Method for producing solubilized material and method for improving solubilization rate

Abstract

To provide a method for producing a soluble material, which can efficiently produce the soluble material with an improved solubilization rate without using a complicated or special production device.SOLUTION: The present invention provides a method for producing a soluble material, which produces the soluble material from solid raw material, containing at least one component out of a hydrolyzable substance selected from the group consisting of proteins, carbohydrates and lipids, and fibers. The method includes the process of making the raw material coexist with water of 0.04-2.4 pts.wt relative to 1 pt.wt. of the raw material in dry weight, which are subjected to shear force in a heated and compressed state, so that at least part of the hydrolyzable substance is hydrolyzed and / or at least part of the fibers is rendered amorphous; and the compression is then released for adiabatic expansion. The heating and compression are conducted at a temperature T selected in a range of 300-374°C and a pressure P. The pressure P is equal to or higher than a saturated vapor pressure of water at the temperature T and equal to or lower than [the saturated vapor pressure+50 air pressure].SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a method for producing a solubilized product and a method for improving the solubilization rate. [Background technology]

[0002] Attempts have been made to solubilize various food materials in water. For example, Patent Document 1 discloses a method for solubilizing starch-containing cereal bran, which involves treatment with a cell wall-modifying enzyme or a starch-modifying enzyme. Patent Document 2 discloses a method for preparing a pulse protein product with reduced astringency, in which a protein source is solubilized using an aqueous calcium salt solution.

[0003] Patent Document 3 relates to a method for treating discarded shellfish, and describes that the decomposition and solubilization of shellfish meat can be carried out by treatment with proteolytic enzymes contained in the discarded shellfish itself, treatment with microorganisms with proteolytic activity, treatment with hydrolases, treatment with yeast, treatment with surfactants, ultrasonic irradiation treatment, supercritical water treatment, acid treatment, alkali decomposition treatment, etc. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-514989 [Patent Document 2] Patent Publication No. 2021-52806 [Patent Document 3] Japanese Patent Application Publication No. 9-122629 Summary of the Invention [Problem to be solved by the invention]

[0005] When solubilizing the product by treatment with enzymes, acids, bases, etc. as described in the above patent documents, it takes a certain amount of time to obtain a solubilized product, and since strict temperature control and acid- and alkali-resistant manufacturing equipment are required, there are many limitations on the manufacturing equipment. Furthermore, since it is difficult to increase the manufacturing speed, there is a problem in that it is difficult to achieve a cost that is commensurate with practical application.

[0006] Patent Document 3 exemplifies supercritical water treatment, but this treatment requires a manufacturing apparatus with a high level of airtightness to retain the supercritical water, and also requires a temperature exceeding 374°C, which inevitably leads to problems in the design of the manufacturing apparatus and the need for excessive energy.

[0007] Therefore, an object of the present invention is to provide a method for producing a solubilized product that can efficiently produce a solubilized product with an improved solubilization rate without using a complex or special production apparatus, and to provide a method for improving the solubilization rate using this production method. [Means for solving the problem]

[0008] The present invention provides a method for producing a solubilized product from a solid raw material containing at least one component selected from the group consisting of proteins, carbohydrates, and lipids, and fibrous materials, the method comprising the steps of: bringing the raw material into coexistence with water in an amount of 0.04 to 2.4 parts by weight per part by weight of the dry matter of the raw material; applying a shear force under heating and pressure to hydrolyze at least a portion of the hydrolyzable material and / or amorphize at least a portion of the fibrous materials; and releasing the pressure to allow adiabatic expansion; the heating and pressure are carried out at a temperature T selected from the range of 300 to 374°C, and a pressure P set to a value equal to or greater than the saturated vapor pressure of water at the temperature T and equal to or less than the saturated vapor pressure + 50 atmospheres.

[0009] This production method can be carried out using an extruder or the like as described below, and since it does not use supercritical water, it does not require complex or special production equipment, and does not cause problems in designing the production equipment or problems with excessive energy.

[0010] In the present invention, the amount of water added is based on the dry weight of the raw material, and is calculated including the moisture contained in the raw material itself. That is, in the present invention, the raw material is heated and pressurized in the presence of 0.04 to 2.4 parts by weight of water per part by weight of the dry weight of the raw material. Below this lower limit, hydrolysis does not proceed sufficiently. Above the upper limit, excessive water remains after adiabatic expansion, and the temperature may not drop sufficiently when the material is discharged from the apparatus.

[0011] Heating and pressurization are carried out at a temperature T and a pressure P, and the temperature T is selected from the range of 300 to 374°C, preferably 300 to 370°C, and more preferably 350 to 370°C. The pressure P is in the range of P1 atm (saturated vapor pressure of water at temperature T) to (P1+50) atm.

