Manufacturing method for biodegradable processed products

Abstract

The present invention provides a biodegradable processed product whose main component is starch, a method for producing the biodegradable processed product, and a system for producing the biodegradable processed product. [Solution] The method for producing biodegradable processed products includes a mixing process (ST1) for mixing starch with water, a heating process (ST2) for heating the starch mixed with water to gelatinize it, a sheet processing process (ST3) for processing the gelatinized starch into a sheet, a drying process (ST4) for drying the sheet-like starch, and a molding process (ST5) for processing the dried sheet-like starch into a biodegradable processed product.

Description

[Technical Field]

[0001] The present disclosure relates to starch-based Living Manufacturing methods for degradable processed products By law Regarding. [Background technology]

[0002] Conventionally, tableware (biodegradable processed products) such as cutlery such as spoons and plates that are made primarily from natural materials and can be decomposed by microorganisms have been proposed. Patent Document 1 discloses a method for producing biodegradable processed products by adding water to starch, protein, cellulose fiber, polyphenols, and sodium chloride, kneading and shaping the mixture, and then heat-treating the shaped mixture. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 4077026 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the prior art, including Patent Document 1, has the problem that the manufacturing process is complicated because multiple compositions are mixed. Also, when mixing animal-derived proteins such as gelatin or collagen, there is a problem that the manufactured processed product may not be available due to religious restrictions, etc.

[0005] Therefore, the present disclosure provides a method for producing starch-based Living Manufacturing methods for degradable processed products The law The purpose is to provide. [Means for solving the problem]

[0006] The inventors of the present disclosure made sincere efforts to solve the above problems and discovered a method for producing biodegradable processed products that use starch as the main component and have practical strength and lifespan, thereby completing the present invention.

[0009] The method for producing a biodegradable processed product of the present disclosure is a method for producing a biodegradable processed product containing 85% to 90% by weight of starch that has been gelatinized while removing gas remaining inside and then re-solidified, and includes a mixing step of mixing starch with water, a heating step of heating the starch mixed with water while stirring to gelatinize the starch while removing gas remaining inside, a sheet processing step of processing the gelatinized starch into a sheet, a drying step of drying the sheet-like starch, and a molding step of processing the dried sheet-like starch into a biodegradable processed product. The drying process includes a first drying process in which air at a temperature of 20°C to 23°C and a humidity of 80% to 85% is blown for 8 minutes, a second drying process in which air at a temperature of 12°C to 20°C and a humidity of 70% to 75% is blown for 8 minutes, a third drying process in which air at a temperature of 6°C to 10°C and a humidity of 50% to 60% is blown for 5 minutes, and a fourth drying process in which air at a temperature of 5°C to 8°C and a humidity of 43% to 50% is blown for 2 minutes. nothing. [Effects of the Invention]

[0011] According to the present disclosure, biodegradable processed products can be produced using starch as the main component. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is an explanatory diagram showing the configuration of a main part of a manufacturing system for biodegradable processed products according to an embodiment of the present disclosure; [Figure 2] 1 is a flow diagram of a method for producing a biodegradable processed product according to one embodiment of the present disclosure. [Figure 3] 1 is a table showing main parameters of drying conditions for examples and comparative examples of a method for producing a biodegradable processed product according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0013] An embodiment of the present disclosure will be described in detail below using the drawings. The configurations, shapes, etc. described below are examples for explanatory purposes and can be modified as appropriate depending on the specifications of the biodegradable processed products and the biodegradable processed product manufacturing system. In addition, the drawings used in the following description may be partially enlarged, and the dimensions and proportions of each component may not be the same as in reality. In the following, corresponding elements in all drawings will be assigned the same reference numerals, and duplicate explanations will be omitted.

[0014] First, referring to Figure 1, the configuration of the main parts of a manufacturing system 1 that uses starch and water as the main ingredients to manufacture biodegradable processed products such as spoons, knives, and plates will be described. The following describes an example in which cornstarch 2 is used as the main starch ingredient. The manufacturing system 1 is configured with a mixing device 4, a heating device 8, a sheet processing device 13, a drying device 20, and a molding device 27.

[0015] In Figure 1, mixing device 4 is, for example, a mixer, and cornstarch 2 and water 3 fed into hopper 5 are mixed and stirred with rotating mixing blades 6, kneading them into a mixture 7 of cornstarch 2 and water 3. Note that mixture 7 may contain an edible color such as vegetable charcoal color, as long as the strength and lifespan (storage period) of the biodegradable processed product 29 to be manufactured are not affected.

