Molded product for frozen fried shrimp and method for manufacturing the same

Abstract

The present invention provides a molded shrimp tempura product for frozen distribution that exhibits an appearance and satisfying texture equivalent to a large shrimp tempura product without relying on a single large-sized raw material, and that suppresses shifting and peeling at the joints, tearing or falling of the batter, and warping, twisting, and curling during frying, as well as a method for manufacturing the same. [Solution] In this invention, a molded body (1) is formed by connecting a plurality of edible shrimp-derived components (2a, 2b) along the longitudinal direction (L), the adjacent ends (4) of the edible components (2a, 2b) are joined by an edible connecting layer (3), the outer circumferential surface (5) is formed as a continuous surface to be used in the coating process, and a coating (6) (including a batter layer (6a) and a breadcrumb layer (6b)) is formed on the outside of the outer circumferential surface (5), after which it is frozen to produce a frozen product. This provides frozen fried shrimp with a stable appearance and satisfying texture, while suppressing shifting or peeling, tearing or falling of the coating, and warping, twisting or curling during frying.

Description

Technical Field

[0001] The present invention relates to a processed food for shrimp fry used in frozen distribution. More specifically, the present invention relates to a molded body formed by connecting a plurality of edible members derived from shrimp in the longitudinal direction, and a method for manufacturing the molded body.

[0002] The molded body of the present invention is such that the ends of adjacent edible members are joined by an edible connecting layer, and the outer peripheral surface subjected to the breading process is formed as a continuous surface, so that after frying, it has an appearance and texture corresponding to a single large-sized shrimp fry. The present invention relates to a molded body for frozen shrimp fry.

Background Art

[0003] Deep-fried foods mainly made of shrimp, especially frozen shrimp fry that are frozen and distributed after going through the breading process, are foods that place importance on the volume feeling in appearance (so-called "large size feeling") and texture.

[0004] Generally, while it is easy to obtain a volume feeling by using large-sized shrimp raw materials, the raw material cost tends to be high, and it is also easily affected by variations in supply volume and size. Therefore, there is a need for a technology that can stably manufacture products that meet the desired outer dimensions or weight specifications, and suppress variations in appearance and fried quality even after frozen distribution.

[0005] Furthermore, during frying, warping, twisting, or curling is likely to occur due to the shrinkage of the edible members derived from shrimp, which may lead to a decrease in appearance quality and problems such as tearing or falling off of the coating. Also, if the conditions for forming the coating (coating liquid, breadcrumbs, number of coatings, etc.) or freezing conditions in the manufacturing process are not appropriate, problems such as being unable to maintain a predetermined shape during cooking may occur.

[0006] Regarding such problems, for example, a technology has been proposed in which a plurality of peeled shrimp are joined with a food processing adhesive to obtain a shrimp material.

[0007] Furthermore, technologies have been proposed for combining multiple small shrimp to obtain composite shrimp products with a larger shrimp-like appearance, as well as for applying a coating to composite seafood products made by linking multiple shrimp.

[0008] Furthermore, a manufacturing process has been proposed in which the shrimp are frozen after being linked together.

[0009] However, with conventionally proposed joining and connecting structures, the continuity of the outer surface is often compromised at the joint, leading to unstable coating, or the coating may tear or fall off due to shifting or peeling during frying. In addition, there is still room for improvement in terms of achieving both standardization (matching external dimensions and weight) for frozen distribution and shape stability during cooking (suppression of warping, twisting, and curling). [Prior art documents] [Patent Documents]

[0010] [Patent Document 1] Japanese Patent No. 5219157 (JP5219157B2) "Shrimp material and method for manufacturing the same" [Patent Document 2] U.S. Patent No. 5,827,558 (US5827558A) “Composite shrimp products and method of making the same” [Patent Document 3] U.S. Patent No. 5,846,586 (US5846586A) “Composite different product and process” [Patent Document 4] U.S. Patent Publication US2008 / 0038444 (US20080038444A1) “Process for the preparation of shrimp product” [Patent Document 5] Japanese Patent Publication No. 2007-037545 (JP2007037545A) "Frozen fried shrimp for microwave cooking and method for manufacturing the same" [Overview of the project] [Problems that the invention aims to solve]

[0011] In recent years, there has been a growing demand for large-sized fried foods such as fried shrimp, which offer both visual satisfaction and a satisfying eating experience. However, large-sized shrimp are susceptible to price increases and fluctuations in supply, and there are challenges in processing off-spec (small, short, bent, broken, etc.) raw materials. Furthermore, when considering frozen distribution, variations in appearance, tearing or shedding of the coating, and deformation such as warping, twisting, or curling can occur during the coating, freezing, storage, transportation, and frying processes after shaping, leading to a decrease in product value and an increased rate of cooking failures.

[0012] Patent Document 1 describes a technique for obtaining shrimp material by joining peeled shrimp together with a food processing adhesive. However, the document does not sufficiently clarify the configuration for reducing coating tearing or shedding by forming the outer surface as a continuous surface, assuming that the material will be used in the coating process for frying, nor does it clearly describe the design for suppressing shape deformation such as warping and twisting caused by differences in shrinkage during frying.

[0013] Patent Document 2 describes a composite shrimp product in which multiple peeled shrimp are joined together with a binder to give a larger shrimp-like appearance. However, the technology described in this document focuses mainly on the joining of multiple components, and does not necessarily provide sufficient measures for stabilizing the appearance specifications (length, thickness, linearity, etc.) during freezing and frying after coating, assuming frozen distribution, or for reducing the tearing and shedding of the coating starting from the joint.

[0014] Patent Document 3 describes a product configuration in which a coating is applied to a composite seafood product made by linking multiple shrimp together. However, since steps and seams may occur at the connection points of the multiple components, problems remain such as the coating easily tearing, falling off, or the joints shifting or peeling during the freezing and frying process after coating.

