Instant noodle manufacturing method

Abstract

To provide a method for producing instant noodles, which makes it possible to improve noodle productivity and a mouthfeel and saltiness of the noodles, and reduce a content of sodium.SOLUTION: A method for producing instant noodles is provided: in which, without using salt in water for kneading, main base powder and the water for kneading, which contains 8-40 g of potassium lactate, 1-5 g of sodium glutamate, and 0.5-3 g of gluconate with respect to 1 kg of the main base powder, are mixed and kneaded to make noodle dough. The noodle dough is shaped into noodles, and as needed, the noodles are steamed and then dried. This method improves noodle productivity and a mouthfeel and saltiness of the noodles, and reduce a content of sodium.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a method for producing instant noodles with a reduced sodium content.

Background Art

[0002] In recent years, many so-called low-salt products with a reduced sodium content have been launched for the prevention of hypertension. In the 2010 edition of the "Dietary Reference Intakes for Japanese" by the Ministry of Health, Labour and Welfare, the daily salt intake target value was less than 9 g for adult men and less than 7.5 g for adult women. In contrast, in the 2015 edition of the "Dietary Reference Intakes for Japanese", the daily salt intake target value was less than 8 g for adult men and less than 7 g for adult women, and in the 2020 edition, the daily salt intake target value was less than 7.5 g for adult men and less than 6.5 g for adult women. Since the daily salt intake target values have decreased respectively, it is considered that the trend towards further reducing salt will continue in the future.

[0003] As a technique for reducing the salt content of noodles, for example, Patent Documents 1 to 6 are disclosed.

[0004] Patent Document 1 describes a technique for udon noodles having sufficient firmness even with a smaller amount of salt added than in the past. In the udon noodles containing wheat flour, a paste composition, and water, the udon noodles containing xanthan gum, roasted bean gum, and guar gum as the paste composition are described.

[0005] Patent Document 2 describes noodles and a method for producing noodles in which the content of sodium salts, especially salt and sodium carbonate, is reduced or zero, and the noodles contain either or both of isomaltulose and reduced isomaltulose.

[0006] Patent Document 3 describes a method for producing noodles that uses magnesium chloride contained in bittern to produce salt-free noodles without adding salt.

[0007] Furthermore, Patent Documents 4-6 describe a technology for instant noodles that reduces salt content by adding potassium lactate. While these technologies are superior to existing technologies in terms of noodle-making properties, texture, and flavor when it comes to reducing salt content, increasing the amount of potassium lactate added to enhance saltiness results in a bitter taste, a softer texture, and poorer noodle-making properties. Therefore, there are still challenges in achieving better noodle-making properties, texture, and a salty taste that is more like table salt. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Patent Publication No. 2015-84772 [Patent Document 2] Patent No. 4644298 [Patent Document 3] Patent No. 4761534 [Patent Document 4] Patent No. 6353499 [Patent Document 5] Patent No. 6334623 [Patent Document 6] Japanese Patent Publication No. 2019-140963 [Overview of the project] [Problems that the invention aims to solve]

[0009] The present invention aims to provide a method for producing instant noodles that have excellent noodle-making properties, superior texture, and a good salty taste, while also having reduced sodium content. [Means for solving the problem]

[0010] The inventors diligently researched salt reduction techniques using potassium lactate, aiming to further improve the texture and saltiness to resemble that of table salt, and as a result, they discovered the present invention.

[0011] In other words, a method for producing instant noodles, comprising the steps of: mixing a main ingredient flour and kneading water to make dough; producing noodles from the dough; and drying the noodles, wherein the kneading water does not contain salt, and the kneading water contains 8 to 40 g of potassium lactate, 1 to 5 g of glutamate, and 0.5 to 3 g of gluconate per 1 kg of the main ingredient flour. [Effects of the Invention]

[0012] The present invention provides a method for producing instant noodles with excellent noodle-making properties, superior texture, and a good salty taste, while also having reduced sodium content. [Modes for carrying out the invention]

[0013] The present invention will be described in detail below. However, the present invention is not limited to the following description.

[0014] 1. Raw material formulation The main flours used in the production of fried noodles according to the present invention include cereal flours such as wheat flour (including durum flour), buckwheat flour, barley flour, and rice flour, as well as various starches such as potato starch, tapioca starch, and corn starch. These may be used individually or in combination. As the starches, raw starch, pregelatinized starch, and modified starches such as acetylated starch, etherified starch, and cross-linked starch may also be used.

