Manufacturing methods for processed foods

Abstract

The primary focus is on effectively utilizing food ingredients that would otherwise be discarded, and on enabling the appropriate processing of even large quantities of food waste. [Means for solving the problem] We propose a method for producing processed food, which includes the step of adding water to powdered edible organic fiber and stirring it, and then stirring it with konjac paste that has swollen due to the addition of water to produce a final mixture, characterized in that the water temperature in the water-adding step of the konjac paste is controlled to be constantly maintained in the range of 6 to 30 degrees.

Description

Technical Field

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

Background Art

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

[0003] Although the organic fibers removed in the process of such food material processing are originally edible, in many cases, they are not used as food materials and are often discarded. Okara removed in the process of food material processing using soybeans as a raw material 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 texture that can be avoided as described above not only enables the effective utilization of the food materials but also leads to the appropriate intake of the nutrients contained in the food materials, thus bringing great utility to general consumers.

[0005] From the above viewpoints, a number of 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 tokoro-tan and konjac and then heating and 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. As mentioned above, since the present invention focuses on effectively utilizing ingredients that would otherwise be discarded, it is desirable to process even large quantities of discarded ingredients in a suitable manner, and 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, which includes the step of adding water to powdered edible organic fiber and stirring it, and then stirring it with konjac paste that has swollen due to the addition of water to produce a final mixture, characterized in that the water temperature in the water-adding step of the konjac paste is controlled to be constantly maintained in the range of 6 to 30 degrees.

[0009] Furthermore, with respect to the above invention, we also propose a configuration that is technically characterized by stirring the final mixture so that its pH is 10 or higher.

[0010] Furthermore, in relation to the above inventions, we also propose a method for producing processed food characterized by stirring the hydrated konjac paste with the organic fibers when its viscosity is between 35 and 380 P.

[0011] Furthermore, in relation to the above inventions, we also propose a method for producing processed food characterized by immersing the final mixture in an alkaline solution. [Effects of the Invention]

[0012] With the features described above, the present invention makes it possible to achieve mass production while ensuring homogeneity in food processing processes that use ingredients that were previously discarded. [Modes for carrying out the invention]

[0013] The embodiments of the present invention will now be described. First, edible organic fiber ground into granules 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.

[0014] Furthermore, the organic fibers must be pre-ground into a powder. This is to facilitate efficient stirring with the alkaline solution described later and subsequent mixing with the konjac paste. 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 where okara (soy pulp) is used as the organic fiber and ground into a powder before use. Again, okara is merely one example of an organic fiber, and the process described below is equally applicable to other edible organic fibers.

[0015] It is desirable that the water used when stirring the organic fibers be an alkaline solution. By alkalizing the organic fibers, the discrepancy in physical properties during stirring with konjac paste (an alkaline food) described later can be suppressed, and significant changes in physical properties during the processing can be avoided. Specific examples of alkaline solutions include aqueous solutions using calcium hydroxide, calcium carbonate, calcium bicarbonate, calcium oxide, magnesium oxide, magnesium carbonate, sodium hydroxide, sodium carbonate, sodium bicarbonate, etc. 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 assumption of an aqueous solution using calcium hydroxide.

[0016] 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 an alkaline solution, the alkalinity can be kept uniform, and consequently, the burden of the mixing process in the post-settlement mixing process described later can be reduced.

[0017] Furthermore, the temperature of the alkaline solution should preferably be lukewarm, at least 45 to 65 degrees Celsius, prior to the stirring process with the organic fibers. Maintaining a consistent temperature level allows for efficient stirring with the organic fibers.

[0018] The stirring of the organic fibers and the alkaline solution can be carried out by any method that is optimal for achieving homogeneous alkalization of the stirred substances, but one example is to continuously spray the alkaline solution onto a predetermined amount of organic fibers. In this embodiment, if the calcium hydroxide aqueous solution is mixed irregularly with the powdered okara, the organic fibers may clump together in some areas, resulting in inefficient stirring and potentially reducing the yield of the processed food. In this regard, for example, by going through a process in which a certain amount of alkaline solution is continuously sprayed from the top of a container in which the powdered organic fibers are stored, it becomes easier to evenly mix the alkaline solution with the organic fibers.

[0019] Also, as another method, a method of adding an alkaline solution while applying pressure to the powdery organic fiber is also conceivable. By adopting this configuration, alkalization of the stirring substance can be promoted, and labor saving or efficiency improvement in the production of the final mixture and thus processed foods can be achieved.

[0020] Furthermore, it is also conceivable to adopt a process in which the alkaline solution is continuously ejected in the above manner while vibrating the container during the stirring process. By vibrating the container, the stored powdery okara also vibrates, and the alkaline solution ejected there is evenly stirred, so it becomes easier to avoid the above-mentioned drawback that air pockets occur in the stirring substance. Also, due to the vibration, it is possible to reduce or suppress the drawback that okara sticks to the container wall due to the viscosity caused by containing an alkaline aqueous solution.

[0021] Incidentally, it is desirable that the temperature of the stirring substance generated through the above stirring process be temperature-controlled or regulated to maintain 20 degrees to 65 degrees through the process. By controlling the temperature as described above, the mixing process with konjac paste described later can be smoothly performed.

[0022] Also, when adding water to the powdery organic fiber and stirring, the hydrogen ion concentration of the stirring substance is preferably maintained at about pH 10 to 12, and more preferably about pH 11. By maintaining this concentration and then mixing with konjac paste as described later, the processed food produced can maintain a rich sense of elasticity in the structure of glucomannan composed of konjac paste.

[0023] In this embodiment, it is desirable to mix the temperature of the agitated substance generated through the above agitation process and the temperature of the konjac paste in a state as close as possible to each other. For example, after controlling the temperature so that the temperature of the agitated substance is maintained within a range of, for example, 20 to 65 degrees, by mixing the agitated substance and konjac powder in a state of approximate temperature, the mixing state (hydrogen ion concentration, shape, etc.) of the organic fiber and the alkaline solution constituting the final mixture can be stabilized and the mixing time can be shortened, and thus it can contribute to mass production.

[0024] Specific modes of temperature control of the agitated substance can be considered in various ways. It is also conceivable to measure the temperature of the konjac paste in parallel with the implementation of each agitation, and perform heating or cooling treatment to control the temperature of the agitated substance so as to approximate the temperature of the konjac paste which is the measurement result. It is also conceivable to adopt a configuration in which the agitated substance is allowed to stand for a predetermined time after the agitation process so that the temperature of the agitated substance approaches the above-mentioned predetermined temperature.

[0025] However, even when adopting a configuration in which the agitated substance is allowed to stand, it is desirable to avoid allowing it to stand for an excessively long time. Even at normal temperature, if it continues to stand for, for example, more than 10 minutes, the moisture contained in the agitated substance evaporates and curing starts, which causes the subsequent mixing process with the konjac paste to take time or air bubbles to form in the processed food.

[0026] Incidentally, the konjac paste used in the mixing process contains mannan, a water-soluble polysaccharide derived from konjac tubers, and is preliminarily stirred with water to become a sol state (paste state) before being mixed with the agitated substance. By making the konjac paste into a sol state, it becomes easier to mix with the agitated substance, and it becomes possible to produce a large amount of the final mixture in a short time.

[0027] One possible process for turning the konjac paste into a sol is to store water in a container and then add the konjac paste to the container while circulating the water either throughout the container or only within the container, and then stir for a predetermined time. When the stirred konjac paste is left to stand for a predetermined time, the water-containing konjac paste swells and becomes a sol.

[0028] At this time, the water used for swelling should be controlled to maintain a constant temperature within the range of 6 to 30 degrees Celsius, similar to the stirring material obtained by adding water to the organic fibers mentioned above. Maintaining such a temperature can slow down swelling, suppressing (controlling) the gelation (hardening) of the konjac paste or the mixture of konjac paste and stirring material that occurs when the mixing process continues for a predetermined time. This facilitates the subsequent molding process of processed foods and, consequently, enables the stabilization and efficiency of mass production.

[0029] In this regard, the konjac paste, after being hydrated, is characterized by being stirred with the stirring substance made of organic fibers at a viscosity of approximately 35 to 380 P. If the viscosity is too low, it will take a long time to form the final mixture, and during that time there is a concern that the konjac paste will harden further. If the viscosity is too high, swelling of the konjac paste cannot be expected, so stirring with the stirring substance will also take a long time. With the viscosity described above, the degree of solification of the konjac paste is such that it can be suitably mixed with a stirring substance that has the properties of typical organic fibers, and it becomes possible to produce the final mixture or processed food product in a short time.

[0030] Incidentally, it is also possible to immerse the final mixture in an alkaline solution. By immersing it in an alkaline solution, the pH of the processed food, which has dropped excessively during the manufacturing process of the final mixture, can be adjusted to suppress the progression of oxidation, and consequently, the attachment or growth of harmful bacteria can be suppressed. There are no particular restrictions on the concentration of the alkaline solution used for immersion or the immersion time; basically, it can be adjusted as appropriate as long as the packaging process of the 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. In any case, by taking measures to suppress the progression of oxidation in this way, the shelf life of the processed food can be improved, and it can be made easier to distribute it to the market in large quantities.

[0031] 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.

[0032] First, in Example 1, we will examine the differences in swelling patterns due to differences in the temperature of the water added to the konjac paste. In all of the Examples 1 described below, the amount of powdered organic fiber, konjac paste, and water added after adding water and stirring is the same, and apart from the differences in conditions described in each example, the ambient temperature, humidity, and other external environmental conditions are the same. In addition, the stirring time after adding water to the konjac paste was 3 minutes in all cases.

[0033] (Example 1-1) Initially, the applicant added water at a temperature of 2.5 degrees Celsius to konjac paste and stirred it. As a result, the paste and water separated, and clumps of paste formed at the bottom, preventing sufficient swelling. Lumps formed in some areas, and sufficient viscosity could not be obtained.