[0015] Patent Document 4 describes a manufacturing procedure that involves connecting shrimp together to form a product, including a freezing process. However, since the multiple connected edible components may exhibit different shrinkage behaviors during frying due to differences in individual size, shape, and processing history, there is still a need for design guidelines that suppress deformation such as warping, twisting, or curling while reducing variations in appearance and fried quality.

[0016] Patent Document 5 describes the concept of maintaining a predetermined shape during cooking through process design such as coating and freezing. However, this document mainly focuses on process design for frozen fried shrimp, including microwave cooking, and does not adequately disclose how to obtain a molded body that exhibits a large size appearance and satisfying texture by connecting multiple shrimp-derived components along the longitudinal direction, or how to form the outer surface of the molded body, including the connecting portion, as a continuous surface for the coating process.

[0017] Therefore, the present invention aims to provide a molded body for frozen fried shrimp, formed by connecting multiple edible shrimp-derived components along the longitudinal direction, which exhibits the appearance and texture equivalent to a single large fried shrimp after frying, as well as a method for manufacturing the same. More specifically, the objective is to reduce tearing or shedding of the coating by forming the outer surface subjected to the coating process as a continuous surface, as well as to suppress displacement, peeling, and shape deformation (warping, twisting, curling) during frying, thereby reducing variations in appearance and fried quality in frozen distribution. [Means for solving the problem]

[0018] To solve the above problems, the molded body for frozen fried shrimp according to the present invention is formed by connecting multiple edible shrimp-derived components along the longitudinal direction, and is configured to exhibit the appearance and texture of a single large fried shrimp after frying. The adjacent ends of the edible components are joined by an edible connecting layer, and the outer surface of the molded body is formed as a continuous surface so that it can be used in the coating process.

[0019] In addition, in one aspect of the present invention, the plurality of edible members include shrimp-derived members having at least two different shrimp species, different grades, or different processing histories (freshness, pre-treatment conditions, water retention treatment conditions, freezing history), and are arranged along the longitudinal direction so that differences in texture or flavor can be obtained step by step.

[0020] In addition, in one aspect of the present invention, the edible connecting layer includes a protein-based binder, a starch-based binder, a polysaccharide-based binder, or a binder capable of causing a crosslinking reaction by an enzyme, and is configured to suppress displacement or peeling between the edible members during frying and reduce tearing or peeling off of the coating.

[0021] In addition, in one aspect of the present invention, the arrangement direction, joining position, or thickness distribution of the connecting layer of the edible member is set so as to suppress warping, twisting, or curling caused by shrinkage differences during frying.

[0022] Furthermore, the manufacturing method according to the present invention includes: (a) a step of preparing a plurality of edible members derived from shrimp; (b) a step of applying an edible binder to adjacent ends of the edible members; (c) a step of arranging a plurality of the edible members along the longitudinal direction and joining them with the binder to obtain a molded body; (d) a step of coating the molded body; and (e) a step of freezing the coated molded body to obtain a frozen product.

[0023] In addition, in one aspect of the present invention, the molded body obtained in step (c) is molded so as to conform to a predetermined outer dimension or weight standard before or during freezing, and variations in appearance and frying quality during frozen distribution after freezing are reduced.

Effects of the Invention

[0024] According to the present invention, by connecting a plurality of edible members derived from shrimp along the longitudinal direction to form a molded body, it is possible to obtain a product that exhibits an appearance and eating satisfaction equivalent to a large-sized shrimp fry after frying without depending on a single large-sized raw material. As a result, it becomes possible to effectively utilize out-of-specification raw materials and the like, and it becomes easier to stably supply a molded body that meets product specifications (outer dimensions, weight, etc.) for frozen distribution.

[0025] Furthermore, since the outer surface of the molded body is formed as a continuous surface for the coating process, even in cases where steps or seams are likely to occur at the joints, as in Patent Documents 1 to 4, it is possible to reduce the tearing or shedding of the coating during the freezing, storage, transportation, and frying processes after coating, thereby reducing variations in appearance and cooking failure rates.

[0026] Furthermore, by appropriately selecting edible connecting layers and / or setting their arrangement direction, joining position, and thickness distribution, it is possible to suppress displacement and peeling between edible components that may occur during frying, as well as warping, twisting, or curling caused by shrinkage differences, thereby improving the conformity of the fried product's appearance to standards and its ease of eating.

[0027] Furthermore, by arranging at least two different shrimp species, grades, or processing histories along the longitudinal direction, it is possible to design the product so that differences in texture or flavor are obtained in stages as you chew, providing a degree of freedom in taste design that is difficult to obtain with a single species or single component.

[0028] Furthermore, by including a process of freezing the product after coating, and a process of shaping it to conform to external dimensions or weight specifications before or during freezing as needed, variations in appearance and fried quality can be reduced during thawing or frying after frozen distribution, contributing to the standardization of in-process control and store operations. [Brief explanation of the drawing]

[0029] [Figure 1] This is a perspective view showing an example of the appearance of a molded product for frozen fried shrimp. [Figure 2] This is an explanatory diagram showing a magnified view of the joint between adjacent ends in the molded body shown in Figure 1. [Figure 3] Figure 1 is a cross-sectional explanatory diagram showing an example of a configuration in which the outer circumferential surface of the molded body is formed as a continuous surface, and an example of the layer structure after coating. [Figure 4]This is an explanatory diagram illustrating an example of a configuration in which multiple edible components, including different shrimp species, grades, or processing histories, are arranged along the longitudinal direction to provide a gradual difference in texture or flavor. [Figure 5] This flowchart shows an example of a method for manufacturing molded products for frozen fried shrimp. [Modes for carrying out the invention]

[0030] The embodiments of the present invention will be described below. However, the present invention is not limited to the embodiments described below, and can be implemented with appropriate modifications without departing from the spirit of the invention.

