 3 hours. In this case, as described above, the neutralization of each mixed substance was insufficient, resulting in a powdery texture remaining in some areas of both the organic fiber and konjac powder. The product also lacked elasticity, and when removed from the container, it was almost sol-like and difficult to maintain its shape.

[0039] (Examples 1-2) Next, the applicant tried changing the heating temperature to 40 degrees. At first glance, the external shape was maintained, but when pressed in certain areas, the resulting indentations did not recover, indicating poor elasticity, a dull color, and a less-than-ideal texture for food.

[0040] (Examples 1-3) When we changed the heating temperature to 50 degrees, we saw improvements in both color and texture, but the issue of elasticity remained, as the indentations when pressed still did not recover.

[0041] (Examples 1-4) Just to be sure, we tried changing the heating temperature to 70 degrees Celsius. This resulted in a more vibrant color that was more appetizing, as well as improved recovery of indentations after pressing. The elasticity also contributed to a quality acceptable for a processed food in the market.

[0042] (Example 2-1) Next, the applicant manufactured a processed food by heating the processed material at 30 degrees Celsius for 5 hours. In this case, there was almost no residual powderiness compared to Example 1-1, and the elasticity was improved to some extent, but it was still difficult to maintain its shape, as it was easily deformed by simply pressing it with a finger.

[0043] (Example 2-2) Next, the applicant tried changing the heating temperature to 40 degrees. As a result, the color was more vibrant compared to the case of Examples 1-2, which contributed to improving appetite, and although indentations still occurred when partially pressed, a certain degree of elasticity could be felt.

[0044] (Examples 2-3) Furthermore, when the heating temperature was changed to 60 degrees Celsius, the recovery of the indentation after pressing was successfully achieved, and the elasticity also contributed to a quality acceptable to the market as a processed food.

Claims

1. A processing step in which edible organic fibers are stirred with an alkaline solution, A filling step in which the processed material that has undergone the above processing step is filled into a container so as to be mixed with a material of different physical properties, A heating and standing step in which the filled processed material is heated to a predetermined temperature and then left to stand, A method for manufacturing processed foods that includes the following:

2. The method for producing a processed food according to claim 1, characterized in that the filled processed material is allowed to stand for a predetermined time prior to the commencement of the heating and standing step.

3. The method for producing a processed food according to claim 1, characterized in that the filled processed material is immersed in an alkaline solution after the heating and standing step.

4. The method for producing a processed food according to claim 1, wherein the filling step is a step of filling a container such that the processed material and the material with different physical properties form a layered structure.

5. The method for producing a processed food according to claim 1, characterized in that the filling step involves filling a container in a substantially rectangular parallelepiped shape so as to mix the processed material that has undergone the processing step with a material having different physical properties.

6. The method for producing a processed food according to claim 5, further comprising the step of making cuts at predetermined intervals on at least one surface of the filled processed material after the heating and standing step.

7. A processing step involves stirring edible organic fiber and konjac powder together with an alkaline solution, A filling step in which the processed material that has undergone the above processing step is filled into a container from different directions to form multiple layered structures, A heating and standing step in which the filled processed material is heated to a predetermined temperature and then left to stand, A method for manufacturing processed foods that includes the following: