Method for manufacturing a molded article, a heat-compressed molded article, and its use

Abstract

To provide a method of manufacturing a molded body, a thermo-compressed molded body, and use thereof, capable of effectively utilizing waste materials including food waste and seaweed for multiple applications.SOLUTION: According to an embodiment, there is provided a method of manufacturing a molded body from a waste material including at least one of food waste and seaweed, the method comprising the steps of: preparing dry powder made from at least the waste material; and forming a molded body by pressurizing the dry powder in a state of being heated to a predetermined temperature.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] Embodiments of the present invention relate to a method for manufacturing a molded body, a hot compression molded body, and its use.

Background Art

[0002] Based on the Sustainable Development Goals (SDGs) adopted by the United Nations member states, there is an increasing interest in the effective use of food waste that is discarded in large quantities. In addition to the problem of food loss such as uneaten food, a large amount of inedible parts of food are also discarded, and effective utilization methods for such food waste are required. Another example of such a large amount of waste generation and insufficient utilization is seaweed.

[0003] As an example of the use of such waste materials, Japanese Patent Application Laid-Open No. 2011-026170 describes a technique for kneading a ceramic raw material or a mineral waste and a vegetable raw material such as food waste to form a molded body. However, the technique of Patent Document 1 is for ceramic products and has limited applications.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, an object of the present invention is to provide a method for manufacturing a molded body, a hot compression molded body, and its use, which can effectively utilize waste materials including food waste and seaweed in multiple applications.

Means for Solving the Problems

[0006] The present invention includes the following aspects. [1] A method for manufacturing a molded body from waste materials including at least one of food waste and seaweed, The steps include at least preparing a dried powder made from the aforementioned waste material, The steps include forming a molded body by heating the dried powder to a predetermined temperature and applying pressure, Methods that include... [2] The food waste is the inedible part of food, as described in [1]. [3] The method according to [1] or [2], wherein the waste material is part or all of one or more materials selected from the group consisting of oranges, edamame, pumpkins, cabbage, onions, Chinese cabbage, bananas, broccoli, maitake mushrooms, Iyokan oranges, coffee beans, sea lettuce, strawberries, crab shells, spinach, and purple sweet potatoes. [4] The method according to any one of [1] to [3], wherein the waste material contains sugar, and the predetermined temperature is equal to or greater than the melting point of the sugar in the waste material. [5] The method according to any one of [1] to [4], wherein the predetermined temperature is 50°C or more and 200°C or less. [6] The method according to any one of [1] to [5], wherein in the step of forming the molded body, the pressure applied to the dry powder is 4 MPa or more and 50 MPa or less. [7] The method according to any one of [1] to [6], wherein the step of preparing a dried powder comprises the steps of drying the waste material and grinding the dried waste material to prepare a dried powder. [8] The method according to [7], wherein the step of drying the waste material includes the step of freeze-drying the waste material. [9] The method according to any one of [1] to [8], wherein in the step of forming a molded body, the dry powder is mixed with a seasoning and then heat-compressed.

[10] The method according to any one of [1] to [8], wherein the step of preparing a dried powder further comprises the step of mixing the waste material and seasonings and boiling them.

[11] The method according to any one of [1] to

[10] , wherein in the step of forming a molded body, the dry powder is mixed with plastic powder and then heat-compressed.

[12] The method according to any one of [1] to

[11] , wherein the molded body consists only of the waste material, or consists only of the waste material and the edible material.

[13] A heat-compressed molded body made from waste material, comprising at least one of food waste and seaweed, wherein the three-point bending strength is 3 MPa or more.

[14] The heat-compressed molded article according to

[13] , comprising only the waste material, or only the waste material and edible material. Building materials, structures, furniture, carpets, containers, interior accessories, tableware, or decorative items, including the heat-compressed molded articles described in

[15]

[13] or

[14] . [Effects of the Invention]

[0007] According to embodiments of the present invention, a method for producing a molded article that can effectively utilize waste materials including food waste and seaweed for various purposes, a heat-compressed molded article, and its use can be provided. [Brief explanation of the drawing]

[0008] [Figure 1] This is a photograph of food after freeze-drying. [Figure 2] This is a photograph of the ingredients after they have been ground. [Figure 3] This is a photograph of the resulting molded product. [Figure 4] This graph shows the results of comparing the bending strength of molded articles obtained from various raw materials. [Figure 5] This graph shows the dependence of the bending strength of molded bodies made from pumpkin, maitake mushroom, sea lettuce, and crab shell on the molding temperature. [Figure 6] This graph shows the dependence of the bending strength of molded banana and Iyokan oranges on molding pressure. [Modes for carrying out the invention]

[0009] The following describes a method for manufacturing the molded article of the embodiment, the heat-compressed molded article, and its use. Note that the following embodiment represents one aspect of the present invention and is not limiting, and can be modified as appropriate within the scope of the technical concept of the present invention.

[0010] <Molded body> In one embodiment, a heat-compressed molded body of waste material comprising at least one of food waste and seaweed is provided. In this specification, “food waste” means food that has been discarded after being consumed, or that was not consumed, or articles that are not edible and are obtained as by-products in the process of manufacturing, processing, or cooking food. In this specification, “heat compression molding” means molding an object into a desired shape by applying pressure while heating it.

[0011] Food waste included in discarded materials is, for example, the inedible parts of food. In this specification, "inedible parts" means articles obtained as by-products in the process of manufacturing, processing, or cooking food that cannot be used for food. Examples of inedible parts include peels, seeds, and cores of vegetables and fruits, bones and scales of meat and fish, but do not include items that are not essentially derived from food, such as containers and packaging.

[0012] Examples of foods include plant-based foods, animal-based foods, etc. Examples of plant-based foods include vegetables, fruits, grains, tubers, mushrooms, edible seaweeds, etc. Examples of vegetables include pumpkins, cabbages, lettuces, onions, carrots, radishes, burdocks, cabbages, broccoli, cauliflowers, spinach, komatsuna, turnips, tomatoes, watermelons, melons, bell peppers, paprika, cucumbers, bamboo shoots, tea leaves, etc. Examples of fruits include oranges, oranges, iyo oranges, strawberries, bananas, blackcurrants, apples, persimmons, pears, cherries, pineapples, grapes, blueberries, peaches, etc. Examples of grains include rice, wheat, corn, millet, foxtail millet, barnyard millet, green soybeans, soybeans, adzuki beans, broad beans, coffee beans, etc. Examples of tubers include potatoes, sweet potatoes, purple yams, taros, long yams, mountain yams, etc. Examples of mushrooms include shiitake mushrooms, maitake mushrooms, enoki mushrooms, shimeji mushrooms, nameko mushrooms, mushrooms, etc. Examples of edible seaweeds include sea lettuce, wakame seaweed, kombu seaweed, mekabu seaweed, hiziki seaweed, nori seaweed, etc. Examples of animal-based foods include meat, eggs, dairy products, seafood, etc. Examples of meat include beef, pork, chicken, venison, horse meat, etc. An example of an egg is a chicken egg. Examples of dairy products include cheese, butter, yogurt, etc. Examples of seafood include fish, shellfish, shrimp, crabs, octopuses, squids, etc. By using food ingredients as the material of the molded body, various molded bodies having colors, tastes, and scents according to the materials can be provided according to the uses.

[0013] Examples of inedible parts of foods include, for vegetables, fruits, and tubers, skins, seeds, stems, etc.; for grains, husks, skins, etc.; for mushrooms, stems, mushroom beds, stone linings, etc.; for meat, bones, etc.; for eggs, shells, etc.; and for seafood, bones, scales, shells, etc. (e.g., fish skins, shrimp and crab shells, and seashells).

[0014] Examples of seaweeds contained in the waste materials include green algae, brown algae, red algae, etc. Examples of green algae include sea lettuce, green laver, sea mustard, cactus moss, fusiform seaweed, mill, saltwort, and hanemo. Examples of brown algae include sea potato, kombu, hijiki, butterbur, sea bamboo, mozuku, trumpet moss, wakame, and amijigusa. Examples of red algae include asakusanoori, tengusa, sea nettle, coral moss, suginori, ogonori, masagoshibari, and igisu.

[0015] The molded body is formed from, for example, powders of one or more types of waste materials, and is preferably formed from dry powders of one or more types of waste materials. As used herein, "dry powder" means a powder having a moisture content of 5% by weight or less. The molded body is formed from powders of waste materials having a moisture content of, for example, 5% by weight or less, 4% by weight or less, 3% by weight or less, 2% by weight or less, or 1% by weight or less. Note that the molded body may be formed from two or more types of waste materials.

[0016] The molded body may contain any material other than the waste material. For example, the molded body can contain an edible material in addition to the waste material. As used herein, "edible" means that it can be used for human or non-human animal consumption. Examples of edible materials include plant-based foods, animal-based foods, seasonings, edible clays, edible inks, edible plastics, etc. Examples of seasonings include sugar, salt, vinegar, soy sauce, miso, pepper, chili peppers, sauce, ketchup, mayonnaise, consommé powder, dashi powder, curry powder, cooking oil, etc. By adding a seasoning as a constituent of the molded body, the taste of the molded body can be adjusted to provide a molded body more suitable for consumption. Also, by adding an edible clay as a constituent of the molded body, an edible molded body with improved durability and density can be provided. The molded body preferably consists only of the waste material or only of the waste material and the edible material. In this case, the molded body has edibility as a whole and can be used for consumption.

[0017] The molded article may contain non-edible materials. Examples of non-edible materials include plastic materials, metal materials, ceramic materials, fiber materials, wood, wood chips, grass, paper, cloth, glass, sand, soil, clay, gravel, stone, cement, concrete, paint, and adhesives. Examples of plastic materials include polyethylene, polypropylene, polystyrene, polyethylene terephthalate, polycarbonate, and polyamide. For example, by adding plastic materials as components of the molded article, it is possible to provide a molded article with improved water resistance. In addition, any other material can be added depending on the properties required for the molded article.

[0018] The content of food waste and / or seaweed in the molded body is, for example, 50% or more by weight, 55% or more by weight, 60% or more by weight, 65% or more by weight, 70% or more by weight, 75% or more by weight, 80% or more by weight, 85% or more by weight, 90% or more by weight, or 95% or more by weight. The content of components other than food waste and seaweed in the molded body is, for example, 50% or less by weight, 40% or less by weight, 30% or less by weight, 25% or less by weight, 20% or less by weight, 15% or less by weight, 10% or less by weight, or 5% or less by weight. The content of seasonings and / or edible clay in the molded body is, for example, 50% or less by weight, 40% or less by weight, 30% or less by weight, 25% or less by weight, 20% or less by weight, 15% or less by weight, 10% or less by weight, or 5% or less by weight. The content of plastic powder in the molded body is, for example, 50% by weight or less, 40% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, or 5% by weight or less.

[0019] The molded body can be used for any purpose, for example, as a material for building materials, buildings, furniture, carpets, containers, interior goods, tableware, or decorative items (hereinafter collectively referred to as "building materials, etc."). By constructing the molded body solely from edible materials, edible building materials, etc. can be formed. Such edible building materials, etc. can be used, for example, as emergency food in times of emergency. Furthermore, after being used as building materials, etc., the molded body may be used as fertilizer.

[0020] The molded body is molded to have any size, shape, structure, density, and weight according to its intended use. Furthermore, the molded body is molded to have various properties such as strength, rigidity, hardness, water resistance, and heat resistance, depending on its intended use. For example, the molded body may have properties suitable for building applications. Preferably, the molded body has a three-point bending strength of 3 MPa or more, which is the standard for the bending strength of interlocking block pavement for sidewalks as specified in JIS A 5371:2016. More preferably, the molded body has a three-point bending strength of 5 MPa or more, which is the standard for the bending strength of interlocking block pavement for roadways as specified in JIS A 5371:2016. Preferably, the molded body has a compressive strength of 17 MPa or more, which is the standard for the compressive strength of interlocking block pavement for sidewalks as specified in JIS A 5371:2016. More preferably, the molded body has a compressive strength of 32 MPa or more, which is the standard for the compressive strength of interlocking block pavement for roadways as specified in JIS A 5371:2016.

[0021] <Method for manufacturing molded articles> In one embodiment, a method is provided for producing a molded body from waste material containing at least one of food waste and seaweed, the method comprising the steps of: preparing a dried powder made from at least the waste material; and forming a molded body by heating the dried powder to a predetermined temperature and applying pressure.

[0022] In one embodiment, the step of preparing a dried powder includes a drying step of drying the waste material and a grinding step of grinding the dried waste material to prepare a dried powder.

[0023] (Drying step) In the drying step, the waste material is dried by any means. For example, the drying step may include a step of vacuum drying of the waste material, a step of freeze-drying the waste material, a step of drying the waste material by heating with a heating device such as an oven or a hot air device, or a combination of these steps. In this specification, "freeze-drying" means a drying method in which the material is placed under reduced pressure to promote the evaporation of moisture. In this specification, "freeze-drying" means a drying method in which the moisture in the material is frozen and the moisture is sublimated under a vacuum (reduced pressure) state (also called freeze-drying). Note that efficient drying is possible by finely chopping, crushing, or mashing the waste material before the drying step.

[0024] (Grinding step) In the grinding step, the dry waste material is ground into a fine powder by any means. For example, the grinding step may include grinding the material using a general kitchen blender or mixer, or it may include grinding the material using any grinder such as a disc mill, ball mill, or jet mill.

[0025] In one embodiment, the step of forming a molded body includes a heat compression step in which the material is heated and then pressurized. The step of forming a molded body may further include a mixing step in which the dry powder is mixed with other materials before the heat compression step.

[0026] (Mixing step) In the mixing step, the dry powder of the waste material crushed in the grinding step is mixed with other materials by any means. For example, the mixing step may include manually mixing each material using cooking utensils such as chopsticks or spoons, or it may include mixing each material using a blender or mixer.

[0027] Examples of other materials mixed with waste materials include various edible and inedible materials as described above. For example, in the step of forming a molded body, the dry powder may be mixed with seasonings and then heat-compressed, or the dry powder may be mixed with plastic powder and then heat-compressed.

[0028] The timing of mixing with other materials is not limited to the examples above. For example, the mixing step may be performed before the drying step, before the grinding step, or incorporated into the grinding step. For example, the step of preparing the dried powder may further include a step of mixing and boiling the waste materials and seasonings before the drying step.

[0029] (Thermal compression step) In the thermal compression step, in which a molded body is formed by thermally compressing dry powder, the pulverized material is heated and then pressurized to form the molded body. In the thermal compression step, for example, a predetermined molding pressure is applied to the material for a predetermined molding time at a predetermined molding temperature.

[0030] The molding temperature can be appropriately determined depending on the application. For example, the molding temperature may be 40°C or higher, 45°C or higher, 50°C or higher, 55°C or higher, 60°C or higher, 65°C or higher, 70°C or higher, 75°C or higher, 80°C or higher, 85°C or higher, 90°C or higher, 95°C or higher, or 100°C or higher. For example, the molding temperature may be 300°C or lower, 250°C or lower, 200°C or lower, 195°C or lower, 190°C or lower, 185°C or lower, 180°C or lower, 175°C or lower, 170°C or lower, 165°C or lower, or 160°C or lower. For example, the molding temperature may be 50°C or higher and 200°C or lower.

[0031] When the waste material contains sugar, the molding temperature is preferably above the melting point of the sugar in the waste material. Alternatively, the molding temperature is preferably below the combustion temperature or thermal decomposition temperature of the sugar. Although the present invention is not limited to theory, as will be explained with reference to the experimental examples below, it is conceivable that by performing thermal compression molding at a molding temperature above the melting point of the sugar contained in the waste material, the sugar in the material melts and functions like an adhesive, maintaining the shape of the molded body and improving its strength.