[0031] A molded body for frozen fried shrimp according to one embodiment of the present invention is formed by connecting multiple edible components derived from shrimp along the longitudinal direction of the molded body. Here, "longitudinal direction" refers to the overall length direction of the molded body when it is presented as fried shrimp after frying.

[0032] The aforementioned plurality of edible members are members containing edible parts (muscle parts) derived from shrimp, and may be, for example, peeled shrimp (with shells and, if necessary, the veins removed), cut pieces obtained by cutting peeled shrimp into a predetermined shape, or shaped pieces obtained by flattening or shaping peeled shrimp. The edible members may be raw (before heating) or partially heated (for example, lightly heated on the surface and shaped).

[0033] The number of the aforementioned edible components is appropriately set according to the desired overall length, weight, and appearance after frying (appearance equivalent to a large size), and may be two or more, for example. For example, two to five edible components may be used to accommodate variations in raw material size and off-spec raw materials while meeting the predetermined specifications (external dimensions or weight).

[0034] The adjacent ends of the edible members are joined by an edible connecting layer. Here, "adjacent ends" refers to the ends (end faces or near ends) of edible members arranged adjacent to each other along the longitudinal direction. The form of the adjacent ends may be a butt joint (so-called butt joint), or one end may slightly overlap the other end (overlap).

[0035] The edible connecting layer is a layer for bonding and binding adjacent ends together, and may be configured as a binding layer containing, for example, a protein-based binder, a starch-based binder, a polysaccharide-based binder, or a binder that can undergo a cross-linking reaction by enzymes. The edible connecting layer may not only be interposed between adjacent ends to join them together, but may also be applied in a manner that wraps around to the outer circumference of the ends to fill in any irregularities or gaps around the joint, as needed.

[0036] In one embodiment of the present invention, the outer surface of the molded body is formed as a continuous surface so that it can be used in the coating process. Here, "continuous surface" means a state in which steps, grooves, gaps, or discontinuities that could become the starting point for thinning, cracking, or peeling of the coating are suppressed, so that the base material is not exposed after coating is applied to the outer surface, including at least the joint portion of the adjacent end. In other words, it means that even though it is formed by connecting multiple members, the outer surface is shaped so that it can be used in the coating process as a "single molded body".

[0037] The outer circumferential surface, which serves as a continuous surface, may be formed, for example, by (i) selecting or shaping edible members so that the outer shape (thickness, width, curvature, etc.) of adjacent edible members does not change abruptly near the joint; (ii) applying an edible connecting layer near the joint to fill any steps or gaps; (iii) pressing the outer circumferential surface with a mold or pressing jig to align the outer shape; and / or (iv) applying an edible coating layer (thin layer) to the outer circumferential surface to smooth the surface.

[0038] In the embodiment described above, "applying an edible coating layer (thin layer) to the outer surface," for example, a binder of the same type or similar to the edible connecting layer may be thinly applied to the area spanning the joint to enhance surface continuity. By enhancing the continuity of the outer surface in this way, the spreading of the batter liquid and the adhesion of breadcrumbs during the coating process are less likely to be hindered at the joint, making it easier to suppress tearing or shedding of the coating during the freezing, storage, transportation, and frying processes after coating.

[0039] As described above, the molded body for frozen fried shrimp according to this embodiment is configured to exhibit the appearance and texture of a single large fried shrimp after frying, by connecting multiple edible shrimp-derived components along the longitudinal direction, joining adjacent ends with an edible connecting layer, and forming the outer surface as a continuous surface that can be used in the coating process.

[0040] <Specific examples of edible components (shrimp-derived components)> In this embodiment, "edible component" refers to a component derived from shrimp that is consumed after frying. The edible component may be the muscular part of shrimp from which the shell and head have been removed (so-called peeled shrimp), or it may be processed shrimp from which the vein (digestive tract) has been removed (vein-removed shrimp).

[0041] The edible components may be thawed frozen raw materials, unfrozen fresh raw materials, or pre-processed raw materials (for example, raw materials that have undergone at least one of the following treatments: brine washing, shaping, or seasoning). Multiple edible components are linked together to create a product that, after frying, has the appearance and texture of a single large fried shrimp.

[0042] The edible component may be a single part cut from a single shrimp, or it may be multiple components obtained from multiple individuals. Furthermore, depending on the product specifications (external dimensions, weight, etc.), components that are difficult to manufacture individually due to being small, short, bent, or chipped can be combined and used.

[0043] Since multiple edible members are connected along their longitudinal direction, adjacent ends (joining ends) may be shaped to suit the joining process. For example, adjacent ends may have end faces formed by cutting (cut end faces), and if these end faces are generally flat, the joining by the edible connecting layer can be stabilized.

[0044] The shape of adjacent ends may be beveled (a so-called bevel shape) from the viewpoint of securing a joining area and reducing steps on the outer surface. By beveling, the contact area of ​​adjacent ends is increased, which can contribute to improving the joining strength and suppressing delamination of the joint, and can also facilitate the formation of a continuous surface on the outer surface.

[0045] The shape of adjacent ends may be tapered by thinning the wall near the end face, from the viewpoint of suppressing steps. For example, the outer circumference of adjacent ends can be shaped with a gentle slope, joined via a connecting layer, and then molded so that the outer surface is continuous.

[0046] The shape of the adjacent ends may be a stepped shape with a difference in height, or an interlocking shape with protrusions and indentations (a simple protrusion and indentation shape), from the viewpoint of suppressing displacement. This can suppress relative movement of edible members due to shrinkage during frying or external forces, and contribute to reducing displacement or peeling of the joint.

[0047] Since the outer surface of the edible component is formed as a continuous surface used in the coating process, when shaping adjacent ends, the corners may be chamfered or the surface irregularities may be reduced (for example, by minor cutting or press molding) so that no protrusions or steep steps are created on the outer surface side.