[0016] The heating device 8 heats the mixture 7 of cornstarch 2 and water 3 while conveying it sequentially through a first heating zone 10 and a second heating zone 11 using a screw conveyor 9. The first heating zone 10 and the second heating zone 11 can be set to different temperatures. The mixture 7 of cornstarch 2 and water 3 is heated in the first heating zone 10 and the second heating zone 11 while being stirred by the screw conveyor 9, and is converted into gelatinized (gelatinized) cornstarch 2 (hereinafter referred to as "gelatinized cornstarch 12"). In this way, the heating device 8 heats and gelatinizes the cornstarch 2 (starch) mixed with water 3. The number of heating zones provided in the heating device 8 is not limited to two (the first heating zone 10 and the second heating zone 11), and may be one or three or more.

[0017] In FIG. 1, the sheet processing apparatus 13 is configured to include an extrusion device 14 and a cutting device 17. The extrusion device 14 extrudes gelatinized cornstarch 12 through a die 15 (mold) and processes it into a continuous sheet 16 of a predetermined thickness. The width of the continuous sheet 16 is set according to the size, specifications, etc. of the molding processing apparatus 27. The thickness of the continuous sheet 16 is set according to the biodegradable processed product 29 to be manufactured. The cutting device 17 cuts the continuous sheet 16 to a predetermined length with a cutter 18 and processes it into sheet-like cornstarch 2 (hereinafter referred to as "gelatinized cornstarch sheet 19"). The length of the gelatinized cornstarch sheet 19 is set according to the size, specifications, etc. of the molding processing apparatus 27.

[0018] In this way, the sheet processing device 13 processes the gelatinized cornstarch 12 (gelatinized starch) into a gelatinized cornstarch sheet 19 (gelatinized starch in a sheet form). The mixer 4, heater 8, and sheet processing device 13 may also be configured with an extruder that transports cornstarch 2 and water 3 charged into a hopper using a screw conveyor 9, heats and kneads the cornstarch 2 and water 3 to gelatinize them, and extrudes them through a die 15 to process them into a continuous sheet 16, and a cutting device 17 that cuts the continuous sheet 16 to the length of the gelatinized cornstarch sheet 19.

[0019] 1, drying device 20 dries gelatinized cornstarch sheet 19 while conveying it sequentially through a first drying area 22, a second drying area 23, a third drying area 24, and a fourth drying area 25 on a belt conveyor 21. The first drying area 22, the second drying area 23, the third drying area 24, and the fourth drying area 25 each spray air at different temperatures and humidities to cool and dry gelatinized cornstarch sheet 19. As gelatinized cornstarch sheet 19 is cooled and dried in drying device 20, it is re-solidified (beta-phased) and changes into re-solidified cornstarch sheet 26 (re-solidified sheet-like starch).

[0020] In this way, the drying device 20 dries the gelatinized cornstarch sheet 19 (gelatinized starch in sheet form). The number of drying zones provided in the drying device 20 is not limited to four (first drying zone 22, second drying zone 23, third drying zone 24, and fourth drying zone 25), and may be one to three, or five or more. Furthermore, the manufacturing system 1 may be configured to include four drying devices each having one drying zone, instead of the drying device 20 having four drying zones.

[0021] 1 , the molding device 27 is, for example, a press processing device, which sandwiches a resolidified cornstarch sheet 26 (resolidified starch sheet) between a pair of dies 28 and applies pressure to cut and shape the sheet into a biodegradable processed product 29. The dies 28 are formed with an uneven shape that corresponds to the shape of the processed biodegradable processed product 29. By exchanging the dies 28, the molding device 27 processes the resolidified cornstarch sheet 26 into desired biodegradable processed products 29, such as cutlery such as spoons, forks, and knives, and tableware such as plates and cups. In this way, the molding device 27 processes the resolidified cornstarch sheet 26 (dried and resolidified starch sheet) into a biodegradable processed product 29.

[0022] Next, a method for manufacturing a biodegradable processed product 29 containing starch as a main component using the manufacturing system 1 will be described with reference to the flow chart in Fig. 2. The following describes an example of a method for manufacturing a spoon (biodegradable processed product 29) using corn starch 2 as the starch in Example 1 shown in Fig. 3.

[0023] In Figure 2, cornstarch 2 (starch) and water 3 are first mixed in a hopper 5 of a mixer 4 (ST1: mixing step). In Example 1, 1 kg of 100-mesh cornstarch 2 is mixed with 140 cc of water 3. In this case, for example, when producing a black spoon, 8 mg of plant carbon powder pigment is mixed with 1 kg of 100-mesh cornstarch 2.

[0024] Next, a mixture 7 of cornstarch 2 and water 3 (starch mixed with water 3) is heated in a heating device 8 to gelatinize it (ST2: heating step). In Example 1, the mixture 7 is transported by a screw conveyor 9 and heated for 5 minutes in a first heating zone 10 set at 50°C (first heating step), and then heated for 5 minutes in a second heating zone 11 set at 78°C (second heating step). By heating the mixture 7 while stirring it on the screw conveyor 9 and increasing the temperature in two stages in the first heating zone 10 and the second heating zone 11, gas remaining inside the gelatinized cornstarch 2 (gelatinized cornstarch 12) is eliminated.