[0032] The molding pressure applied to the dry powder can be appropriately determined depending on the application. Examples of molding pressures include 1 MPa or more, 2 MPa or more, 3 MPa or more, 4 MPa or more, 5 MPa or more, 10 MPa or more, 15 MPa or more, 20 MPa or more, 25 MPa or more, or 30 MPa or more. Other examples include 100 MPa or less, 90 MPa or less, 80 MPa or less, 70 MPa or less, 60 MPa or less, or 50 MPa or less. Finally, an example of a molding pressure between 4 MPa and 50 MPa is also possible.

[0033] The molding time may be determined as appropriate depending on the application. For example, the molding time may be 10 seconds or more, 20 seconds or more, 30 seconds or more, 40 seconds or more, 50 seconds or more, 1 minute or more, 2 minutes or more, 3 minutes or more, 4 minutes or more, 5 minutes or more, or 10 minutes or more. For example, the molding time may be 1 hour or less, 50 minutes or less, 40 minutes or less, 30 minutes or less, 25 minutes or less, or 20 minutes or less.

[0034] In the step of forming a molded body, the dry powder may be mixed with water and then heat-compressed. For example, water may be added to the dry powder in the mixing step, or water may be added to the dry powder immediately before heat compression. Hereinafter, the ratio of the weight of water to the total weight of the dry powder and water when water is added to the dry powder raw material before heat compression will be referred to as the "moisture content". A moisture content of 0% means that no water was added. The moisture content may be, for example, 0% or more, 1% or more, 2% or more, 3% or more, 4% or more, or 5% or more. The moisture content may be, for example, 20% or less, 15% or less, or 10% or less. [Examples]

[0035] Examples of the present invention will be described below with reference to Figures 1 to 6. These examples are not intended to limit the present invention.

[0036] [1. Shaping using only ingredients] First, we investigated the feasibility of molding using only dried powdered food ingredients. Using a molding temperature of 100°C, a molding pressure of 50 MPa, a molding time of 10 minutes, and a moisture content (amount of water added to the material) of 0% as basic conditions, we attempted molding by varying the molding temperature, molding pressure, molding time, and moisture content. The experimental conditions for each example are summarized in Table 1 below.

[0037] The ingredients used were orange (Experimental Example 1), edamame (Experimental Example 2), pumpkin (Experimental Examples 3-11), cabbage (Experimental Examples 12-16), onion (Experimental Example 17), Chinese cabbage (Experimental Examples 18, 19), banana (Experimental Examples 20-27), broccoli (Experimental Examples 28-30), maitake mushroom (Experimental Examples 31-34), Iyokan orange (Experimental Examples 35-47), coffee beans (Experimental Examples 48-50), sea lettuce (Experimental Examples 51-59), strawberry (Experimental Example 60), crab shell (Experimental Examples 61-65), spinach (Experimental Example 66), purple sweet potato (Experimental Example 67), and a mixture of pumpkin and Chinese cabbage (Experimental Example 68). In Experimental Examples 1-50 and 68, heat compression molding was performed on dried powder obtained from the inedible parts of commercially available ingredients. In Experimental Examples 51-67, heat compression molding was performed using commercially available dried powders. The inedible parts of each food item used were orange peel, edamame pods, pumpkin peel, whole cabbage, onion peel, whole Chinese cabbage, banana peel, broccoli stem, maitake mushroom stem and substrate, Iyokan orange peel, and coffee bean husks.

[0038] (Experimental Example 1) The edible and inedible parts of commercially available oranges were separated. The edible parts were consumed, and the remaining inedible parts were used as raw materials. The inedible parts were chopped as finely as possible and dried for 10 to 30 hours in a vegetable dryer (AFD-550 Dry Food Maker, manufactured by Apix International Co., Ltd.). Next, the material was freeze-dried using a vacuum dryer (FDU-2200, manufactured by Tokyo Rikakikai Co., Ltd.) to remove moisture from the inedible parts. Drying was terminated after confirming that the change in mass due to moisture removal had stopped. A photograph of the freeze-dried food is shown in Figure 1.

[0039] The dried inedible portion was ground using a disc mill. The ground, dried powder was sealed in a resealable bag to prevent absorption of moisture from the air during storage. In each of the following experimental examples, a disc mill or a household blender was used for grinding, depending on the hardness of the inedible portion. Photographs of the ground food are shown in Figure 2.

[0040] Next, the dry powder was thermally compressed using a thermal compression molding machine (H300-15, manufactured by AS ONE Corporation). A molding frame was placed on a hot plate and heated to 100°C, after which the dry powder was poured into the frame. No water was added to the dry powder (moisture content 0%). A pressure of 50 MPa was applied to the dry powder by operating the lever of a manual hydraulic pump. During pressurization, a decrease in pressure occurred due to the release of air and other substances from the dry powder, so the pressure was adjusted as needed to maintain a pressure of 50 MPa. After applying pressure for 10 minutes, the pressure was released, and the thermally compressed dry powder was demolded to obtain a molded body made from oranges. A photograph of the obtained molded body is shown in Figure 3.

[0041] (Experimental Example 2) Except for using commercially available edamame instead of oranges, and adding water to the dried powder so that the moisture content was 10% before heat compression, a molded body made from edamame was obtained in the same manner as in Experimental Example 1.

[0042] (Experimental Example 3) Except for using commercially available pumpkins instead of oranges and setting the molding temperature to room temperature (without heating), we attempted to form a molded body using pumpkins as the raw material in the same manner as in Experimental Example 1. However, the molded body obtained under these conditions was extremely brittle and easily crumbled.

[0043] (Experimental Example 4) Except for using commercially available pumpkins instead of oranges and setting the molding temperature to 60°C, we attempted to form a molded body using pumpkins as the raw material in the same manner as in Experimental Example 1. However, the molded body obtained under these conditions was very brittle and easily crumbled.

[0044] (Experimental Example 5) Except for using commercially available pumpkins instead of oranges and setting the molding temperature to 80°C, a molded body made from pumpkin was obtained in the same manner as in Experimental Example 1.

[0045] (Experimental Example 6) A molded body made from pumpkin was obtained in the same manner as in Experimental Example 1, except that commercially available pumpkins were used instead of oranges.

[0046] (Experimental Example 7) Except for using commercially available pumpkins instead of oranges and setting the molding temperature to 120°C, a molded body made from pumpkin was obtained in the same manner as in Experimental Example 1.

[0047] (Experimental Example 8) Except for using commercially available pumpkins instead of oranges and setting the molding temperature to 140°C, a molded body made from pumpkin was obtained in the same manner as in Experimental Example 1.

[0048] (Experimental Example 9) Except for using commercially available pumpkins instead of oranges and setting the molding temperature to 160°C, a molded body made from pumpkin was obtained in the same manner as in Experimental Example 1.

[0049] (Experimental Example 10) Except for using commercially available pumpkins instead of oranges, setting the molding temperature to 180°C, and the molding pressure to 6 MPa, a molded body made from pumpkin was obtained in the same manner as in Experimental Example 1.

[0050] (Experimental Example 11) Except for using commercially available pumpkins instead of oranges and setting the molding temperature to 180°C, a molded body made from pumpkin was obtained in the same manner as in Experimental Example 1.

[0051] (Experimental Example 12) Except for using commercially available cabbage instead of oranges and setting the molding temperature to 60°C, a molded body made from cabbage was obtained in the same manner as in Experimental Example 1.

[0052] (Experimental Example 13) Except for using commercially available cabbage instead of oranges and setting the molding temperature to 80°C, a molded body made from cabbage was obtained in the same manner as in Experimental Example 1.

[0053] (Experimental Example 14) Except for using commercially available cabbage instead of oranges, we attempted to form a molded body using cabbage as the raw material in the same manner as in Experimental Example 1. However, under these conditions, the powder melted and leaked out through the gaps in the mold, resulting in a molding failure.

[0054] (Experimental Example 15) Except for using commercially available cabbage instead of oranges and adding water to the dry powder to achieve a moisture content of 5% before heat compression, we attempted to form a molded body using cabbage as the raw material in the same manner as in Experimental Example 1. However, under these conditions, the powder melted and leaked out through the gaps in the mold, resulting in a molding failure.

[0055] (Experimental Example 16) Except for using commercially available cabbage instead of oranges and adding water to the dry powder to achieve a moisture content of 10% before heat compression, we attempted to form a molded body using cabbage as the raw material in the same manner as in Experimental Example 1. However, under these conditions, the powder melted and leaked out through the gaps in the mold, resulting in a molding failure.

[0056] (Experimental Example 17) A molded body made from onions was obtained in the same manner as in Experimental Example 1, except that commercially available onions were used instead of oranges.

[0057] (Experimental Example 18) Except for using commercially available Chinese cabbage instead of oranges and setting the molding temperature to 80°C, a molded body made from Chinese cabbage was obtained in the same manner as in Experimental Example 1.

[0058] (Experimental Example 19) A molded body made from Chinese cabbage was obtained in the same manner as in Experimental Example 1, except that commercially available Chinese cabbage was used instead of oranges.

[0059] (Experimental Example 20) Except for using commercially available bananas instead of oranges, setting the molding temperature to 80°C, and setting the molding pressure to 4 MPa, a molded body made from bananas was obtained in the same manner as in Experimental Example 1.

[0060] (Experimental Example 21) Except for using commercially available bananas instead of oranges, setting the molding temperature to 80°C, and setting the molding pressure to 10 MPa, a molded body made from bananas was obtained in the same manner as in Experimental Example 1.

[0061] (Experimental Example 22) Except for using commercially available bananas instead of oranges, setting the molding temperature to 80°C, and setting the molding pressure to 20 MPa, a molded body made from bananas was obtained in the same manner as in Experimental Example 1.

[0062] (Experimental Example 23) Except for using commercially available bananas instead of oranges, setting the molding temperature to 80°C, and setting the molding pressure to 30 MPa, a molded body made from bananas was obtained in the same manner as in Experimental Example 1.

[0063] (Experimental Example 24) Except for using commercially available bananas instead of oranges, setting the molding temperature to 80°C, and setting the molding pressure to 40 MPa, a molded body made from bananas was obtained in the same manner as in Experimental Example 1.

[0064] (Experimental Example 25) Except for using commercially available bananas instead of oranges and setting the molding temperature to 80°C, a molded body made from bananas was obtained in the same manner as in Experimental Example 1.

[0065] (Experimental Example 26) A molded body made from bananas was obtained in the same manner as in Experimental Example 1, except that commercially available bananas were used instead of oranges.

[0066] (Experimental Example 27) Except for using commercially available bananas instead of oranges and setting the molding temperature to 120°C, we attempted to form a molded body using bananas as the raw material in the same manner as in Experimental Example 1. However, under these conditions, the powder melted and leaked out through the gaps in the mold, resulting in a molding failure.

[0067] (Experimental Example 28) Except for using commercially available broccoli instead of oranges and setting the molding temperature to 60°C, a molded body made from broccoli was obtained in the same manner as in Experimental Example 1.

[0068] (Experimental Example 29) Except for using commercially available broccoli instead of oranges and setting the molding temperature to 80°C, a molded body made from broccoli was obtained in the same manner as in Experimental Example 1.

[0069] (Experimental Example 30) Except for using commercially available broccoli instead of oranges, we attempted to form a molded body using broccoli as the raw material in the same manner as in Experimental Example 1. However, under these conditions, the powder melted and leaked out through the gaps in the mold, resulting in a molding failure.

[0070] (Experimental Example 31) Except for using commercially available maitake mushrooms instead of oranges and setting the molding temperature to 60°C, we attempted to form a molded body using maitake mushrooms as the raw material in the same manner as in Experimental Example 1. However, the molded body obtained under these conditions was extremely brittle and easily crumbled.

[0071] (Experimental Example 32) Except for using commercially available maitake mushrooms instead of oranges and setting the molding temperature to 80°C, a molded body made from maitake mushrooms was obtained in the same manner as in Experimental Example 1.

[0072] (Experimental Example 33) A molded body made from maitake mushrooms was obtained in the same manner as in Experimental Example 1, except that commercially available maitake mushrooms were used instead of oranges.

[0073] (Experimental Example 34) Except for using commercially available maitake mushrooms instead of oranges and setting the molding temperature to 120°C, a molded body made from maitake mushrooms was obtained in the same manner as in Experimental Example 1.

[0074] (Experimental Example 35) A molded body made from Iyokan was obtained in the same manner as in Experimental Example 1, except that commercially available Iyokan was used instead of oranges.

[0075] (Experimental Example 36) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 60°C, and the molding pressure to 4 MPa, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0076] (Experimental Example 37) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 60°C, and the molding pressure to 10 MPa, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0077] (Experimental Example 38) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 60°C, and the molding pressure to 20 MPa, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0078] (Experimental Example 39) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 60°C, and the molding pressure to 30 MPa, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0079] (Experimental Example 40) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 60°C, and the molding pressure to 40 MPa, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0080] (Experimental Example 41) Except for using commercially available Iyokan oranges instead of regular oranges and setting the molding temperature to 60°C, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0081] (Experimental Example 42) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 60°C, the molding pressure to 20 MPa, and the molding time to 5 minutes, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0082] (Experimental Example 43) A molded body made from Iyokan was obtained in the same manner as in Experimental Example 1, except that commercially available Iyokan was used instead of oranges, the molding temperature was set to 60°C, the molding pressure to 20 MPa, and the molding time to 15 minutes.

[0083] (Experimental Example 44) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 60°C, the molding pressure to 20 MPa, and the molding time to 20 minutes, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0084] (Experimental Example 45) A molded body made from Iyokan was obtained in the same manner as in Experimental Example 1, except that commercially available Iyokan was used instead of oranges, the molding temperature was set to 60°C, the molding pressure to 20 MPa, and the molding time to 25 minutes.

[0085] (Experimental Example 46) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 60°C, the molding pressure to 20 MPa, and the molding time to 30 minutes, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0086] (Experimental Example 47) A molded body made from Iyokan was obtained in the same manner as in Experimental Example 1, except that commercially available Iyokan was used instead of oranges, the molding temperature was set to 60°C, the molding pressure was set to 20 MPa, and water was added to the dry powder so that the moisture content was 5% before heat compression.

[0087] (Experimental Example 48) Except for using commercially available coffee beans instead of oranges and setting the molding temperature to 180°C, a molded body made from coffee beans was obtained in the same manner as in Experimental Example 1.

[0088] (Experimental Example 49) Except for using commercially available coffee beans instead of oranges, setting the molding temperature to 180°C, and setting the moisture content to 5%, a molded body made from coffee beans was obtained in the same manner as in Experimental Example 1.

[0089] (Experimental Example 50) Except for using commercially available coffee beans instead of oranges, setting the molding temperature to 200°C, and setting the moisture content to 5%, a molded body made from coffee beans was obtained in the same manner as in Experimental Example 1.

[0090] (Experimental Example 51) Commercially available dried aonori powder (500g of Koumi Mansai domestically produced commercial aonori powder, Asahi Foods Industry) was prepared, and the dried powder was thermally compressed using a heat compression molding machine under the same conditions as in Experimental Example 1: molding temperature of 100°C, molding pressure of 50 MPa, molding time of 10 minutes, and moisture content of 0%. However, the molded body obtained under these conditions was very brittle and easily collapsed.

[0091] (Experimental Example 52) Except for setting the molding temperature to room temperature (without heating), we attempted to form a molded body using dried sea lettuce powder as the raw material, in the same manner as in Experimental Example 51. However, the molded body obtained under these conditions was very brittle and easily crumbled.