[0015] In this invention, 8 to 40 g of potassium lactate is dissolved in the kneading water and added to 1 kg of these main raw material flours. If the amount of potassium lactate is less than 8 g, the dough will lack extensibility and viscoelasticity, making it difficult to obtain sufficient noodle-making properties, elastic texture, and sufficient saltiness. With potassium lactate alone, if the amount added exceeds 20 g, stickiness occurs, the noodle-making properties deteriorate, and the texture becomes soft. However, in this invention, by adding monosodium glutamate, the noodle-making properties and texture are improved, making it possible to add up to 40 g of potassium lactate.

[0016] Furthermore, in this invention, 1 to 5 g of glutamate is dissolved in the kneading water and added to 1 kg of the main raw material flour. Examples of glutamate include monosodium glutamate and potassium glutamate. Monosodium glutamate, in particular, is used as an umami seasoning and is also used as an ingredient in the flavoring liquid for instant noodles. However, it is rarely added to the kneading water, and in situations where a large amount of salt is added to the kneading water, it is not possible to know the effect of glutamate on improving noodle-making properties and texture. The effect of glutamate on improving noodle-making properties and texture was discovered for the first time in the context of reducing salt content. In addition, unlike potassium lactate, glutamate has the effect of firming the texture even when only a small amount is added, so it can prevent deterioration of texture even when a large amount of potassium lactate is added. If the amount is less than 1 g, it is difficult to obtain sufficient improvement in noodle-making properties and texture, and if it is more than 5 g, the texture becomes too hard and the taste of glutamate becomes too strong. While monosodium glutamate (MSG) offers superior flavor compared to other glutamates, potassium glutamate can be used to further reduce salt content, provided it does not affect the flavor.

[0017] Furthermore, in this invention, 0.5 to 3 g of a gluconate, such as sodium gluconate or potassium gluconate, is added per 1 kg of main flour. Either a sodium salt or a potassium salt can be used as the gluconate, but a potassium salt is preferable in terms of reducing sodium content. Adding gluconate alone has little effect on improving noodle-making properties, and its effect on improving texture and enhancing saltiness is weaker compared to glutamate. However, it can mask the bitterness caused by adding a large amount of potassium lactate, and a salty flavor can be obtained. Below 0.5 g, it is difficult to obtain a flavor improvement effect, and above 3 g, not only does the texture become hard, but the taste of gluconate also becomes strong.

[0018] As other auxiliary raw materials, in the present invention, an alkaline agent, phosphates, various thickeners, noodle quality improvers, edible oils and fats, pH adjusters, various pigments such as carotene pigments, and preservatives, etc., which are generally used in the production of instant noodles, can be added. These may be added together with the main raw material powder, or dissolved or suspended in kneading water and then added. Regarding salt, it is not used in the production of noodles except when used as a seasoning liquid for noodles. Also, when adding an alkaline agent such as carbonate or phosphates, adding a sodium salt will not have a great impact on salt reduction because the sodium content contained is small. However, in order to further reduce salt, it is preferable not to use sodium salts as much as possible, such as using potassium salts, etc.

[0019] 2. Mixing and kneading process The method for producing the noodle dough according to the present invention may be carried out according to a conventional method. That is, kneading may be performed using a batch mixer, a flow jet mixer, a vacuum mixer, etc. so that the noodle raw material powder and the kneading water are uniformly mixed, and a crumbly dough may be produced.

[0020] 3. Noodle making process Next, noodle strands are produced from the produced dough. As the production method, it may be carried out according to a conventional method. That is, after the dough is made into a thick noodle strip by a roll, it is made into a noodle strip by compounding, etc., and then rolled a plurality of times by a roll to obtain a predetermined noodle strip thickness, and then the noodle strip is cut out by a cutting roll called a cutting blade to produce noodle strands. Also, after producing a noodle strip using an extruder, rolling and cutting may be performed, or after producing a noodle strip having a multilayer structure by combining a plurality of noodle strips, rolling and cutting may be performed.

[0021] 4. Cooking process If necessary, the raw noodles obtained in the noodle-making process are steamed using conventional methods to gelatinize them. The preferred steaming conditions vary depending on the type and thickness of the noodles, so the conditions should be set appropriately according to the desired texture. Steaming methods include not only boiling and heating with saturated steam, but also heating with superheated steam, and it is also possible to combine this with moisture replenishment processes such as showering or soaking. The cooked noodles can be soaked in seasoning liquid or treated with loosening agents as needed.

[0022] 5. Drying process For fried noodles, the noodles are cut and weighed into single servings, packed into a container called a drying retainer, and then fried. The drying temperature is preferably 140-160°C. After drying, the moisture content should be 1.5-5% by weight.