[0025] In FIG. 2, the gelatinized cornstarch 2 (gelatinized cornstarch 12) is then processed into a continuous sheet 16 of a predetermined thickness using an extrusion device 14 (extrusion step), and cut to a predetermined length using a cutting device 17 (cutting step), to form a sheet-like cornstarch 2 (gelatinized cornstarch sheet 19) (ST3: sheet processing step). That is, in the sheet processing step (ST3), the gelatinized starch (cornstarch 2) is processed into a sheet. In the spoon of Example 1, the gelatinized cornstarch 12 is processed into a gelatinized cornstarch sheet 19 having a thickness of 3 mm to 4 mm. At this point, the gelatinized cornstarch sheet 19 is hot and soft.

[0026] Next, the sheet-like cornstarch 2 (gelatinized cornstarch sheet 19) is dried in a drying device 20 and processed into a re-solidified sheet-like cornstarch 2 (re-solidified cornstarch sheet 26) (ST4: drying step). That is, in the drying step (ST4), the sheet-like gelatinized starch (cornstarch 2) is dried. In Example 1, while being transported on the belt conveyor 21, the gelatinized cornstarch sheet 19 is dried by blowing air at a temperature of 20°C to 23°C and a humidity of 80% to 85% in the first drying area 22 for 8 minutes (first drying step), air at a temperature of 12°C to 20°C and a humidity of 70% to 75% in the second drying area 23 for 8 minutes (second drying step), air at a temperature of 6°C to 10°C and a humidity of 50% to 60% in the third drying area 24 for 5 minutes (third drying step), and air at a temperature of 5°C to 8°C and a humidity of 43% to 50% in the fourth drying area 25 for 2 minutes (fourth drying step).

[0027] In Example 1, the temperature and humidity are gradually lowered through the first drying step, the second drying step, and the third drying step, and the moisture inside the gelatinized cornstarch sheet 19 is evaporated and the gelatinized cornstarch sheet 19 is re-solidified (beta-formed), thereby transforming the gelatinized cornstarch sheet 19 into a re-solidified cornstarch sheet 26 with few cracks on the surface and high strength and toughness. Furthermore, by adding a fourth drying step in which air at a relatively low temperature and low humidity is blown in, the shape of the finally formed biodegradable processed product 29 is stabilized.

[0028] In FIG. 2, the dried sheet-like cornstarch 2 (resolidified cornstarch sheet 26) is then processed into a biodegradable processed product 29 in a molding device 27 (ST5: molding step). That is, in the molding step (ST5), the dried and resolidified sheet-like starch (cornstarch 2) is processed into a biodegradable processed product 29. The molding step (ST5) is performed within 30 minutes after the drying step (ST4). It is desirable to perform the molding step (ST5) immediately after the drying step (ST4). In Example 1, the resolidified cornstarch sheet 26 is processed into a spoon (biodegradable processed product 29) by pressing in the molding device 27.

[0029] Thus, the biodegradable processed product 29 (spoon) containing 85 to 90% by weight of gelatinized and re-solidified cornstarch 2 (starch) produced by the manufacturing method of Example 1 has strength and lifespan sufficient for practical use. Note that the proportion of gelatinized and re-solidified cornstarch 2 contained in the biodegradable processed product 29 is preferably 87% by weight from the viewpoint of strength and lifespan.

[0030] If the proportion of gelatinized and re-solidified cornstarch 2 contained in the biodegradable processed product 29 is less than 85% by weight, i.e., if there is a lot of residual moisture, the manufactured biodegradable processed product 29 will be soft and its shape will not be stable, making it unsuitable for practical use. Also, if the proportion of gelatinized and re-solidified cornstarch 2 contained in the biodegradable processed product 29 is more than 90% by weight, i.e., if there is little residual moisture, the manufactured biodegradable processed product 29 will crack and break, making it unsuitable for practical use.

[0031] Next, Comparative Examples 1 to 3 of the method for producing the biodegradable processed product 29 will be described with reference to Fig. 3. Comparative Examples 1 to 3 are the same as Example 1 except for the drying conditions in the drying step (ST4).

[0032] In Comparative Example 1, in the drying step (ST4), air at a temperature of 30°C to 35°C and a humidity of 90% to 95% is blown into the first drying area 22 for 10 minutes (first drying step), air at a temperature of 20°C to 25°C and a humidity of 70% to 75% is blown into the second drying area 23 for 10 minutes (second drying step), and air at a temperature of 10°C to 15°C and a humidity of 50% to 60% is blown into the third drying area 24 for 7 minutes (third drying step) to dry the gelatinized cornstarch sheet 19.