[0092] (Experimental Example 53) Except for setting the molding temperature to 60°C, we attempted to form a molded body using dried sea lettuce powder as the raw material, in the same manner as in Experimental Example 51. However, the molded body obtained under these conditions was very brittle and easily disintegrated.

[0093] (Experimental Example 54) Except for setting the molding temperature to 80°C, we attempted to form a molded body using dried sea lettuce powder as the raw material, in the same manner as in Experimental Example 51. However, the molded body obtained under these conditions was very brittle and easily disintegrated.

[0094] (Experimental Example 55) Except for setting the molding temperature to 120°C, a molded body made from dried sea lettuce powder was obtained in the same manner as in Experimental Example 51.

[0095] (Experimental Example 56) A molded body made from dried sea lettuce powder was obtained in the same manner as in Experimental Example 51, except that the molding temperature was set to 140°C.

[0096] (Experimental Example 57) Except for setting the molding temperature to 160°C, a molded body made from dried sea lettuce powder was obtained in the same manner as in Experimental Example 51.

[0097] (Experimental Example 58) A molded body made from dried sea lettuce powder was obtained in the same manner as in Experimental Example 51, except that the molding temperature was set to 180°C and the molding pressure to 6 MPa.

[0098] (Experimental Example 59) A molded body made from dried sea lettuce powder was obtained in the same manner as in Experimental Example 51, except that the molding temperature was set to 180°C.

[0099] (Experimental Example 60) A molded body made from dried strawberry powder was obtained in the same manner as in Experimental Example 51, except that commercially available dried strawberry powder (cotta freeze-dried strawberry powder, manufactured by cotta Co., Ltd.) was used instead of dried sea lettuce powder.

[0100] (Experimental Example 61) Except for using commercially available dried crab shells for fertilizer (1 kg of domestically produced crab shell powder, Tamagoya Co., Ltd.) instead of dried sea lettuce powder, and setting the molding temperature to 60°C, a molded body made from dried crab shell powder was obtained in the same manner as in Experimental Example 51.

[0101] (Experimental Example 62) Except for setting the molding temperature to 80°C, a molded body made from dried crab shell powder was obtained in the same manner as in Experimental Example 61.

[0102] (Experimental Example 63) Except for setting the molding temperature to 100°C, a molded body made from dried crab shell powder was obtained in the same manner as in Experimental Example 61.

[0103] (Experimental Example 64) Except for setting the molding temperature to 120°C, a molded body made from dried crab shell powder was obtained in the same manner as in Experimental Example 61.

[0104] (Experimental Example 65) Except for setting the molding temperature to 140°C, we attempted to form a molded body using dried crab shell powder as the raw material, in the same manner as in Experimental Example 61. However, under these conditions, the powder melted and leaked out through the gaps in the mold, resulting in a molding failure.

[0105] (Experimental Example 66) A molded body made from dried spinach powder was obtained in the same manner as in Experimental Example 51, except that commercially available dried spinach powder (spinach powder, manufactured by Mikasa Sangyo Co., Ltd.) was used instead of dried sea lettuce powder.

[0106] (Experimental Example 67) A molded body made from dried purple sweet potato powder was obtained in the same manner as in Experimental Example 51, except that commercially available dried purple sweet potato powder (purple sweet potato powder, manufactured by Mikasa Sangyo Co., Ltd.) was used instead of dried sea lettuce powder.

[0107] (Experimental Example 68) In order to investigate the feasibility of molding by mixing multiple ingredients, commercially available pumpkins and Chinese cabbages were used instead of oranges, and a molded body made from pumpkins and Chinese cabbages was obtained in the same manner as in Experimental Example 1, except that the dried powder, mixed so that the weight ratio of the inedible parts of the pumpkins to the inedible parts of the Chinese cabbages was 3:1, was heat-compressed.

[0108] As described above, it was confirmed that molded bodies could be obtained for at least oranges, edamame, pumpkins, cabbage, onions, Chinese cabbage, bananas, broccoli, maitake mushrooms, Iyokan oranges, coffee beans, sea lettuce, strawberries, crab shells, spinach, and purple sweet potatoes by adjusting the molding conditions. Furthermore, it was confirmed that molded bodies could be obtained even when multiple ingredients were mixed, as in Experimental Example 68. However, with some ingredients, if the molding temperature was too low, the molded body would easily collapse, and if the molding temperature was too high, the powder would melt and leak out through the gaps in the mold.

[0109] [2. Shaping using ingredients and seasonings] Secondly, we investigated the feasibility of molding when seasonings were added to dried food powders. Two methods were used for adding seasonings: boiling the food and seasonings together before drying (Experimental Examples 69-77) and adding and mixing the seasonings to the dried food powder (Experimental Examples 78-82). The experimental conditions for each example are summarized in Table 2 below.

[0110] (Experimental Example 69) Water was brought to a boil in a pot, and finely chopped commercially available oranges were added to the pot along with commercially available sugar and boiled for about 30 minutes. Next, the water was drained using a colander, and the oranges were dried in a vegetable dryer and a vacuum dryer as in Experimental Example 1 to obtain a dried powder. Then, as in Experimental Example 1, the dried powder was subjected to thermal compression using a thermal compression molding machine under the conditions of a molding temperature of 100°C, a molding pressure of 50 MPa, a molding time of 10 minutes, and a moisture content of 0%. However, under these conditions, the powder melted and leaked out through the gaps in the mold, resulting in a molding failure.

[0111] (Experimental Example 70) Except for setting the molding temperature to 60°C, a molded body was obtained using sugar and boiled oranges as raw materials in the same manner as in Experimental Example 69.

[0112] (Experimental Example 71) Except for setting the molding temperature to 100°C and the molding pressure to 6 MPa, a molded body was obtained using sugar and boiled oranges as raw materials in the same manner as in Experimental Example 69.

[0113] (Experimental Example 72) Except for boiling the inedible parts of the pumpkin with commercially available consommé powder instead of boiling the inedible parts of the orange with sugar, we attempted to form a molded body under the same conditions as in Experimental Example 69: molding temperature of 100°C, molding pressure of 50 MPa, molding time of 10 minutes, and moisture content of 0%. However, under these conditions, the powder melted and leaked out through the gaps in the mold, resulting in a molding failure.

[0114] (Experimental Example 73) Except for setting the molding temperature to 60°C, the molding pressure to 30 MPa, and the molding time to 5 minutes, a molded body made from consommé powder and boiled pumpkin was obtained in the same manner as in Experimental Example 72.

[0115] (Experimental Example 74) Except for setting the molding temperature to 60°C and the molding time to 5 minutes, a molded body made from consommé powder and boiled pumpkin was obtained in the same manner as in Experimental Example 72.

[0116] (Experimental Example 75) Except for setting the molding temperature to 60°C, a molded body was obtained using consommé powder and boiled pumpkin as raw materials in the same manner as in Experimental Example 72.

[0117] (Experimental Example 76) Except for boiling the inedible parts of oranges with sugar, the inedible parts of bananas were boiled with commercially available sugar instead, and the molding process was the same as in Experimental Example 69, with a molding temperature of 100°C, a molding pressure of 50 MPa, a molding time of 10 minutes, and a moisture content of 0% to obtain a molded body made from bananas boiled with sugar.

[0118] (Experimental Example 77) Except for setting the molding pressure to 6 MPa, a molded body was obtained using sugar and boiled bananas as raw materials in the same manner as in Experimental Example 76.

[0119] (Experimental Example 78) A molded body made from oranges and sugar was obtained under the same conditions as in Experimental Example 1, except that the dried orange powder and commercially available sugar were mixed in a weight ratio of 3:1 before the heat compression of the dried orange powder, with a molding temperature of 100°C, a molding pressure of 50 MPa, a molding time of 10 minutes, and a moisture content of 0%.