[0048] The shape and orientation of the edible components may be set so that the outer surface is smoothly continuous along the longitudinal direction, from the viewpoint of ensuring a good appearance after frying. For example, by aligning the curvature direction of the edible components, or by selecting components so that the thickness of adjacent components does not change abruptly, variations in appearance and the occurrence of warping, twisting, and curling can be suppressed.

[0049] In this embodiment, the adjacent ends of multiple shrimp-derived edible members are joined by an edible connecting layer (binding layer). The edible connecting layer mechanically holds the edible members together to suppress displacement or peeling, and also plays a role in interface filling (gap filling) and surface smoothing, forming the outer surface of the molded body into a continuous surface that can be used in the coating process.

[0050] The edible connecting layer may be formed from a material containing, for example, (i) a protein-based binder, (ii) a starch-based binder, (iii) a polysaccharide-based binder, or (iv) a binder that can undergo a crosslinking reaction by an enzyme. These may be used individually or in combination of two or more. The edible connecting layer is preferably designed to undergo gelation, tackiness, crosslinking, or increased viscoelasticity upon heating during frying, or upon heating and moisture transfer.

[0051] Specific examples of the protein-based binders include egg white, milk protein (e.g., whey protein, casein, etc.), soy protein, shrimp or seafood-derived protein (e.g., surimi, myofibrillar protein, etc.), gelatin, collagen, or hydrolyzed products thereof. These can coagulate and gel upon heating, providing interfacial strength and suppressing displacement or separation between edible components during frying.

[0052] Specific examples of the starch-based binders include wheat flour, cornstarch, tapioca starch, potato starch, and their modified starches (modified starch). Starch-based binders exhibit tackiness and viscoelasticity through gelatinization upon heating, filling voids at the bonding interface and substantially increasing the bonding area, thereby contributing to improved peel resistance.

[0053] Specific examples of the polysaccharide-based binders include alginates, carrageenan, pectin, xanthan gum, guar gum, agar, gellan gum, pullulan, and cellulose-based thickening polysaccharides. Polysaccharide-based binders suppress the flow of the binder by thickening, making it easier to hold it in the desired position, and by selecting a method that gels in the presence of heat or ions, the bonding stability during frying can be improved.

[0054] As a binder capable of undergoing a cross-linking reaction by the enzyme, for example, a material that promotes protein-protein bonding by utilizing a cross-linking reaction such as transglutaminase may be used. This allows for a configuration in which bonding strength is imparted by combining it with a holding process in the low or medium temperature range, and then the final strength is obtained during frying. The binder may contain edible additives such as salt, sugars, pH adjusters, and spices as needed, but the present invention is not limited to these.

[0055] The method for applying the edible connecting layer may be, for example, by coating the ends of the edible member, applying it in dots, spraying it, brushing it on, or dispensing it quantitatively using a dispenser. Alternatively, the edible connecting layer may be formed into a sheet or film and interposed between the ends, or a paste-like binder may be interposed and pressed in place.

[0056] The edible members may be joined together by interposing the edible connecting layer, for example, by positioning and pressing them along the longitudinal direction. The pressing may be performed within a mold (forming jig), which reduces steps and gaps in the connecting portion and makes it easier to form the outer surface as a continuous surface that can be used in the coating process. Furthermore, cooling or freezing (including partial freezing) may be performed after joining to suppress the flow of the connecting layer and temporarily fix the shape.

[0057] In molded bodies joined by the aforementioned edible connecting layer, displacement or peeling between edible components is suppressed during frying, thus reducing cracking at the connecting points, tearing of the coating, or loss of coating after coating. In particular, if the local gap at the connecting points is small and the outer surface is formed as a continuous surface, the coating during the coating process becomes stable, and localized fractures caused by steam pressure or shrinkage differences during frying become less likely.

[0058] In this embodiment, "the outer surface is formed as a continuous surface so as to be used in the coating process" means that the outer surface, including the connecting portion of a plurality of edible members, is formed in such a way that the coating is less likely to break during the coating process (e.g., batter application and breadcrumb application), and that after coating, the surface is in a state where the base material is not exposed in the region including the joint portion.

[0059] The formation of a continuous surface can be facilitated by adjusting the end shape of the edible members as a pretreatment before joining adjacent ends. For example, at least one of the adjacent ends can be beveled or chamfered to ensure sufficient contact area between the ends and to create a shape that is less likely to produce a steep step on the outer surface.

[0060] Furthermore, to ensure that the outer surfaces of the edible components connect smoothly at the joint, the outer surfaces of adjacent ends can be rounded (curved), or any protrusions or chips on the edge of the ends can be trimmed. This reduces the unevenness of the joints that may appear on the outer surface after joining, and reduces the starting point of coating defects during the coating process.

[0061] The formation of a continuous surface can be made even more reliable by using an edible connecting layer not only "for joining" but also "for smoothing the outer surface." For example, when applying an edible connecting layer (bonding agent) to the contact surfaces of adjacent ends, the application area may be extended to the end periphery (outer surface side) to fill any minute gaps or steps that may appear on the outer surface side after joining.

[0062] The connecting layer can be formed by coating, dotting, or interposing a paste-like material to fill the "joints" on the outer surface. This prevents the batter from being interrupted at the connecting parts or the breadcrumbs from becoming too thin during the coating process.

[0063] Furthermore, by using a molding jig that holds multiple edible components in a predetermined outer shape, the outer surface can be smoothed by light compression during joining. Light compression suppresses misalignment of adjacent ends and makes it easier for the connecting layer to wrap around the gap on the outer surface side, thereby improving the continuity of the outer surface including the connecting portion.

[0064] If minute recesses remain on the outer surface after joining, a connecting layer may be added to the surface to smooth it out, or the surface may be leveled, in order to improve the continuity of the outer surface. This makes it easier for the coating to adhere continuously during the coating process and prevents the coating from chipping off at the connecting point during transport and handling after freezing.