[0033] In Comparative Example 2, in the drying step (ST4), air at a temperature of 30°C to 35°C and a humidity of 90% to 95% is blown into the first drying area 22 for 15 minutes (first drying step), air at a temperature of 20°C to 30°C and a humidity of 70% to 80% is blown into the second drying area 23 for 15 minutes (second drying step), and air at a temperature of 12°C to 20°C and a humidity of 60% to 70% is blown into the third drying area 24 for 5 minutes (third drying step) to dry the gelatinized cornstarch sheet 19.

[0034] In Comparative Example 3, in the drying step (ST4), air at a temperature of 23°C to 30°C and a humidity of 85% to 90% is blown into the first drying area 22 for 15 minutes (first drying step), air at a temperature of 20°C to 25°C and a humidity of 65% to 70% is blown into the second drying area 23 for 10 minutes (second drying step), and air at a temperature of 15°C to 20°C and a humidity of 55% to 60% is blown into the third drying area 24 for 10 minutes (third drying step) to dry the gelatinized cornstarch sheet 19.

[0035] In Comparative Examples 1 to 3, the fourth drying step, which is the fourth stage in the drying step (ST4), was not carried out.

[0036] 3, in Comparative Examples 1 and 2, the first stage (first drying step) is at a higher temperature and humidity than in Example 1. The spoons (biodegradable processed products 29) manufactured by the manufacturing methods of Comparative Examples 1 and 2 break after molding, or have many deep cracks on the surface of the spoon after molding, resulting in low strength and lacking strength and lifespan sufficient for practical use.

[0037] In Comparative Example 3, the third stage (third drying step) is at a higher temperature and humidity than in Example 1. The spoon (biodegradable processed product 29) manufactured by the manufacturing method of Comparative Example 3 is deformed after molding, and has low strength after molding, so it does not have the strength or lifespan to withstand practical use.

[0038] As explained above, the method for producing biodegradable processed product 29 of the present disclosure includes a mixing step (ST1) of mixing starch (cornstarch 2) with water 3, a heating step (ST2) of heating and gelatinizing the starch mixed with water 3 (mixture 7), a sheet processing step (ST3) of processing the gelatinized starch (gelatinized cornstarch 12) into a sheet, a drying step (ST4) of drying the starch sheet (gelatinized cornstarch sheet 19), and a molding step (ST5) of processing the dried starch sheet (resolidified cornstarch sheet 26) into biodegradable processed product 29. This allows the production of biodegradable processed product 29 whose main component is starch (cornstarch 2).

[0039] Although the above description has been given of the production of biodegradable processed product 29 using corn starch 2 as the starch main raw material, biodegradable processed product 29 can also be produced using starches other than corn starch 2 as the raw material. For example, natural starches derived from natural products such as corn starch (corn starch 2), rice starch (rice flour), wheat starch (wheat flour), potato starch (potato starch), sweet potato starch (sweet potato flour), and tapioca starch (tapioca starch) can be used as the raw material for biodegradable processed product 29. Furthermore, not only a single starch but also two or more types of starches may be used as the raw material for biodegradable processed product 29. [Industrial Applicability]

[0040] It is possible to provide a biodegradable processed product containing starch as a main component, a method for producing the biodegradable processed product, and a system for producing the biodegradable processed product. [Explanation of symbols]

[0041] 1. Manufacturing System 2 cornstarch 3 water 4 Mixing device 8 Heating device 13 Sheet processing equipment 20 Drying equipment 27 Molding processing equipment 29 Biodegradable processed products

Claims

1. A method for producing a biodegradable processed product containing 85% to 90% by weight of starch that has been gelatinized and then resolidified while removing gas remaining inside, a mixing step of mixing starch and water; a heating step of heating the starch mixed with the water while stirring to gelatinize the starch while removing any gas remaining inside; a sheet processing step of processing the gelatinized starch into a sheet; a drying step of drying the starch sheet; a molding process step of processing the dried sheet-like starch into a biodegradable processed product, The drying step includes: a first drying step of blowing air at a temperature of 20°C to 23°C and a humidity of 80% to 85% for 8 minutes; a second drying step in which air having a temperature of 12°C to 20°C and a humidity of 70% to 75% is blown for 8 minutes; a third drying step in which air having a temperature of 6°C to 10°C and a humidity of 50% to 60% is blown for 5 minutes; A method for manufacturing biodegradable processed products, including a fourth drying step in which air at a temperature of 5 to 8°C and a humidity of 43 to 50% is blown for 2 minutes.

2. 2. The method for producing a biodegradable processed product according to claim 1, wherein the molding step processes the dried starch in a sheet form into the biodegradable processed product by pressing.

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