[0023] In the case of non-fried noodles, the noodles are cut and weighed into serving portions, filled into containers called drying retainers, and then dried by known methods such as hot air drying, high-temperature hot air drying, superheated steam drying, or microwave drying. Drying by hot air, such as hot air drying or high-temperature hot air drying, is common, and it is preferable to dry at a temperature of 60-150°C and a wind speed of 1-70 m / s. The drying process may be carried out by combining multiple conditions, and the drying should be performed so that the moisture content after drying is 14.5% by weight or less.

[0024] 6. Other projects The dried noodles then move on to the packaging process, where they are packaged in cups or bags along with soup and toppings as needed, and sold as instant noodles.

[0025] As described above, by manufacturing noodles using kneading water without using salt, and by dissolving 8 to 40 g of potassium lactate, 1 to 5 g of monosodium glutamate, and 0.5 to 3 g of gluconate per 1 kg of main ingredient flour, it is possible to provide a method for manufacturing instant noodles with reduced sodium content, excellent noodle-making properties, texture, and saltiness. The embodiment will be described in more detail below with reference to examples.

[0026] <Experiment 1: Investigation using fried noodles> (Example 1-1) To the main ingredient flour consisting of 1000g of medium-strength flour, 10.2g of 78% potassium lactate aqueous solution (8g as potassium lactate), 2.2g of kansui preparation (sodium carbonate 6: potassium carbonate 4), 2.0g of monosodium glutamate, and 1.0g of potassium gluconate were dissolved in 347.8g of water to make a kneading mixture, which was then mixed in a normal pressure mixer for 15 minutes to produce noodle dough.

[0027] The prepared dough was rolled into a rough noodle sheet using rollers, and then compounded to create a noodle sheet. The prepared noodle sheet was rolled using rollers to a final noodle sheet thickness of 1.1 mm, and the noodle sheet was cut with a No. 18 round cutting roll to form noodle strands.

[0028] Next, the noodles were steamed for 2 minutes in a steamer with saturated steam at 250 kg / h to gelatinize them.

[0029] The gelatinized noodle strands were folded in half, and filled into a frying retainer (container) in 110g portions. They were then dried at 150°C for 2 minutes and 30 seconds to obtain a fried noodle sample with a moisture content of 2% by weight.

[0030] (Examples 1-2) A fried noodle sample was prepared according to Example 1-1, except that the amount of potassium lactate aqueous solution added was 19 g (15 g as potassium lactate) and the amount of water added was 346 g.

[0031] (Examples 1-3) A fried noodle sample was prepared according to Example 1-1, except that the amount of potassium lactate added was 32g (25g as potassium lactate) and the amount of water added was 343g.

[0032] (Examples 1-4) A fried noodle sample was prepared according to Example 1-1, except that the amount of potassium lactate added was 51.2g (40g as potassium lactate) and the amount of water added was 338.8g.

[0033] (Examples 1-5) Fried noodle samples were prepared according to Examples 1-3, except that the amount of monosodium glutamate added was 1 g.

[0034] (Examples 1-6) Fried noodle samples were prepared according to Examples 1-3, except that the amount of monosodium glutamate added was 3g.

[0035] (Examples 1-7) Fried noodle samples were prepared according to Examples 1-3, except that the amount of monosodium glutamate added was 5g.

[0036] (Examples 1-8) Fried noodle samples were prepared according to Examples 1-3, except that the amount of monosodium glutamate added was 1 g and potassium glutamate was 1.6 g.

[0037] (Examples 1-9) Fried noodle samples were prepared according to Examples 1-3, except that the amount of potassium gluconate added was 0.5 g.

[0038] (Examples 1-10) Fried noodle samples were prepared according to Examples 1-3, except that the amount of potassium gluconate added was 3g.

[0039] (Examples 1-11) Fried noodle samples were prepared according to Examples 1-3, except that the amount of sodium gluconate added was 1 g.

[0040] (Comparative Example 1-1) To the main ingredient flour consisting of 1000g of medium-strength flour, 16g of salt and 2.2g of a lye solution (sodium carbonate 6: potassium carbonate 4) were dissolved in 350g of water to make a kneading mixture, which was then mixed in a normal pressure mixer for 15 minutes to produce noodle dough. The remaining steps were followed to produce a fried noodle sample according to the method of Example 1-1.

[0041] (Comparative Example 1-2) Except for not adding salt, the fried noodle samples were prepared according to the method of Comparative Example 1-1.