[0065] The outer surface, formed as a continuous surface in this manner, can reduce tearing or shedding of the coating near the connection point during freezing, storage, transportation, and frying processes after coating. Furthermore, by suppressing coating defects, localized increases in oil penetration during frying are also suppressed, thereby reducing variations in appearance and texture.

[0066] Therefore, in addition to the configuration of the molded body of this embodiment, which connects multiple edible members to obtain an appearance and eating experience equivalent to a large size, the outer surface including the connecting portion is formed as a continuous surface, thereby improving suitability for the coating process and the reproducibility of fried quality after frozen distribution.

[0067] <Arrangement of different types, grades, and processing histories>

[0068] In the molded body for frozen fried shrimp according to this embodiment, the plurality of edible components may include at least two different shrimp species, or may include components of the same shrimp species but with different grades (e.g., classifications based on size, yield, and flesh quality). Furthermore, the plurality of edible components may include shrimp-derived components of the same shrimp species and grade but with different processing histories.

[0069] Here, "processing history" refers to the processing history that may affect the physical properties or taste of the edible ingredients, and includes differences in freshness (storage days of raw materials, whether or not they were thawed, etc.), pre-processing conditions (washing conditions, deveining, shaping conditions, etc.), water retention treatment conditions (whether or not water retention treatment was performed, differences in processing conditions, etc.), or freezing history (number of freezes, freezing speed, storage conditions before freezing, etc.). These differences may manifest as differences in texture (elasticity, crispness, moistness, etc.) or flavor (sweetness, umami, aroma, etc.) after frying.

[0070] In this embodiment, the multiple edible components can be arranged in a predetermined order along the longitudinal direction of the molded body so that differences in texture or flavor are obtained in stages as the food is chewed during consumption. That is, by arranging the components so that different shrimp species, different grades, or components with different processing histories appear depending on their position along the longitudinal direction of the molded body, the degree of freedom in flavor design can be increased compared to the case where a single component is used.

[0071] As an example of arrangement, when using two types of edible components A and B, component A may be placed on one end of the molded body in the longitudinal direction, and component B on the other end, in a series arrangement (A→B). For example, component A may be derived from Pacific white shrimp, and component B may be derived from black tiger shrimp. Furthermore, the ratio (length ratio or mass ratio) of component A and component B to the total length in the longitudinal direction can be set according to the design of the desired texture or flavor, for example, component A:component B = 3:7, 5:5, or 7:3.

[0072] As another example of arrangement, when using three or more edible components, (i) an arrangement with multiple levels of difference, such as A→B→C, or (ii) an arrangement with identical components at both ends, such as A→B→A, may be used. The former makes it easy to impart multiple stages of changes in texture or flavor as one chews. The latter allows for a consistent impression of texture or flavor at both ends while providing a different taste in the middle, and by arranging the differences in physical properties between components (e.g., differences in shrinkage behavior) symmetrically in the longitudinal direction, it can also contribute to shape stability during frying.

[0073] Furthermore, when using components with different processing histories, for example, a component with a processing history that easily imparts a moist texture and a component with a processing history that easily imparts elasticity may be combined and arranged along the longitudinal direction of the molded body to obtain a gradual difference in texture. Moreover, the arrangement order and ratio of these components may be managed as a predetermined arrangement specification during manufacturing, so as to satisfy product specifications (appearance, weight, etc.) while obtaining the desired taste profile (chewiness in the first half, sweetness in the second half, etc.).

[0074] <Design to suppress warping, twisting, and curling> When a molded body is constructed by connecting multiple edible components along its longitudinal direction, differences in the size, thickness, moisture content, muscle tissue state, or processing history of each edible component can lead to uneven shrinkage during frying. As a result, bending deformation (warping) along the longitudinal direction of the molded body, twisting deformation (twisting) with the longitudinal direction as the axis, or deformation where the ends curl inward may occur, potentially reducing the appearance and ease of eating. Therefore, in this embodiment, warping, twisting, or curling is suppressed by appropriately setting the arrangement direction of the edible components, the joining position, or the thickness distribution of the connecting layer.

[0075] Examples of setting the arrangement direction of edible components include arranging them in the same direction so that the thickness bias or shrinkage-prone side (e.g., the side prone to bending) of each edible component is aligned, or arranging them alternately in opposite directions so that the shrinkage directions of adjacent edible components cancel each other out. Here, the bending direction refers to the bending direction exhibited by the edible component in its natural state without being straightened by external forces, and opposite directions means arranging them so that the convex sides of the curve of adjacent edible components face opposite directions. This reduces the bending moment or torsional moment of the molded body as a whole, and improves the linearity or stability of the external shape after frying. The arrangement direction may be predetermined according to the type, grade, or processing history of the edible components, and may be set in a way that ensures reproducibility within the same lot.

[0076] Examples of setting the joining position include joining at a location where the cross-sectional area or thickness of adjacent ends does not change abruptly, staggering the joining position so that the peaks of thickness in the longitudinal direction of the edible material are not consecutive, or arranging multiple joining positions so that they are not concentrated on the same line in the longitudinal direction. This suppresses the localization of shrinkage differences during frying at the joining point, and reduces the occurrence of localized bending, warping, or twisting starting from the joining point.

[0077] Furthermore, by cutting the ends at an angle or shaping them to minimize steps, in relation to the shape of adjacent ends and the joint position, the joint area can be secured, thereby increasing the mechanical strength of the joint while suppressing shifting or peeling during frying. This makes it easier to achieve both suppression of shape deformation and reduction of batter tearing or shedding.

[0078] For example, when setting the thickness distribution of the connecting layer, gaps or steps can be filled so that the outer surface of the molded body becomes a continuous surface, while making the connecting layer relatively thicker in the area corresponding to the side with greater shrinkage during frying, or the thickness of the connecting layer can be gradually increased or decreased along the longitudinal direction. This can mitigate bending deformation caused by differences in shrinkage and suppress warping or curling. Furthermore, by locally adjusting the thickness of the connecting layer, resistance to torsional deformation can also be provided.