[0120] (Experimental Example 79) A molded body made from oranges and salt was obtained in the same manner as in Experimental Example 78, except that commercially available salt was used instead of sugar.

[0121] (Experimental Example 80) Except for using onions instead of oranges and commercially available consommé powder instead of sugar, molded bodies made from onions and consommé powder were obtained in the same manner as in Experimental Example 78.

[0122] (Experimental Example 81) Except for using Chinese cabbage instead of oranges, using commercially available consommé powder instead of sugar, and setting the molding temperature to 80°C, a molded body made from Chinese cabbage and consommé powder was obtained in the same manner as in Experimental Example 78.

[0123] (Experimental Example 82) Except for mixing the dried aonori powder with commercially available consommé powder in a weight ratio of 3:1 before heat-compressing the dried aonori powder, and setting the molding temperature to 120°C, a molded body made from dried aonori powder and consommé powder was obtained by heat-compressing the dried powder using a heat-compression molding machine, similar to Experimental Example 51.

[0124] As described above, it was confirmed that, for at least oranges, pumpkins, bananas, onions, Chinese cabbage, and sea lettuce, a molded body containing seasonings can be obtained by boiling them together with seasonings or by mixing them with seasonings in a dried powder form.

[0125] [3. Molding using food ingredients and edible clay] Thirdly, we investigated the feasibility of molding when edible clay was added to dried food powders. This investigation was conducted using cabbage (Experimental Examples 83-85) and bananas (Experimental Examples 86-88). The experimental conditions for each example are summarized in Table 3 below.

[0126] (Experimental Example 83) Except for using commercially available cabbage instead of oranges, mixing the dried cabbage-derived powder with commercially available edible clay (Greypress Natural Edible Clay, manufactured by UCLAY) in a weight ratio of 3:1 before heat-compressing the dried cabbage-derived powder, and setting the molding temperature to 80°C, a molded body made from cabbage and edible clay was obtained in the same manner as in Experimental Example 1, under the conditions of a molding temperature of 100°C, a molding pressure of 50 MPa, a molding time of 10 minutes, and a moisture content of 0%.

[0127] (Experimental Example 84) A molded body made from cabbage and edible clay was obtained in the same manner as in Experimental Example 83, except that the dried cabbage powder and edible clay were mixed in a weight ratio of 2:1.

[0128] (Experimental Example 85) A molded body made from cabbage and edible clay was obtained in the same manner as in Experimental Example 83, except that the dried cabbage powder and edible clay were mixed in a weight ratio of 1:1.

[0129] (Experimental Example 86) Except for using commercially available bananas instead of cabbage, we attempted to form a molded body using bananas and edible clay (mixed in a weight ratio of 3:1) as raw materials, in the same manner as in Experimental Example 83.

[0130] (Experimental Example 87) A molded body made from bananas and edible clay was obtained in the same manner as in Experimental Example 86, except that the dried banana powder and edible clay were mixed in a weight ratio of 2:1.

[0131] (Experimental Example 88) A molded body made from bananas and edible clay was obtained in the same manner as in Experimental Example 86, except that the dried banana powder and edible clay were mixed in a weight ratio of 1:1.

[0132] As described above, it was confirmed that molded bodies containing edible clay can be obtained from at least cabbage and banana.

[0133] [4. Molding using food ingredients and plastic powder] Fourth, we investigated the feasibility of molding when plastic powder is added to dried food powder. This investigation was conducted using Iyokan oranges. The experimental conditions for each experiment are summarized in Table 4 below.

[0134] (Experimental Example 89) A molded body made from Iyokan and plastic powder was obtained under the same conditions as in Experimental Example 35, with a molding temperature of 100°C, a molding pressure of 50 MPa, a molding time of 10 minutes, and a moisture content of 0%, except that before thermal compression of the dried powder derived from Iyokan, the dried powder derived from Iyokan was mixed with commercially available polyethylene fine powder (N2000640, Featherfield Corporation) in a weight ratio of 3:1.

[0135] (Experimental Example 90) A molded body made from Iyokan citrus and plastic powder was obtained in the same manner as in Experimental Example 89, except that the dried powder derived from Iyokan citrus and polyethylene powder were mixed in a weight ratio of 2:1.

[0136] (Experimental Example 91) A molded body made from Iyokan citrus and plastic powder was obtained in the same manner as in Experimental Example 89, except that the dried powder derived from Iyokan citrus and polyethylene powder were mixed in a weight ratio of 1:1.

[0137] As described above, it has been confirmed that a molded body containing plastic powder can be obtained, at least with regard to Iyokan oranges.

[0138] [5.Remolding] Fifth, we investigated the reusability of molded bodies once they had been produced. This investigation was conducted using cabbage (Experimental Example 92), Chinese cabbage (Experimental Example 93), and sea lettuce (Experimental Examples 94 and 95). The experimental conditions for each example are summarized in Table 5 below.

[0139] (Experimental Example 92) In Experimental Example 13, the cabbage-derived molded body was crushed using a disc mill, and then subjected to further heat compression molding under the conditions of a molding temperature of 80°C, a molding pressure of 6 MPa, a molding time of 10 minutes, and a moisture content of 0%, to obtain a molded body made from cabbage.

[0140] (Experimental Example 93) After crushing the cabbage-derived molded body prepared in Experimental Example 18 using a disc mill, it was subjected to further heat compression molding under the conditions of a molding temperature of 100°C, a molding pressure of 10 MPa, a molding time of 10 minutes, and a moisture content of 0%, to obtain a molded body made from cabbage.

[0141] (Experimental Example 94) In Experimental Example 52, the molded body derived from sea lettuce was crushed using a disc mill, and then subjected to thermal compression molding again under the conditions of a molding temperature of 120°C, a molding pressure of 10 MPa, a molding time of 10 minutes, and a moisture content of 0%, to obtain a molded body made from sea lettuce.

[0142] (Experimental Example 95) In Experimental Example 52, the molded body derived from sea lettuce was crushed using a disc mill, and then subjected to thermal compression molding again under the conditions of a molding temperature of 140°C, a molding pressure of 10 MPa, a molding time of 10 minutes, and a moisture content of 0%, to obtain a molded body made from sea lettuce.

[0143] As described above, it was confirmed that, at least for cabbage, Chinese cabbage, and sea lettuce, the molded bodies produced once can be crushed and remolded.

[0144] [6. Drying using an oven] (Experimental Example 96) A molded body made from oranges was obtained in the same manner as in Experimental Example 1, except that instead of freeze-drying in a vacuum dryer, oranges that had been pre-dried in a vegetable dryer were placed in an oven set to 105°C for drying.

[0145] (Experimental Example 97) A molded body made from onions was obtained in the same manner as in Experimental Example 96, except that commercially available onions were used instead of oranges.

[0146] (Experimental Example 98) A molded body made from bananas was obtained in the same manner as in Experimental Example 96, except that commercially available bananas were used instead of oranges.

[0147] As described above, it was confirmed that, at least for oranges, onions, and bananas, molded bodies can be formed by drying in an oven instead of freeze-drying.

[0148] [7. Molding for water resistance evaluation] (Experimental Example 99) Except for using commercially available Iyokan oranges instead of regular oranges, setting the molding temperature to 80°C, and the molding pressure to 20 MPa, a molded body made from Iyokan oranges was obtained in the same manner as in Experimental Example 1.

[0149] (Experimental Example 100) Commercially available powdered green tea (product name: Powdered Green Tea, manufactured by Honjien) was prepared, and a molded body made from green tea was obtained by thermally compressing the dried powder using a heat compression molding machine under the following conditions: molding temperature of 80°C, molding pressure of 20 MPa, molding time of 10 minutes, and moisture content of 0%.

[0150] (Experimental Example 101) Except for using commercially available Iyokan oranges and powdered green tea instead of oranges, and performing heat compression molding of the dried powder mixed with the inedible part of the Iyokan orange and powdered green tea in a weight ratio of 1:1, the molding temperature was set to 80°C, and the molding pressure was set to 20 MPa, a molded body made from Iyokan oranges and green tea was obtained in the same manner as in Experimental Example 99.