[0012] It is known that the critical temperature of water is 374°C and the critical pressure is 22.1 MPa (218.3 atmospheres = 218.3 atm), and the state of both the critical temperature and critical pressure is called the critical point. Generally, supercritical water is considered to be water whose temperature and pressure exceed the critical temperature and critical pressure, respectively (https: / / www.mext.go.jp / b_menu / shingi / gijyutu / gijyutu0 / shiryo / attach / 1331584.htm), and water below the critical temperature and above the saturated vapor pressure of water is sometimes called subcritical water. There are various definitions of subcritical water, but in this specification, water below the critical temperature and above the saturated vapor pressure of water (excluding the critical point) is called subcritical water, and water at the critical temperature and critical pressure is called water at the critical point.

[0013] The heating and pressurizing conditions used in the present invention overlap with those used to produce subcritical water or critical point water, and hydrolysis of hydrolyzable substances and decrystallization of cellulose can easily occur by the action of water alone without the presence of a catalyst, etc., thereby enabling the production of a solubilized product suitable for a variety of uses in a short period of time. Furthermore, the method of the present invention can achieve a solubilization rate of 35% or higher (preferably 40% or higher, and even 60% or higher).

[0014] The method of the present invention can be carried out using an extruder. That is, heating and pressurization are performed inside the extruder, and adiabatic expansion can be performed by discharging from the extruder's discharge port. Using an extruder makes it possible to apply shear force by heating and pressurizing the raw material in a narrow space, making it suitable for carrying out the present invention. In particular, a twin-screw extruder is preferred because it can efficiently apply shear force and therefore shorten the processing time of the raw material.

[0015] The raw material can be at least one selected from the group consisting of food ingredients, feed, and factory residues generated in the processing of these, and suitable food ingredients include those containing fiber (such as grains, potatoes, and factory residues generated in the processing of these).

[0016] The present invention also provides a solubilized product obtained by the above-mentioned production method. The form of the solubilized product is not limited, but for example, when a fiber-containing raw material is used, the solubilized product may be in the form of a puffed product. When a fiber-free raw material is used, the solubilized product may be in the form of a granule.

[0017] When soybeans and / or wheat are used as raw materials, a method for producing soy sauce can be provided that includes a step of producing koji from the solubilized product obtained by the above-mentioned method. By carrying out this production method, soy sauce with an excellent, deep flavor can be obtained.

[0018] The present invention also provides a method for improving the solubilization rate of a solubilized product obtained from a solid raw material containing at least one component selected from the group consisting of proteins, carbohydrates, and lipids, and fibrous materials, wherein the solubilized product is obtained by bringing the raw material into coexistence with water in an amount of 0.04 to 2.4 parts by weight per part by weight of the dry matter of the raw material, applying a shear force under heating and pressure to hydrolyze at least a portion of the hydrolyzable materials and / or amorphize at least a portion of the fibrous materials, and then releasing the pressure to allow adiabatic expansion; the heating and pressure are carried out at a temperature T selected from the range of 300°C to 370°C, and at a pressure P set to a value equal to or greater than the saturated vapor pressure of water at the temperature T and equal to or less than the saturated vapor pressure + 50 atmospheres. [Effects of the Invention]

[0019] According to the present invention, there is provided a method for producing a solubilized product that can efficiently produce a solubilized product with an improved solubilization rate without using a complex or specialized production device, and there is also provided a method for improving the solubilization rate using this production method. [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 is a diagram showing the relationship between the saturated vapor pressure of water (P1) and the saturated vapor pressure of water +50 atmospheres (P1+50). [Figure 2] FIG. 1 shows the relationship between the solubilization rate of total solubilisate, protein and starch and temperature. DETAILED DESCRIPTION OF THE INVENTION

[0021] In the method for producing a solubilized product according to the embodiment, a solid raw material containing at least one component selected from the group consisting of a hydrolyzable substance selected from the group consisting of proteins, carbohydrates, and lipids, and a fiber, is used. Only one type of raw material may be used, or multiple types may be used in combination. If a solid raw material is included, a non-solid raw material may be added.

[0022] Here, the terms protein, carbohydrates, lipids, and fiber are based on the Standard Tables of Food Composition in Japan, 2015 Edition (7th Edition), Supplement 2018. In the Standard Tables of Food Composition in Japan, 2015 Edition (7th Edition), Supplement 2018, carbohydrates are referred to as available carbohydrates. Fiber is also referred to as dietary fiber. Proteins are hydrolyzed to produce peptides, which then produce amino acids. Carbohydrates are hydrolyzed to produce oligosaccharides, disaccharides, monosaccharides, etc. Lipids are hydrolyzed to produce glycerol and fatty acids (saturated fatty acids, monovalent fatty acids, and polyvalent fatty acids).