[0079] Methods for determining the external shape of a molded body include, for example, holding the joined molded body in a predetermined shape using a molding jig or holding jig while cooling or freezing it, or lightly compressing the joined body to reduce any steps on the outer surface and then shaping the external shape. This makes it less likely for the shape to collapse during frozen distribution and reduces the occurrence of warping, twisting, or curling during frying. The external shape specifications may include at least one of the following: length, diameter, linearity, and end shape.

[0080] As described above, in this embodiment, by setting the arrangement direction of the edible components, the joining position, or the thickness distribution of the connecting layer to suppress warping, twisting, or curling caused by shrinkage differences during frying, the conformity of the fried appearance to standards, ease of eating, and coating retention can be improved. These settings may be applied individually or in combination.

[0081] <Manufacturing method> The method for manufacturing a molded body for frozen fried shrimp according to this embodiment includes, for example, the steps of (a) preparing a plurality of edible components derived from shrimp, (b) applying an edible binder to adjacent ends of the edible components, (c) arranging a plurality of the edible components along the longitudinal direction and joining them with the binder to obtain a molded body, (d) coating the molded body, and (e) freezing the coated molded body to produce a frozen product, in this order. In particular, by not changing the order of coating (d) and freezing (e), the coating can be formed along the continuous surface of the outer periphery, and then frozen for frozen distribution, which contributes to reducing coating breakage or shedding, as well as variations in appearance.

[0082] (a) In step (a), several edible components derived from shrimp are prepared. The edible components may be, for example, peeled shrimp, peeled shrimp with the veins removed, or components cut and shaped into a predetermined form. If there is an excess of free water adhering to the surface of the edible components, pretreatment such as removing the drip, lightly wiping off the surface moisture, or cooling for a predetermined time to stabilize the surface condition may be performed from the viewpoint of suppressing slippage during joining or dilution of the binder.

[0083] (b) In step (b), an edible binder is applied to the adjacent ends. The binder may be applied by, for example, coating, spot application, dipping, or interposition of a sheet-like member. The amount of binder applied may be set within a range that ensures joint strength without distorting the outer shape due to excessive overflow, and the application location may be the entire surface of the adjacent ends, the peripheral edge, or multiple points. As an example of the amount applied, it may be applied in a range where the thickness of the connecting layer is approximately 0.5 to 3 mm, and as an example of the application range, it may be applied by spot application to the entire surface of the adjacent ends, the peripheral edge on the outer side, or multiple points.

[0084] (c) In step (c), multiple edible members are arranged along the longitudinal direction, and adjacent ends are joined together with the binder applied in step (b) to obtain a molded body. The arrangement may be done so as to align the curvature, thickness, or fiber direction of the edible members, thereby improving the shape stability in subsequent processes. During joining, the ends may be brought into contact and then lightly pressed together, or the outer shape may be adjusted with a molding jig to reduce steps or gaps at the joint, and the outer surface may be formed to become a continuous surface that can be used in the coating process.

[0085] (c) The molded body obtained in step (c) may be further molded as needed to conform to predetermined external dimensions or weight specifications. For example, from the viewpoint of improving the continuity of the outer surface, the area around the connecting part may be filled with a binder, the outer surface may be lightly compressed to smooth out any steps, or the shape may be stabilized by holding it in the mold for a certain period of time. In addition, a short cooling or light pre-freezing may be performed before coating to stabilize the bonded state (however, this step is performed prior to coating (d)).

[0086] In step (d), the molded body obtained in step (c) is coated. Coating may include, for example, a dusting step, a batter application step, and a breadcrumb application step. If the outer surface of the molded body is formed as a continuous surface, the coating is less likely to break at the joints, and the occurrence of coating tearing or coating shedding starting from the joints can be suppressed. Coating conditions (batter viscosity, breadcrumb particle size, amount of coating applied, etc.) may be set as appropriate according to the product specifications and fried quality.

[0087] (e) In step (e), the molded product after coating is frozen to produce a frozen product. Freezing may be carried out by, for example, forced-air freezing, rapid freezing, or contact freezing, and the molded product may be frozen until its temperature falls below a predetermined temperature for use in frozen distribution. After freezing, glazing, packaging, or inspection such as metal detection may be performed as necessary.

[0088] By performing steps (d) and (e) in the order described above, the state after coating (coating adhesion and external shape) can be easily preserved by freezing, reducing variations in appearance during storage and transportation. Furthermore, even during frying, it is easier to maintain the continuity of the coating, improving the reproducibility of appearance and texture.

[0089] Furthermore, between coating and freezing, a settling process to promote coating fixation or a cooling process to stabilize the surface condition may be intervened as needed. This can suppress shifting or unevenness of the coating before freezing and contribute to stabilizing the appearance standards of the frozen product after freezing.

[0090] Furthermore, the above manufacturing method can be applied to factory production based on frozen distribution, and since it is easy to design the external dimensions or weight by combining multiple edible components, it is possible to stably produce molded products for frozen fried shrimp that meet the specifications, even when there are fluctuations in raw material procurement.

[0091] In the manufacturing method of this embodiment, the molded body obtained by step (c) above is molded to conform to predetermined external dimensions or weight specifications before or during freezing, thereby reducing variations in appearance and fried quality during frozen distribution after freezing. Here, "molding" includes adjusting the arrangement of multiple edible members connected in the longitudinal direction, the position of the joints, and the outer circumference shape to standardize the external shape.