[0151] [Evaluation Example 1: Bending Strength] Three-point bending tests were performed on the molded bodies produced in each experimental example, and the bending strength of each molded body was determined. The three-point bending test was conducted using a compression testing machine with a relative indication error of 2.0% or less, which has a metal support rod with a diameter of approximately 10 mm and a metal pressure rod with a diameter of 10 mm. The molded body was supported by two support rods, and a pressure of 1 ± 0.2 N / mm² per second was applied to the center. 2The process involved applying a load at a certain speed and measuring the maximum load at which the molded body fractured, as well as the thickness of the thinnest part of the fracture surface of the fractured sample (see also JIS A 1509-4:2014). Table 1 shows the raw materials, molding conditions, success or failure of molding, and bending strength of each molded body from Experimental Examples 1 to 68.

[0152] [Table 1A] [Table 1B]

[0153] (Bending strength of each material) Figure 4 shows the results of comparing the bending strength of molded bodies obtained under basic conditions (molding temperature 100°C, molding pressure 50 MPa, molding time 10 minutes, moisture content 0%) for various raw materials. However, for some raw materials, such as those that failed to mold under the basic conditions, the results of molding under different conditions close to the basic conditions are shown. Specifically, the results are shown for edamame with a moisture content of 5%, coffee beans at a molding temperature of 180°C, cabbage and broccoli at a molding temperature of 80°C, and sea lettuce at a molding temperature of 120°C (other conditions are the same as the basic conditions).

[0154] The flexural strength of molded products made from edamame, coffee beans, crab shells, spinach, purple sweet potato, strawberries, maitake mushrooms, broccoli, sea lettuce, onions, Iyokan oranges, cabbage, bananas, oranges, and Chinese cabbage exceeded the 3 MPa standard for flexural strength of interlocking block pavements for sidewalks specified in JIS A 5371:2016. In particular, the flexural strength of molded products made from strawberries, maitake mushrooms, broccoli, sea lettuce, onions, Iyokan oranges, cabbage, bananas, oranges, and Chinese cabbage also exceeded the 5 MPa standard for flexural strength of interlocking block pavements for roadways specified in JIS A 5371:2016. The molded product made from Chinese cabbage showed the highest flexural strength among all the materials.

[0155] (Molding temperature dependence) The temperature dependence of flexural strength was investigated for molded bodies of pumpkin, maitake mushroom, sea lettuce, and crab shell, produced at three or more molding temperatures under the conditions of a molding pressure of 50 MPa, a molding time of 10 minutes, and a moisture content of 0%. Figure 5 shows the temperature dependence of the flexural strength of the molded bodies of pumpkin, maitake mushroom, sea lettuce, and crab shell. Overall, there was a tendency for flexural strength to increase as the temperature rose. On the other hand, at excessively high temperatures, the increase in flexural strength became smaller, or the flexural strength tended to decrease after passing the maximum point. For all of the materials used—pumpkin, maitake mushroom, aonori seaweed, and crab shell—a bending strength exceeding 3 MPa, the standard for bending strength of interlocking block pavements for sidewalks as specified in JIS A 5371:2016, could be obtained by adjusting the molding temperature. In particular, it was confirmed that pumpkin, maitake mushroom, and aonori seaweed could achieve a bending strength exceeding 5 MPa, the standard for bending strength of interlocking block pavements for roadways as specified in JIS A 5371:2016.

[0156] While this invention is not limited by theory, one possible explanation for this tendency is the following mechanism: As the temperature rises, the sugars in heated food ingredients melt, acting like an adhesive to bond the dry powders of the ingredients together, maintaining the shape of the heat-compressed molded body and improving its strength. If the molding temperature is too low, the sugars do not melt sufficiently, causing the molded body to easily collapse or failing to achieve sufficient flexural strength. On the other hand, if the molding temperature is too high, the sugars may not function as an adhesive due to combustion or charring, potentially reducing flexural strength. Examples of sugars include maltose, which has a melting point of 102°C to 108°C; glucose, which contains one molecule of hydrated water, which has a melting point of 86°C; anhydrous crystalline glucose, which has a melting point of 146°C to 150°C; and fructose, which has a melting point of 102°C to 104°C.

[0157] (Dependent on molding pressure) In experimental examples 20-25 using bananas and experimental examples 35-41 using Iyokan oranges, the pressure dependence of molding was investigated by performing molding at molding pressures of 4 MPa, 10 MPa, 20 MPa, 30 MPa, 40 MPa, and 50 MPa. As a result, molded bodies were obtained for both bananas and Iyokan oranges at all molding pressures. Figure 6 shows the molding pressure dependence of the bending strength of the molded bodies of bananas and Iyokan oranges. For bananas, the maximum bending strength was obtained at a molding pressure of 10 MPa, and for Iyokan oranges, the maximum bending strength was obtained at a molding pressure of 40 MPa. Furthermore, it was confirmed that bending strengths exceeding 3 MPa, the standard for bending strength of interlocking block pavement for sidewalks as specified in JIS A 5371:2016, were obtained at all molding pressures, and that bending strengths exceeding 5 MPa, the standard for bending strength of interlocking block pavement for roadways as specified in JIS A 5371:2016, were obtained at all molding pressures of 10 MPa or higher.

[0158] (Molding time dependence) In experimental examples 38 and 42-46 using Iyokan oranges, the time dependence of molding was investigated by performing molding for 5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, and 30 minutes. As a result, molded bodies were obtained for all molding times. The maximum bending strength was obtained at a molding time of 25 minutes.

[0159] (moisture content dependence) In experimental examples 38 and 47 using Iyokan oranges, the moisture content dependence of molding was investigated by performing molding at moisture content of 0% and 5%. As a result, molded bodies were obtained in both examples, and the bending strength was greater at 0% moisture content.

[0160] (Molding using multiple materials) In Experiment 68, which involved a mixture of pumpkin and Chinese cabbage, it was confirmed that replacing some of the pumpkin (2.86 MPa), which had the lowest bending strength in Figure 4, with Chinese cabbage (17.73 MPa), which had the highest bending strength, improved the bending strength of the molded body compared to the case using only pumpkin (9.37 MPa).

[0161] (Shaping using ingredients and seasonings) Table 2 shows the raw materials, molding conditions, molding success / failure status, and flexural strength of each molded body in Experimental Examples 69-82. Of Experimental Examples 69-82, in which the raw materials and seasonings were boiled together, Experimental Examples 69-77 showed different results in terms of molding success / failure status and flexural strength compared to the case with raw materials alone. On the other hand, in Experimental Examples 78-82, in which the seasonings were mixed immediately before heat compression, the flexural strength was improved compared to the case without seasonings.

[0162] [Table 2]

[0163] (Molding using food ingredients and edible clay) Table 3 shows the raw materials, molding conditions, molding success / failure status, and flexural strength of each molded body in Experimental Examples 83-88. The flexural strength of the cabbage molded bodies mixed with edible clay (Experimental Examples 83-85) was greater than that of Experimental Example 13 (9.47 MPa) without edible clay, at least when the weight ratio of raw material to edible clay was in the range of 3:1 to 2:1. Similarly, the flexural strength of the banana molded bodies mixed with edible clay (Experimental Examples 86-88) was greater than that of Experimental Example 27 (9.67 MPa) without edible clay, at least when the weight ratio of raw material to edible clay was in the range of 3:1 to 2:1.

[0164] [Table 3]

[0165] (Molding using food ingredients and plastic powder) Table 4 shows the raw materials, molding conditions, molding success / failure status, and flexural strength of each molded product in Experimental Examples 89-91. The flexural strength of Experimental Examples 89-91, which were mixed with plastic powder, was greater than that of Experimental Example 35 (9.34 MPa), which was made solely from Iyokan oranges.