[0023] Protein refers to a polymeric compound that is a dehydration condensation product of amino acids (e.g., arginine, histidine, lysine, aspartic acid, glutamic acid, serine, threonine, asparagine, glutamine, cysteine, selenocysteine, glycine, proline, alanine, isoleucine, leucine, methionine, phenylalanine, tryptophan, tyrosine, and valine), but also includes proteins to which compounds are attached, such as glycoproteins (e.g., gliadin). Proteins may consist of one type or two or more types, and an example of a protein consisting of two or more types is gluten (including glutenin and gliadin).

[0024] Dietary fiber can be broadly classified into water-soluble dietary fiber and insoluble dietary fiber, and water-soluble dietary fiber can be further classified into low-molecular-weight water-soluble dietary fiber and high-molecular-weight water-soluble dietary fiber. Water-soluble dietary fiber includes pectin, alginic acid, gum, glucomannan, etc., while insoluble dietary fiber includes hemicellulose, lignin, chitin, cellulose, etc.

[0025] Cellulose is broadly classified into type I and type II, with natural cellulose belonging to type I. Type I cellulose is crystalline and has a triclinic I structure. α and monoclinic I β The heating and pressure applied in this manufacturing method causes at least a portion of these crystals to become amorphous.

[0026] As described above, at least one of grains, potatoes, and meats can be used as raw materials containing at least one component selected from the group consisting of hydrolyzable substances and fiber. Examples of grains include at least one selected from soybeans, adzuki beans, kidney beans, black beans, corn, sesame, buckwheat, millet, foxtail millet, barnyard millet, wheat, and rice. Examples of potatoes include at least one selected from potatoes, sweet potatoes, and taro (e.g., taro). Meats can be broadly divided into meat and seafood, and examples of meat include chicken, pork, beef, mutton, wild boar, and venison. Examples of seafood include fish, shellfish, cephalopods, echinoderms, and crustaceans.

[0027] According to the 2015 edition (7th revision) of the Standard Tables of Food Composition in Japan (Supplement 2018), barley, wheat, rice, potatoes, red beans, kidney beans, and soybeans are all considered to contain protein, carbohydrates (available carbohydrates), lipids, and dietary fiber. The same table also states that fish, beef, and chicken all contain protein and lipids. Thus, grains, potatoes, and meat are considered to be ingredients that contain at least one of hydrolyzable substances selected from the group consisting of protein, carbohydrate, and lipid, and dietary fiber.

[0028] The raw materials are not limited to food ingredients, but also include feed (for livestock, etc.) and factory residues generated in the processing of food ingredients and feed. Incidentally, "food ingredients, feed, and factory residues" include fish meal, rice bran, bones, resins, etc. The obtained solubilized materials may include not only ingredients for human food, but also feed, supplements, etc., or their raw materials. When the raw materials are bone and resin, the obtained solubilized materials may be bone meal and resin components (such as resin hydrolysates), respectively.

[0029] When the raw material is a food ingredient, those containing fiber are particularly suitable. That is, it is preferable to use grains and potatoes. When soybeans, defatted soybeans, and / or wheat are used as raw materials, the solubilized material obtained by carrying out the present invention can be suitably used for soy sauce production. By using this solubilized material, soy sauce can be produced without the need for a steaming process.

[0030] The raw material is solid. Here, "solid" means that it has not been processed into a liquid, slurry, or the like, and may be in a lumpy state. Note that it is not considered to be processed in the above manner if the raw material is simply cut to a size that fits into a machine for heat and pressure treatment, or if a powdered material is added to a solid raw material.

[0031] Heating and pressurization are carried out in the presence of 0.04 to 2.4 parts by weight of water per 1 part by weight of the dry matter of the raw material. That is, rather than adding 0.04 to 2.4 parts by weight of water per 1 part by weight of the raw material, the method is characterized in that water in the above range is made to coexist per 1 part by weight of the "dry matter" of the raw material, that is, water is added so that the total amount, including the water originally contained in the raw material (for example, water of crystallization), is 0.04 to 2.4 parts by weight.

[0032] When raw materials are foodstuffs or feedstuffs, their moisture content is typically 1 to 25% by weight. When using 100 g of raw material with a moisture content of 10% by weight, the dry matter weight is 90 g. Adding 35 g of water to this 100 g dry matter weight results in a total of 10 + 35 = 45 g, so the amount of water to be coexistent per 1 part by weight of dry matter of the raw material is 45 / 90 = 0.5 parts by weight. Note that if the raw material contains a very high moisture content, it is possible to "coexist 0.04 to 2.4 parts by weight of water per 1 part by weight of dry matter" using only the water contained therein, without adding additional water.