[0042] (Comparative Examples 1-3) Fried noodle samples were prepared according to the method of Example 1-1, except that monosodium glutamate and potassium gluconate were not added.

[0043] (Comparative Examples 1-4) Fried noodle samples were prepared according to the method of Example 1-2, except that monosodium glutamate and potassium gluconate were not added.

[0044] (Comparative Examples 1-5) Fried noodle samples were prepared according to the methods of Examples 1-3, except that monosodium glutamate and potassium gluconate were not added.

[0045] (Comparative Examples 1-6) Fried noodle samples were prepared according to the methods of Examples 1-4, except that monosodium glutamate and potassium gluconate were not added.

[0046] (Comparative Examples 1-7) Fried noodle samples were prepared according to the methods of Examples 1-3, except that potassium gluconate was not added.

[0047] (Comparative Examples 1-8) Fried noodle samples were prepared according to the methods of Examples 1-3, except that monosodium glutamate was not added.

[0048] The noodle-making properties and texture of the noodles after cooking were evaluated for each test group in Experiment 1, using Comparative Example 1-1 as the baseline. For noodle-making properties, 5 were equivalent to Comparative Example 1-1, 4 were slightly inferior to Comparative Example 1-1 but still good, 3 were inferior to Comparative Example 1-1 but still capable of continuous machine noodle making, 2 were inferior to Comparative Example 1-1 and there was a possibility that continuous machine noodle making would not be possible due to noodle sheet breakage, and 1 was significantly inferior to Comparative Example 1-1 and clearly not capable of continuous machine noodle making.

[0049] Sensory evaluation was conducted by cooking and consuming each sample. For cooking, the fried noodle sample was placed in 500 ml of boiling water and boiled in a pot for 3 minutes. Evaluation was conducted by five experienced panelists. Regarding texture, a score of 5 was given for samples that were elastic and good, similar to Comparative Example 1-1; a score of 4 for samples that were slightly more or less elastic than Comparative Example 1-1 but generally good; a score of 3 for samples that were more or less elastic than Comparative Example 1-1 but acceptable as a product; a score of 2 for samples that were too elastic or too weak compared to Comparative Example 1-1 and unacceptable as a product; and a score of 1 for samples that were significantly too elastic or too weak compared to Comparative Example 1-1 and inedible.

[0050] Furthermore, regarding saltiness, we evaluated the intensity of the saltiness and any off-flavors (astringency or bitterness) that arose from the aftertaste. For saltiness intensity, a score of 4 was given for being equivalent to Comparative Example 1-1, a score of 5 for being stronger than Comparative Example 1-1, a score of 3 for being slightly weaker than Comparative Example 1-1 but still acceptable as a product, a score of 2 for being weaker than Comparative Example 1-1 and unacceptable as a product, and a score of 1 for having almost no saltiness (equivalent to Comparative Example 1-2).

[0051] Regarding off-flavors (astringency or bitterness) in the aftertaste, Comparative Example 1-1 was used as the baseline. 5 samples were equivalent and no off-flavors were detected; 4 samples had a slight astringency or bitterness but were still good; 3 samples had astringency or bitterness but were still acceptable as a product; 2 samples had a strong astringency or bitterness and were unacceptable as a product; and 1 sample had a significant bitterness or astringency and was inedible.

[0052] The noodle-making properties and sensory evaluation results for each test group in Experiment 1 are shown in Table 1 below.

[0053] [Table 1]

[0054] As shown in Comparative Examples 1-2 to 1-6, when no salt was added to the kneading water, the saltiness intensified with the addition of potassium lactate. However, when the amount added relative to the main flour reached 15g, the noodle-making properties began to deteriorate, becoming sticky, the texture softened, and the distinctive bitterness of potassium lactate became more pronounced.

[0055] In contrast, as shown in Examples 1-1 to 1-4, by adding glutamate and gluconate salts to the kneading water in addition to potassium lactate, it was possible to obtain fried noodles with superior noodle-making properties, texture, and saltiness compared to the same amount of potassium lactate added. In particular, when the amount of potassium lactate added was small, the noodle-making properties, texture, and saltiness were improved, while when the amount of potassium lactate added was large, it was observed that it had the effect of suppressing deterioration of noodle-making properties and softening of texture, as well as suppressing the bitterness of potassium lactate. In this invention, the amount of potassium lactate added is such that the saltiness is weaker as the amount added decreases, and the bitterness of potassium lactate appears as well as deterioration of noodle-making properties and texture when added. Therefore, it is considered preferable to add 8 to 40 g of potassium lactate per 1 kg of main ingredient flour.