[0034] (Examples 1-2) In this regard, when we changed the water temperature to 5 degrees and added water again, this time no clumps of konjac paste like those mentioned above occurred, nor did any lumps form. Although the viscosity remained somewhat loose, it was confirmed that the quality was sufficient for use as a processed food ingredient, and no lumps formed even when mixed with other materials such as organic fibers.

[0035] (Examples 1-3) Next, the applicant added tap water at a temperature of 30 degrees Celsius to the konjac paste and then stirred it. As a result, although it felt slightly hard in terms of elasticity, no lumps formed, and the viscosity was not unpleasant.

[0036] (Examples 1-4) Finally, the applicant added 40-degree Celsius heated water to the konjac paste and then stirred it. As a result, the degree of hardness increased compared to the cases described in Examples 1-3, and viscosity could not be maintained. Furthermore, when organic fibers were further stirred into the konjac paste in this state, the konjac paste solidified quickly, resulting in partially insufficient mixing with the organic fibers, and thus preventing the achievement of a homogenized texture.

[0037] As described above, by keeping the temperature of the water added to the konjac paste within a range of at least 5 to 30 degrees Celsius, it is possible to avoid the formation of lumps in the konjac paste itself and to achieve homogenization as a food product through mixing with organic fibers.

[0038] (Example 2) Next, we investigated the changes in the quality of the processed food in response to changes in the pH value of the final mixture, and the results are shown in Table 1 below. In this example, the amounts of organic fiber, konjac paste, and water used were all equal.

[0039] (Table 1) JPEG2026108608000001.jpg4098

[0040] As shown in the table above, when the alkali concentration of the final mixture was pH 9, the binding between the konjac paste and the organic fibers was insufficient, leaving challenges in terms of achieving homogenized texture. Furthermore, the elasticity of glucomannan was not adequately obtained, resulting in a lack of texture as a processed food.

[0041] On the other hand, when the alkali concentration of the final mixture is pH 10, although it feels slightly soft, the aforementioned issues are resolved to a level of quality acceptable to the market as a processed food. Furthermore, it was confirmed that when the pH is 11 or higher, it is possible to provide an even more desirable texture and elasticity.

[0042] Furthermore, the applicant also verified the optimal viscosity of the konjac paste as described above. Note that, in all the examples described below, the conditions used are the same, except where otherwise specifically mentioned.

[0043] (Example 3-1) Initially, the applicant processed the final mixture using konjac paste with a viscosity of 22.8P. As a result, the paste lacked elasticity and viscosity, requiring a long mixing process with other materials. Furthermore, it was not possible to completely eliminate the powdery texture of the organic fibers, resulting in a foreign-feeling texture in the final mixture due to these granular particles. Moreover, because the paste itself lacked elasticity, the final mixture also lacked sufficient resilience, producing a final mixture with an unpalatable texture.

[0044] (Example 3-2) Next, the final mixture was processed with konjac paste at a viscosity of 35.4p. As a result, the aforementioned issues such as residual organic fiber particles did not occur, and it can be said that this is suitable for mass production as a processed food. However, the viscosity was somewhat low, and some defects occurred during the molding of the final mixture, such as partial indentations, which meant that a certain amount of defective products could be produced from the standpoint of achieving uniform shape.

[0045] (Example 3-3) Furthermore, the final mixture was processed when the konjac paste had a viscosity of 377.4P. In this case, due to the high viscosity, the swelling rate was slow, and the stirring process with organic fibers also took a little longer. On the other hand, the final mixture produced after stirring was of a certain quality or higher in terms of elasticity, texture, and color.

[0046] (Examples 3-4) Finally, the final mixture was processed with the konjac paste having a viscosity of 406.3P. As a result, the konjac paste was too hard and could not be properly mixed with the organic fibers, leaving some granular shape of the organic fibers and some of the organic fiber's color in the final mixture, which prevented it from maintaining the quality of a processed food.

[0047] As described above, it was found that, in order to achieve mass production while ensuring the uniformity of elasticity and color acceptable in the market for konjac paste, a viscosity of approximately 35 to 380 lbs is generally required.

Claims

1. A method for producing processed food, comprising the steps of adding water to powdered edible organic fiber and stirring, and then stirring with konjac paste that has swollen due to the addition of water to produce a final mixture, A method for manufacturing processed food, characterized by controlling the temperature of the water used in the hydration step of the konjac paste to maintain a constant temperature range of 6 to 30 degrees Celsius.

2. The method for producing a processed food according to claim 1, characterized in that the final mixture is stirred so that its pH is 10 or higher.

3. The method for producing a processed food according to claim 1, characterized in that the konjac paste to which water has been added is stirred with the organic fibers when the viscosity is between 35 and 380 P.

4. A method for producing a processed food according to claim 1, characterized in that the final mixture is immersed in an alkaline solution.

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