[0033] The dry weight is the weight minus the water (crystallization water, etc.) contained in the raw material, as in the example above. If the amount of water contained is unknown, the water content can be measured by the Karl Fischer method, etc. Even if the raw material is a mixture of multiple types, the total dry weight is calculated and the amount of water to be added is determined based on that.

[0034] Regarding "water equivalent to 0.04 to 2.4 parts by weight per part by weight of the dry matter of the raw material," when the raw material is a protein (dry matter), this corresponds to the presence of water at a molar ratio of 0.24 to 14.6 times the theoretical amount of hydrolyzable groups. Here, the theoretical amount of hydrolyzable groups is calculated by "protein weight (g) / average molecular weight of amino acids (110)." That is, for 1 g of protein, the theoretical amount of hydrolyzable groups can be calculated as 1 / 110 mole. Therefore, if water (molecular weight 18) is used at a molar ratio of 1 to 1 mole of hydrolyzable groups, the amount of water is (1 / 110) × 18 = 0.16 g.

[0035] The raw materials prepared as described above are subjected to the process at a temperature T and a pressure P, with the temperature T being selected from the range of 300 to 374°C, preferably 300 to 370°C, and more preferably 350 to 370°C. The pressure P is in the range of P1 atmosphere (the vapor pressure of water at temperature T) to (P1+50) atmosphere. The pressure P can be P1 atmosphere to (P1+40), P1 atmosphere to (P1+30), P1 atmosphere to (P1+20), P1 atmosphere to (P1+10), or P1 atmosphere to (P1+5). The pressure need only be within the above range during the production process, and does not need to be a constant value and may vary. This temperature and pressure range is included in the state of subcritical water.

[0036] The ranges of temperature T and pressure P, including preferred examples, are shown in Table 1 below. Also, the relationship between "saturated vapor pressure of water (P1)" and "saturated vapor pressure of water + 50 atmospheres (P1+50)" is shown in Figure 1. [Table 1]

[0037] At temperatures above 300°C, for example, the raw material processed in an extruder has sufficient heat to undergo adiabatic expansion, making it possible to obtain a stable solubilized product. At temperatures below this level, the solubilization rate is low. The solubilization rate varies depending on whether it is measured for the entire solubilized product or for each individual component (carbohydrates such as starch, protein) that makes up the solubilized product. A "high solubilization rate" refers to a solubilized product with a total solubilization rate of 30% or more (preferably 40% or more, more preferably 60% or more), a protein solubilization rate of 75% or more (preferably 80% or more, more preferably 90% or more), and a starch solubilization rate of 75% or more (preferably 80% or more, more preferably 85% or more). The solubilization rate is measured using the method described in the Examples.

[0038] There are no limitations on the shear force to be applied, and it may be any value that is applied by the rotation of a stirrer in a batch-type device (autoclave, pressure kettle, etc.). When using an extruder, which is a continuous device, the shear force may be within a range that can be determined by the gap between the cylinder and the screw, the shape of the screw groove, the rotation speed of the screw, the meshing of the screws (in the case of a twin screw, whether the shafts rotate in the same direction or in different directions), the feed amount of the raw material, etc.

[0039] The above-mentioned heating and pressurization makes it possible to hydrolyze at least a portion of the hydrolyzable substance and / or amorphize at least a portion of the fibrous material. The degree of hydrolysis and amorphization can be confirmed for the solubilized material after adiabatic expansion, for example, by the test method described in the Examples.

[0040] For adiabatic expansion after heating and pressurization, the batch or continuous device (extruder) may be adjusted so that the pressure can be suddenly released and heating can be stopped, but it is preferable to release the pressure and instantly cool to 100°C within 1 second. When an extruder is used, the above requirements are met by discharging the mixture from the extruder outlet.

[0041] Examples of the form of the solubilized material include puffed material, granules, and combinations thereof. However, the form is not limited to these. The raw material expands by adiabatic expansion after heating and pressurization, but the form after production varies depending on the ingredients of the raw material. For example, if the raw material contains fiber, adiabatic expansion results in a puffed material (porous solubilized material), and if the raw material does not contain fiber or has a low fiber content, a granule is obtained. The solubilized material can have a length (major axis) of, for example, about 1 to 20 mm, and in the case of a puffed material, the density is 0.2 to 0.8 g / cm. 3 It is preferable that the degree of

[0042] When the solubilized material is granular, it is easily soluble in water, etc. On the other hand, even if the solubilized material is puffed, it has excellent solubility in water even if it is of a certain size (e.g., lumpy) because it is porous and has a large surface area. Furthermore, whether the solubilized material is granular or puffed, it has excellent handleability and processability when processed to produce other food materials. The result obtained by the above production method is a sterilized solubilized material, which can be used as a soluble food material, feed, etc.