[0056] As shown in Examples 1-3 and 1-5 to 1-7, when the amount of monosodium glutamate added was reduced, the effect of improving noodle-making properties and texture, as well as the intensity of the saltiness, weakened. When the amount of monosodium glutamate added was too high, the dough became hard, the noodle-making properties deteriorated, the texture became hard, and a bitter taste of monosodium glutamate was detected. Furthermore, as shown in Example 1-8, similar effects were observed when a portion of the monosodium glutamate was replaced with potassium glutamate. Therefore, it is considered preferable to add 1 to 5 g of glutamate per 1 kg of main flour in this invention.

[0057] As shown in Examples 1-3 and 1-9 to 1-10, when the amount of potassium gluconate added was small, the effect of masking the bitterness of potassium lactate was weak, and when it was added too much, the dough became hard, similar to monosodium glutamate, the noodle-making properties deteriorated, the texture became hard, and the bitterness of potassium gluconate became noticeable. Also, as shown in Example 1-11, a similar effect was observed when sodium was used instead of potassium gluconate. Therefore, it is considered preferable to add 0.5 to 3 g of gluconate per 1 kg of main raw material flour in this invention.

[0058] <Experiment 2: Investigation using non-fried noodles> (Example 2-1) To the main ingredient flour consisting of 950g of wheat flour and 50g of tapioca acetylated starch, 32g of 78% potassium lactate aqueous solution (25g as potassium lactate), 2.0g of monosodium glutamate, 1.0g of potassium gluconate, 3g of trisodium phosphate, 1g of sodium pyrophosphate, and 0.4g of tocopherol preparation were added to 343g of water to create a dough. This dough was then mixed in a normal pressure mixer for 15 minutes to produce noodle dough.

[0059] The prepared dough was rolled into a rough noodle sheet using rollers, and then compounded to create a noodle sheet. The prepared noodle sheet was rolled using rollers to a final noodle sheet thickness of 0.9 mm, and the noodle sheet was cut with a No. 26 round cutting roll to form noodle strands.

[0060] Next, the noodles were steamed for 2 minutes and 30 seconds in a steamer with saturated steam at 270 kg / h to gelatinize them.

[0061] The gelatinized noodles were immersed in a loosening solution prepared by dissolving 12g of soy dietary fiber, 4g of monosodium glutamate, and 1g of emulsified oil in water to a volume of 1L. After cutting them into approximately 30cm lengths, they were filled into retainers in 120g portions and dried at 70°C for 50 minutes to obtain a non-fried noodle sample with a moisture content of 7% by weight.

[0062] (Comparative Example 2-1) A non-fried noodle sample was prepared according to Example 2-1, except that a kneading mixture was made by dissolving 15g of salt, 3g of trisodium phosphate, 1g of sodium pyrophosphate, and 0.4g of tocopherol preparation in 350g of water to a main ingredient flour consisting of 950g of wheat flour and 50g of tapioca acetylated starch, and mixing it in an atmospheric pressure mixer for 15 minutes to make noodle dough.

[0063] (Comparative Example 2-2) Non-fried noodle samples were prepared according to Example 2-1, except that monosodium glutamate and potassium gluconate were not added.

[0064] Experiment 2 was evaluated in the same manner as Experiment 1. However, for the cooking method, the noodle sample and powdered soup were placed in a cup-shaped foam paper container, 380 ml of boiling water was added, the lid was closed, and it was cooked for 3 minutes. The taste and flavor were then evaluated. Furthermore, the evaluation of noodle-making properties and texture was based on Comparative Example 2-1. The results of noodle-making properties and sensory evaluations for each test group in Experiment 2 are shown in Table 2 below.

[0065] [Table 2]

[0066] As shown in Experiment 2, in addition to potassium lactate, glutamic acid is also present in non-fried noodles. By adding salt and gluconates, a large amount of potassium lactate was added to enhance the salty taste. It prevents deterioration of noodle-making properties due to stickiness, softening of texture, enhances saltiness, and retains potassium lactate. We were also able to mask the stick-like texture.

Claims

[Claim 1] A step of mixing the main ingredient flour and kneading water to make dough, The process of making noodles from the dough prepared, Instant noodles manufactured by a method for manufacturing instant noodles, which includes the step of drying the aforementioned noodle strands, The aforementioned kneading water does not contain salt. The kneading water is characterized by containing 8 to 40 g of potassium lactate, 1 to 5 g of glutamate, and 0.5 to 3 g of gluconate per 1 kg of the main raw material flour, for instant noodles.

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