[0092] The aforementioned external dimensions or weight specifications include, for example, at least one of the total length, maximum width, maximum thickness, linearity (curvature), and mass (weight) of the molded body. Here, linearity (curvature) may be evaluated, for example, as the maximum distance (maximum deflection) between the straight line connecting both ends of the molded body and the outer surface when the molded body is placed on a horizontal surface after frying. Alternatively, it may be evaluated as the height of the central part when both ends of the molded body are supported. Furthermore, the external dimensions or weight specifications may be set so that the product, after being fried following frozen distribution, exhibits an appearance and eating experience equivalent to a single large-sized fried shrimp. In addition, the specifications may include tolerances (e.g., total length ±ΔL, weight ±ΔM, etc.). For example, as an example of external dimensions, the total length after frying may be set in the range of 150 to 220 mm, and the maximum width or maximum thickness in the range of 20 to 40 mm. As an example of a weight specification, the mass after frying may be set in the range of 30 to 150 g. For example, the product could be standardized so that the total length after frying is approximately 180 mm and the maximum width or thickness is approximately 30 mm.

[0093] In the method of molding before freezing, the molded body is placed on a molding jig or tray having a predetermined outer shape (for example, a mold with a recess extending in the longitudinal direction), and lightly compressed as needed, thereby reducing steps and gaps on the outer surface while conforming to the standard outer dimensions. For example, after aligning adjacent ends, any excess portion that may be created by the connecting layer can be smoothed out, or the connecting layer can be spread outwards and filled to create a continuous outer surface.

[0094] Furthermore, in the case of molding before freezing, the entire length may be standardized by cutting and shaping both longitudinal ends of the molded body, or the maximum width or maximum thickness may be adjusted to the standard by adjusting the amount (thickness) of the connecting layer. This ensures that the outer shape is consistent when subjected to the coating process, making it easier for the coating to adhere and suppressing variations in coating thickness.

[0095] In methods of molding during freezing, the molded body is restrained in a molding jig or tray during freezing, which fixes its external shape as freezing progresses, making it less likely for deformation outside of specifications to occur during handling after freezing and during frozen distribution. For example, in freezing methods such as plate freezing, contact freezing, or blast freezing, the molded body may be held in a jig and restrained until the surface of the molded body reaches a predetermined hardened state (for example, a state in which the surface can stand on its own).

[0096] The molding jig or tray may be shaped to exert a restraining force in directions where the molded body is prone to warping, twisting, or curling. For example, it may have side walls along the longitudinal direction, or be configured to be held in place by a pressing member from the top. This stabilizes the shape before and after freezing and suppresses deformation during frying.

[0097] In an embodiment that conforms to weight standards, the mass of the molded body may be measured, and based on the measurement results, the combination of edible components, the amount of cutting at the ends, or the amount of connecting layer added may be adjusted to bring the weight within a predetermined range. For example, if the weight is excessive compared to the target weight, the ends may be shaped to reduce the weight, and if it is insufficient, a connecting layer may be added as a filler to increase the weight.

[0098] As described above, by shaping the product to match external dimensions or weight specifications before or during freezing, variations in appearance are suppressed during storage, transportation, and handling after frozen distribution, and variations in floating posture in oil and uneven heating during frying are also reduced. This improves the reproducibility of the appearance (linearity, length, continuity of the coating) and texture (crispness of the coating, etc.) of the fried product, contributing to the standardization of in-process control and store operations.

[0099] The molding process may be performed immediately after step (c), or after step (d) (coating) and before step (e) (freezing). In the latter embodiment, the external shape (appearance including coating thickness) after coating can be standardized, making it easier to suppress chipping, cracking, or peeling of the coating.

[0100] It should be noted that the present invention is not limited to the embodiments described above, and various modifications and changes are possible without departing from the spirit of the invention. Below, examples of modifications that are useful from the standpoint of responding to notices of rejection and securing the scope of rights are given.

[0101] The number of edible components must be at least two, but may be three or more, four or more, etc. For example, the head, body, and tail portions may be divided among multiple edible components along the longitudinal direction of the molded body. Alternatively, a configuration may be used in which many relatively short edible components are connected to obtain the same length. This increases the design flexibility to accommodate desired external dimensions and weight specifications in response to variations in raw material size and supply conditions.

[0102] The end shapes used to connect edible components are not limited to butt joints of flat surfaces; they may also be beveled, stepped, or interlocking concave and concave shapes. For example, the joint strength of the connecting layer may be increased by increasing the joining area by beveling the ends. Alternatively, the ends may be chamfered or curved to prevent steps between adjacent ends from appearing on the outer surface. This improves the continuity of the outer surface used in the coating process, making it less likely for the coating to break, tear, or peel.

[0103] The placement of the connecting layer is not limited to covering the entire surface of adjacent ends, but may also be limited to a portion of the ends (for example, only the periphery, only the center, or multiple points of application). Furthermore, in addition to the butt joints at the ends, the connecting layer may also be filled into gaps or steps on the outer surface to fill in recesses on the outer surface. The thickness of the connecting layer does not have to be uniform; for example, a thickness distribution such as making the outer surface side thicker and the center side thinner may be used to achieve both continuity of the outer surface and joint strength. An example of a connecting layer thickness is 0.5 to 3 mm, and a thickness distribution where the outer surface side is relatively thicker and the inner side is relatively thinner may also be used.

[0104] The material of the connecting layer (binding agent) is not limited to one of the following: protein-based binding agents, starch-based binding agents, polysaccharide-based binding agents, or binding agents that can undergo cross-linking reactions by enzymes; multiple types may be combined. The connecting layer may also be in the form of a paste, gel, or sheet (including edible film). The application method can be appropriately selected according to the manufacturing equipment, such as coating, spot application, spraying, dipping, or interposition of a sheet-like component. Furthermore, the connecting layer may contain flavoring components, seasoning components, or water-retaining components to provide a change in flavor or texture near the connecting portion (however, the connecting layer must be edible and capable of suppressing displacement or peeling between edible components during frying).

[0105] The coating is not limited to the so-called frying coating using batter and breadcrumbs, but may also be a multi-layer coating including a pre-dusting (flour dusting) process, a tempura-style coating, or a coating that combines different breadcrumb particle sizes (coarse or fine). For example, if the coating tends to break at the joints, the coating may be improved by applying batter after pre-dusting, and then adding breadcrumbs. The coating may be applied continuously to the entire molded body, or the coating thickness may be adjusted according to the shape of the ends and joints.