[0043] The solubilized material is preferably obtained in a dry state. That is, it can be a dried puffed material, a dried granular material, or a combination thereof. Here, "dry" means that the solubilized material immediately after carrying out the production method contains almost no free water (generally meaning water in the raw material that allows molecules and particles to move freely. It is this free water that microorganisms can use for growth). By drying the solubilized material in this way, the effect is achieved that the obtained solubilized material does not spoil. From this perspective, it can be said that drying means that the obtained solubilized material does not spoil.

[0044] The heating and pressurization are preferably carried out using an extruder. The extruder is equipped with a temperature-controllable cylinder having a supply port and a discharge port, a rotatable screw inserted into the cylinder, and a drive unit for rotating the screw. The cylinder may be provided with a vent port, and a hopper may be connected to the supply port. Extruders are broadly classified into single-screw extruders with one screw and twin-screw extruders with two screws arranged to intermesh.

[0045] Twin-screw extruders are further divided into co-rotating twin-screw extruders, in which the screws rotate in the same direction, and counter-rotating twin-screw extruders, in which the screws rotate in opposite directions. Co-rotating twin-screw extruders include double-start and triple-start screw types, while counter-rotating twin-screw extruders include parallel-start and diagonal-start types. The configuration of the extruder can be determined appropriately depending on the type and amount of raw material to be fed.

[0046] When heating and pressurizing are performed using an extruder, the time from the start to the end of heating and pressurizing (i.e., until the start of adiabatic expansion) is determined by the length of the extruder, the number of rotations of the screw, the screw pitch, etc. Because heating and pressurizing can be performed efficiently using an extruder, the time from the start to the end of pressurization can be as short as, for example, 1 to 60 seconds.

[0047] By carrying out the above-mentioned production method, the raw materials are subjected to high temperatures, which allows for sufficient sterilization of contaminating bacteria in the raw materials. Here, "sufficient sterilization" means that no colonies of the contaminating bacteria to be eliminated are observed after enrichment culture in a liquid medium.

[0048] When soybeans or defatted soybeans and / or wheat are used as raw materials, the dried and puffed food material can be used as a raw material for soy sauce. In other words, it is possible to provide a soy sauce production method that includes a step of producing koji from the solubilized material obtained by the above-mentioned production method. By carrying out this production method, it is possible to obtain soy sauce with an excellent flavor and a deep taste.

[0049] In this case, there are two methods: one in which the raw materials are solubilized separately, and one in which the raw materials are mixed and processed to obtain solubilized products all at once. In the former method, the production method of the present invention is carried out separately on soybeans and wheat to obtain two types of solubilized products (which may be in the form of dried puffed food materials), and seed koji is added to a mixture of these two types without going through a steaming step to produce koji, which is used in the production of soy sauce. In the latter method, the production method of the present invention is carried out on a mixture of soybeans or defatted soybeans and wheat to obtain a solubilized product (which may be in the form of dried puffed food materials), and seed koji is added to the mixture without going through a steaming step to produce koji, which is used in the production of soy sauce.

[0050] The soy sauce may be any of dark soy sauce, light soy sauce, tamari soy sauce, re-brewed soy sauce, and white soy sauce, and various production methods such as the honjozo method can be adopted depending on the type of soy sauce. [Example]

[0051] The present invention will be described below with reference to examples, but the present invention is not limited to the following examples.

[0052] The solubilization rate was evaluated by the following method.

[0053] [Solubilization rate of solubilized material] The moisture content of the solubilized material was measured using a moisture meter. Based on this measurement, a weighed amount of solubilized material was taken so that the total weight was 5.0 g after excluding the moisture content. This was mixed with 50 g of water (to make the total weight 50 g, including the moisture content of the solubilized material), and the mixture was stirred and mixed in a mixer. The Brix value of the mixture was measured over time using an Atago PAL-1, and the sample when this value stabilized was used as the sample for measuring the solubilization rate. This measurement sample was filtered, and the residue (cake) and filtrate (solution) were separated. Each was dried, and the weight of the solids from the residue was defined as a gram, and the weight of the solids from the filtrate was defined as b gram, and the solubilization rate (%) was calculated by "b / 5 × 100".

[0054] [Protein solubilization rate] The mass percent of protein was measured according to Chapter 1, "General and Related Components," 2-4, "Combustion Method (Improved Dumas Method)" of the Standard Tables of Food Composition in Japan, 2015 Edition (7th revision). The mass percent of protein was also measured for untreated solid raw materials using the same method, and the solubilization rate was calculated from this protein ratio.

[0055] In the "combustion method (modified Dumas method)," a combustion total nitrogen analyzer is used. An appropriate amount of sample is weighed accurately to within 0.1 mg and measured using a method appropriate for the analyzer. A standard sample for creating a calibration curve, which has been weighed accurately to within 0.1 mg, is measured in advance, and the nitrogen content (g / 100g) in the sample is calculated from the calibration curve obtained. The amount of nitrogen (g / 100g) is calculated by (A / 1000 x 100) / W, and the protein content (g / 100g) is calculated by the amount of nitrogen (g / 100g) x (nitrogen-protein conversion factor). Here, A is the N (mg) detected from the calibration curve, and W is the amount of sample taken (g).

[0056] [Starch solubilization rate] The mass % of starch in the solubilized product was measured by iodine colorimetry. The mass % of starch in the untreated solid raw material was also measured by the same method, and the solubilization rate was calculated from the mass % ratio.

[0057] The iodine colorimetric method was performed according to the "Quantitative Determination of Amylose by Iodine Colorimetric Method" (p. 120) in "New Food Analysis Handbook" (Kenpakusha, 2000), edited by Sugawara Tatsuyuki and Maekawa Akio (2000) (first published November 20, 2000). A spectrophotometer was used as the analyzer. Measurements were performed using a reagent containing ethanol, 10% sodium hydroxide, 6 mol / L hydrochloric acid, and iodine solution (0.2% iodine, 2.0% potassium iodide) as follows: (1) 100 mg of defatted sample was swollen with 1 ml of ethanol and 10 ml of pure water, and then 2 ml of 10% sodium hydroxide was added. The sample was then left overnight in a refrigerator to undergo alkaline gelatinization. (2) Neutralize with 6 mol / L hydrochloric acid and adjust the volume to 100 ml. Transfer 5 ml of the solution to a 500 ml measuring flask, add 5 ml of iodine solution, and adjust the volume to 500 ml with pure water. (3) Read the absorbance at 660 nm. Prepare a control solution without adding the sample to serve as the blank. (4) Measure the color development of a mixture of amylose and amylovectin in an appropriate ratio, and use this as a calibration curve.

[0058] Example 1A A 1 / 1 (kg / kg) mixture of defatted soybeans and wheat was used as the raw material. This raw material can be used as a soy sauce raw material. To hydrolyze and solubilize the proteins, lipids, and sugars (carbohydrates) in the raw material, a mixture was prepared by adding 10% water by weight to the crystal moisture (10%) in the raw material. In this example, 90 g of dry matter and 10 g of water were contained in the raw material per 100 g of raw material. Since 10% by weight of water was added to the raw material, the amount of water added was 10 g per 100 g of raw material. This means that 20 g of water was present per 90 g of dry matter (0.22 parts by weight of water per 1 g of dry matter).

[0059] Next, the prepared raw materials were continuously fed (feeding rate: 120 kg / h) through the raw material inlet of the twin-screw extruder, while being conveyed, mixed, heated (300°C, 84.2 atmospheres), and compressed within the screw. After a residence time of 10 seconds, the raw materials were immediately released into the atmosphere, and a soy sauce raw material (solubilized material, moisture content 5%) was obtained that was instantaneously cooled (within 1 second) to below 100°C. The solubilized material was obtained as a puffed product. The solubilization rate of the entire solubilized material and the solubilization rates of the protein and starch contained in the solubilized material were measured using the methods described above, and the results are shown in Table 2.

[0060] Example 1B A solubilized product was produced in the same manner as in Example 1A except that the pressure was set to 134.2 atmospheres, and a solubilized product similar to that in Example 1A was obtained in the form of a puffed product.

[0061] Example 2A A solubilized product was produced in the same manner as in Example 1A, except that the temperature was 350°C and the pressure was 163.2 atmospheres. The solubilization rate of the entire solubilized product and the solubilization rates of the protein and starch contained in the solubilized product were measured by the methods described above, and the results are shown in Table 2.

[0062] Example 2B A solubilized product was produced in the same manner as in Example 2A except that the pressure was set to 213.2 atmospheres, and a solubilized product similar to that in Example 2A was obtained in the form of a puffed product.

[0063] Example 3A A solubilized product was produced in the same manner as in Example 1A, except that the temperature was 370°C and the pressure was 207.8 atmospheres. The solubilization rate of the entire solubilized product and the solubilization rates of the protein and starch contained in the solubilized product were measured by the methods described above, and the results are shown in Table 2.

[0064] Example 3B A solubilized product was produced in the same manner as in Example 3A except that the pressure was set to 257.8 atmospheres, and a solubilized product similar to that in Example 3A was obtained in the form of a puffed product.