[0106] The freezing method may be any of the following: Individual Quick Freezing (IQF), tunnel freezing, blast freezing, plate freezing, contact freezing, or immersion freezing. For example, if shape retention is important, tunnel freezing or plate freezing may be performed while the outer shape is held in place by a molding jig or tray, fixing the outer shape during freezing. On the other hand, if productivity and handling are important, the molded body after coating may be individually frozen by IQF to improve handling during frozen distribution.

[0107] The distribution method after freezing is not limited to individual packaging; it may also be tray packaging, bagging, or packaging of multiple items together. Furthermore, glazing (ice coating) or moisture-proof packaging may be applied as needed to prevent drying or chipping of the coating during frozen distribution.

[0108] The standardization of the external shape of the molded body is not limited to molding and fixing before or during freezing (as in the above embodiment), but may also be carried out by readjusting the external shape after coating but before freezing. For example, the outer surface may be lightly compressed after coating to reduce surface irregularities and improve the continuity of the coating before freezing. This makes it less likely for the coating to crack, peel, or fall off during frying after frozen distribution.

[0109] Design for suppressing warping, twisting, or curling is not limited to just one of the following: the arrangement direction of edible components, the joining position, the thickness distribution of the connecting layer, and the method of specifying the external shape. Multiple design elements may be combined. For example, when edible components with large differences in shrinkage are placed next to each other, deformation during frying can be suppressed by increasing the thickness of the outer surface of the connecting layer or by constraining the outer shape with a jig and freezing it to fix it in place.

[0110] The above modifications are illustrative, and the configurations of each modification can be combined with each other as appropriate. Those skilled in the art can implement the invention by appropriately changing the type, shape, arrangement of the edible members, the material and manner of application of the connecting layer, the form of the coating, and the freezing method, without departing from the spirit of the present invention. [Explanation of Symbols]

[0111] 1. Molded body for frozen fried shrimp (molded body) 2. Edible components (shrimp-derived components) 2a, 2b Edible components (examples of each component) 3. Edible connecting layer (connecting layer, binder layer) 4. Adjacent ends (ends to be joined) 5. Outer surface (continuous surface) 6 Clothes 6a Batter layer (an example of clothing) 6b Breadcrumb layer (an example of a coating) L Longitudinal direction

Claims

1. A molded body for frozen fried shrimp, formed by connecting multiple edible shrimp-derived components along the longitudinal direction, and then coated and frozen, The adjacent ends of the edible members are arranged with their end faces abutting against each other. At least one of the adjacent ends is shaped into a tapered form with an oblique cut or a thinned end face. Between the adjacent ends, an edible connecting layer is interposed to join the edible members together, and fills any gaps or steps that may occur on the outer circumferential surface of the adjacent ends. The outer surface including the joint is further smoothed by applying the edible connecting layer to the surface side. The arrangement directions of the edible members are set to be opposite to each other so that the curvature directions of adjacent edible members cancel each other out. The molded body for frozen fried shrimp is characterized in that the outer surface of the molded body is formed as a continuous surface so as to be subjected to a coating process, the continuous surface is an outer surface that does not expose the base material after coating is applied to the outer surface including the joint, and the coating is formed on the outside of the continuous surface.

2. In the molded body for frozen fried shrimp according to claim 1, The plurality of edible members include shrimp-derived members having at least two different shrimp species, Along the longitudinal direction, the edible members having different shrimp species are arranged such that they switch at at least one boundary. A molded body for frozen fried shrimp, characterized by the following features.

3. In the molded body for frozen fried shrimp according to claim 1 or 2, The edible connecting layer comprises a protein-based binder, a starch-based binder, a polysaccharide-based binder, or a binder capable of undergoing a cross-linking reaction by an enzyme. During deep-frying, this suppresses displacement or separation between the edible components and reduces tearing or shedding of the coating. A molded body for frozen fried shrimp, characterized by the following features.

4. In the molded body for frozen fried shrimp according to claim 1 or 2, A molded body for frozen fried shrimp, characterized in that the joining positions are offset from each other along the longitudinal direction, so that multiple joining positions do not concentrate at the same location.

5. A method for manufacturing a molded product for frozen fried shrimp according to claim 1, (a) A step of preparing multiple edible components derived from shrimp, (b) A step of shaping at least one of the adjacent ends of the edible member into a tapered shape by cutting it obliquely or thinning the end face, and applying an edible binder to the adjacent end, (c) A step of obtaining a molded body by arranging the edible members in opposite directions to each other so that the curvature directions of adjacent edible members cancel each other out, butting the end faces of the adjacent ends together, and joining them while filling any gaps or steps that may occur on the outer circumferential surface side of the adjacent ends with the fastening material, (d) A step of applying the binder to the outer surface including the joint and smoothing it out, (e) A step of applying a coating to the molded body, (f) A process of freezing the molded body after coating to make it a frozen product, A manufacturing method characterized by including the following.

6. In the manufacturing method described in claim 5, After step (c) or (d), the molded body is held in a molding jig and lightly compressed to reduce the step on the outer surface including the joint, and before or during freezing, it is molded to conform to a predetermined external dimension or weight standard (at least one of the total length, maximum width, maximum thickness, linearity, and mass). To reduce variations in appearance and fried quality during frozen distribution after freezing, A manufacturing method characterized by the following features.

7. A molded body for frozen fried shrimp according to claim 1, characterized in that the total length after frying is 150 mm or more, and the maximum width or maximum thickness is 20 mm or more.

8. A molded body for frozen fried shrimp according to claim 1 or 2, wherein the plurality of edible members include shrimp-derived members having different grades or different processing histories, and the processing histories include differences in at least one of freshness, pre-processing conditions, water retention treatment conditions, and freezing history.

Images