[0065] Example 4A A solubilized product was produced in the same manner as in Example 1A, except that the temperature was 374°C and the pressure was 218.3 atmospheres. The solubilization rate of the entire solubilized product and the solubilization rates of the protein and starch contained in the solubilized product were measured by the methods described above, and the results are shown in Table 2.

[0066] Example 4B A solubilized product was produced in the same manner as in Example 4A except that the pressure was set to 268.3 atmospheres, and a solubilized product similar to that in Example 4A was obtained in the form of a puffed product.

[0067] (Comparative Example 1) A treated product was obtained in the same manner as in Example 1A, except that the temperature was 150°C and the pressure was 4.7 atmospheres. The solubilization rate of the treated product and the solubilization rates of the protein and starch contained in the treated product were measured by the methods described above, and the results are shown in Table 2.

[0068] (Comparative Example 2) A solubilized product was produced in the same manner as in Example 1A, except that the temperature was 200°C and the pressure was 15.3 atmospheres. The solubilization rate of the entire solubilized product and the solubilization rates of the protein and starch contained in the solubilized product were measured by the methods described above, and the results are shown in Table 2.

[0069] (Comparative Example 3) A solubilized product was produced in the same manner as in Example 1A, except that the temperature was 250°C and the pressure was 39.3 atmospheres. The solubilization rate of the entire solubilized product and the solubilization rates of the protein and starch contained in the solubilized product were measured by the methods described above, and the results are shown in Table 2.

[0070] Comparative Example 4 An attempt was made to treat the material in the same manner as in Example 1A at a temperature of 400° C. and a pressure of 218 atmospheres or more, but carbonization occurred.

[0071] [Table 2]

[0072] FIG. 2 shows the relationship between the solubilization rate of total solubilisate, protein and starch and temperature as shown in the table above.

[0073] [Stability test] The solubilized products (soy sauce raw materials) obtained in Examples 3A and 4A were stored at 25°C and a relative humidity of 60%RH for one year, and no changes were observed, demonstrating excellent storage stability.

[0074] [Evaluation of sterilization status] The dried raw material (the soy sauce raw material solubilized in Example 4A) continuously discharged by heating in an extruder was aseptically collected, and 5 g was placed in a 500 ml flask containing 50 ml of sterilized water. Microbial enrichment culture was performed for 7 days in a shaking incubator at 30 °C. As a comparative example, 5 g of the raw material prepared before heating in the extruder was placed in a 500 ml flask and autoclaved at 120 °C for 20 minutes. Then, 50 ml of sterilized water was added and cultured for 7 days in a shaking incubator at 30 °C. 1 ml of each of the cultured liquids was applied to an agar plate for detecting general viable bacteria and cultured at 30 °C for 7 days. The presence or absence of sterilization was determined by detecting the number of microbial colonies growing on the agar medium. As a result, no general viable bacterial colonies were detected in the soy sauce raw material obtained in Example 4A, confirming that it was sufficiently sterilized. On the other hand, the raw material sterilized in the autoclave in the comparative example had 10 colonies per ml after enrichment culture. 7 More than 100 common live bacteria were detected, and the solid raw material could not be sterilized by normal autoclave heating.

[0075] Solubilisates were produced using raw materials other than defatted soybeans / wheat as follows.

[0076] Example 5 A solubilized product was obtained in the same manner as in Example 1A, except that 5 kg of brown rice was used instead of the 1 / 1 (kg / kg) mixture of defatted soybeans and wheat, and the amount of water per 1 g of dry matter and other conditions were the same as in Example 1A. The solubilization rate of the entire solubilized product obtained was measured by the above-mentioned method and was found to be 97%.

[0077] Example 6 A solubilized product was obtained in the same manner as in Example 1A, except that 5 kg of corn was used instead of the 1 / 1 (kg / kg) mixture of defatted soybeans and wheat, and the amount of water per 1 g of dry matter and other conditions were the same as in Example 1A. The solubilization rate of the entire solubilized product obtained was measured by the above-mentioned method and was found to be 98%.

[0078] Example 7 3 kg of the soy sauce solubilized material (soy sauce raw material) obtained in Example 4A was dispersed in sterilized water, and 3 liters of a solution prepared by dispersing soy sauce koji starter mold in sterilized water was added to the soy sauce raw material so that the mixture was uniform. Culture was conducted for 3 days at 30°C with aeration (koji production process) to obtain koji. 3 liters of saline solution with a salt concentration of 26% was added and mixed to obtain a mash. The mash was fermented at 30°C for 1 month, and then yeast and lactic acid bacteria were added to mature the mash. It was then pressed and clarified and filtered to obtain a high-nitrogen kiage soy sauce with a high concentration of 2.0%.

[0079] This was pasteurized (85°C for 30 minutes), and soy sauce with excellent umami, richness, and aroma was produced in a short period of time (3 months, compared to the usual aging period of 6 months) (Table 3). The sterilization methods for the raw materials used in the usual soy sauce production of Comparative Example 5 were a steaming process (heating in an autoclave at 125°C for 3 minutes) for the hydrated defatted soybeans and a roasting process (heating in a roaster at 500°C for 3 minutes) for the wheat. After each heat treatment, the ingredients were mixed and koji mold was cultured in the koji-making process. In particular, because the steaming process does not sufficiently sterilize thermophilic bacteria, viable bacteria also proliferated considerably during the koji mold culture in the koji-making process.

[0080] [Table 3]

[0081] The sensory evaluation of the obtained soy sauce was carried out by a blind panel of five people in comparison with the comparative example.

Claims

1. A method for producing a solubilized material from a solid raw material containing at least one component selected from the group consisting of a hydrolyzable substance selected from the group consisting of a protein, a carbohydrate, and a lipid, and a fiber, comprising the steps of: The method includes a step of bringing the raw material and water corresponding to 0.04 to 2.4 parts by weight per 1 part by weight of the dry matter amount of the raw material into coexistence, applying a shear force in a heated and pressurized state to hydrolyze at least a part of the hydrolyzable substance and / or amorphize at least a part of the fibrous material, and then releasing the pressure to allow adiabatic expansion, The heating and pressurizing are carried out at a temperature T selected from the range of 300 to 374°C and a pressure P, and the pressure P is set to be equal to or higher than the saturated vapor pressure of water at the temperature T and equal to or lower than the saturated vapor pressure + 50 atmospheres.

2. The method according to claim 1, wherein the temperature T is selected from the range of 300 to 370°C.

3. 3. The method according to claim 1, wherein the heating and pressurizing are performed inside an extruder, and the adiabatic expansion is performed by discharging the mixture from a discharge port of the extruder.

4. The method of claim 3 , wherein the extruder is a twin-screw extruder.

5. The method according to any one of claims 1 to 4, wherein the raw material is at least one selected from the group consisting of foodstuffs, feedstuffs, and factory residues generated in the processing of these.

6. The manufacturing method according to any one of claims 1 to 5, wherein the raw material contains a fibrous material.

7. A manufacturing method described in any one of claims 1 to 6, wherein the solubilization rate of the solubilized product produced is 30% or more as measured by the following measurement method. [Solubilization rate of solubilized material: The water content of the solubilized material is measured using a moisture meter. Based on this measurement, the solubilized material is weighed out so that the water content is 5.0 g, and this is mixed with 50 g of water (to make 50 g including the water content contained in the solubilized material), and stirred and mixed. The Brix value of the mixture is measured over time, and the sample for measuring the solubilization rate is the one whose value has stabilized. This measurement sample is filtered, and the filtrate (solution) is separated and dried. The weight of the solid content resulting from the filtrate is defined as b grams, and the solubilization rate (%) is calculated by "b / 5 x 100".]

8. The method according to any one of claims 1 to 7, wherein the raw material is soybeans, defatted soybeans, or wheat, and the solubilized product is for use in soy sauce production.

9. A method for producing soy sauce, comprising a step of producing koji from the solubilized material obtained by the production method according to claim 8.

10. A method for improving the solubilization rate of a solubilized product obtained from a solid raw material containing at least one component selected from the group consisting of a hydrolyzable substance selected from the group consisting of proteins, carbohydrates, and lipids, and a fiber, by the following measurement method: The solubilized material is obtained by causing the raw material to coexist with water in an amount corresponding to 0.04 to 2.4 parts by weight per 1 part by weight of the dry matter of the raw material, applying a shear force under heating and pressure, thereby causing hydrolysis of at least a part of the hydrolyzable substance and / or amorphization of at least a part of the fibrous material, and then releasing the pressure to allow adiabatic expansion, The heating and pressurizing are carried out at a temperature T selected from the range of 300°C to 370°C and a pressure P, and the pressure P is set to be equal to or higher than the saturated vapor pressure of water at the temperature T and equal to or lower than the saturated vapor pressure + 50 atmospheres. [Solubilization rate of solubilized material: The water content of the solubilized material is measured using a moisture meter. Based on this measurement, the solubilized material is weighed out so that the water content is 5.0 g, and this is mixed with 50 g of water (to make 50 g including the water content contained in the solubilized material), and stirred and mixed. The Brix value of the mixture is measured over time, and the sample for measuring the solubilization rate is the one whose value has stabilized. This measurement sample is filtered, and the filtrate (solution) is separated and dried. The weight of the solid content resulting from the filtrate is defined as b grams, and the solubilization rate (%) is calculated by "b / 5 x 100".]

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