[0166] [Table 4]

[0167] (Remolding) Table 5 shows the raw materials, molding conditions, molding success / failure status, and flexural strength of each remolded product in Experimental Examples 92-95. In Experimental Examples 92-95, where remolding of the molded product was attempted, the flexural strength decreased compared to the original molded product in all cases. However, at least for the sea lettuce (Experimental Examples 94 and 95), a higher flexural strength was obtained in Experimental Example 95, where the molding temperature during remolding was higher, than in Experimental Example 94.

[0168] [Table 5]

[0169] [Evaluation Example 2: Appearance and Edibility] The resulting molded products were visually observed, and their surface color, pattern, and comparisons with the raw state were examined. Furthermore, the molded products were crushed into small pieces and tasted to evaluate their flavor, melt-in-the-mouth texture, and aroma.

[0170] First, freeze-drying and oven drying were compared for oranges, onions, and bananas. In the oven-dried samples, charring was noticeable, and the appearance was darker. The taste also had a burnt flavor and was generally bitter. Regarding the aroma, the orange retained its original scent, the onion smelled like sautéed onions, and the banana changed to a damp smell different from its original scent. In all cases, the burnt smell was not very noticeable.

[0171] On the other hand, the molded products dried in a vacuum dryer showed little change in color from before drying, and were more vibrant and decorative compared to those dried in an oven. The taste also showed little change from before drying. Regarding the aroma, the orange had the scent of the food, the onion had an aroma similar to raw onion, and the banana had a faint sweet scent of the food.

[0172] Next, we examined the effects of different molding temperatures. Although there were differences depending on the ingredients, overall, there was a tendency for the products to turn brown or black as the molding temperature increased.

[0173] Next, the appearance and edibility of the mixtures with added seasonings were examined. In experiments 69-77, where the mixtures were boiled with seasonings, the molded products were darker in color than those made with only the ingredients, and some color unevenness was observed. Upon tasting, all of the products tasted good, and the astringency and bitterness of the raw materials were almost completely eliminated. In experiments 78-82, where the seasonings were mixed immediately before heat compression, the color of the molded products varied slightly depending on the ingredient compared to those made with only the ingredients. Regarding the taste, in experiments 78 and 79 using oranges, the bitterness of the peel was suppressed, making them relatively easy to eat. In experiments 80-82 using onions, Chinese cabbage, and sea lettuce, the taste of consommé was strongly perceived.

[0174] Next, the appearance and edibility of the food after adding edible clay were investigated. In Experiments 83-88, two types of food, cabbage and banana, were compared when edible clay was added at different ratios. The cabbage turned gray even at low clay addition ratios, but some of the cabbage's green color remained at low clay ratios. The banana gradually changed to a lighter gray as the clay addition ratio increased. In all of the experiments, the change in taste due to the addition of clay was small, but the texture became closer to the texture of clay. Regarding the aroma, there was a tendency for the aroma of the food to be suppressed as the clay ratio increased.

[0175] [Evaluation Example 3: Durability] Oranges, oranges with added sugar, sea lettuce, Chinese cabbage, and maitake mushrooms were subjected to a bending test. One of the two halves of the molded material was left on a plate at room temperature (22°C) for about a month, while the other half was stored in a sealed container. After one month, changes in color and smell, as well as the presence or absence of spoilage, mold, and insect infestation were checked to investigate the differences due to exposure to the outside air.

[0176] When the molded objects made with oranges were left on a plate, their color faded more than those kept sealed. When left on a plate, all the molded objects had almost no scent left. Even when left on a plate, there was no dirt or insects attached to the surface. There was also little difference in texture.

[0177] [Evaluation Example 4: Water Resistance (Moisture Absorption)] For molded bodies of Iyokan oranges to which polyethylene powder was added (Experimental Examples 89-91), the water resistance was evaluated by immersing the resulting molded bodies in water for 24 hours and measuring the increase in weight before and after immersion. A larger increase in weight before and after immersion indicated higher hygroscopicity of the molded body and inferior water resistance.

[0178] Table 6 shows the results of the water resistance evaluation for experimental examples 89-91. The weight increase rate (%) is the value obtained by dividing the weight increase of the molded body before and after immersion by the weight of the molded body before immersion. It was confirmed that the greater the amount of plastic powder added, the smaller the weight increase rate (i.e., the amount of water absorbed by the molded body) and the improved water resistance tended to be.

[0179] [Table 6]

[0180] [Evaluation Example 5: Water Resistance (Maintaining the Shape of the Molded Body)] For molded bodies made from Iyokan oranges (Experimental Example 99), green tea (Experimental Example 100), and a mixture of Iyokan oranges and green tea (Experimental Example 101), the molded bodies were immersed in water for one hour and then removed. The degree to which their shape was maintained was then evaluated.

[0181] In all of the experimental examples, the shape before immersion was sufficiently maintained. However, comparing experimental examples 99 to 101, the effect of immersion on the shape of the molded body was smallest for the green tea molded body (experimental example 100), followed by the molded body made from a mixture of Iyokan and green tea (experimental example 101). Therefore, it was confirmed that green tea has superior water resistance to maintaining the shape of the molded body compared to Iyokan. It was also confirmed that by mixing a material with superior water resistance (green tea) with a material with inferior water resistance (Iyokan) to form a molded body, it is possible to improve the water resistance compared to a molded body made only from the material with inferior water resistance.

[0182] Furthermore, for molded bodies of Iyokan oranges (Experimental Example 99) and green tea (Experimental Example 100), the molded bodies were immersed in salad oil for approximately 5 seconds, then immersed in water for 1 hour, and removed to evaluate how well their shape was maintained.

[0183] In all experimental cases, the shape before immersion was sufficiently maintained. However, when the molded body was immersed in salad oil before immersion in water, the shape was maintained to the same or better extent compared to when it was not immersed in salad oil. The shape of the molded body was also particularly well-maintained when touched by hand compared to when it was not immersed in salad oil. Therefore, it was confirmed that immersing the molded body in oil after formation can improve its water resistance in terms of maintaining its shape.

Claims

1. A method for producing a molded body from waste materials containing at least one of food waste and seaweed, The steps include at least preparing a dried powder made from the aforementioned waste material, The steps include forming a molded body by heating the dried powder to a predetermined temperature and applying pressure, Includes, The three-point bending strength of the molded body is 3 MPa or more. The thermal compression in the step of forming the molded body is performed at a temperature of 50°C to 200°C and a pressure of 4 MPa to 50 MPa. The content of at least one of the food waste and seaweed in the molded body is 60% by weight or more. In the step of forming the molded body, (a) Only the dried powder obtained by crushing the dried waste material is subjected to thermal compression, (b) The pre-dried powder obtained by crushing the dried waste material is mixed with seasonings and then heat-compressed, (c) The dried powder obtained by crushing the dried waste material is mixed with edible clay and heat-compressed, The aforementioned waste material consists of at least one of food waste and seaweed. method.

2. A method for producing a molded body from waste material comprising at least one of food waste and seaweed, The steps include at least preparing a dried powder made from the aforementioned waste material, The steps include forming a molded body by heating the dried powder to a predetermined temperature and applying pressure, Includes, The three-point bending strength of the molded body is 3 MPa or more. The thermal compression in the step of forming the molded body is performed at a temperature of 50°C to 200°C and a pressure of 4 MPa to 50 MPa. The content of at least one of the food waste and seaweed in the molded body is 60% by weight or more. The step of preparing the aforementioned dried powder is, The process further includes the step of mixing the aforementioned waste materials with seasonings and boiling them together. method.

3. The content of at least one of the food waste and seaweed in the molded body is 90% by weight or more. The method according to claim 1 or 2.

4. The content of at least one of the food waste and seaweed in the molded body is 95% by weight or more. The method according to claim 1 or 2.

5. The aforementioned food waste consists of the inedible parts of food. The method according to any one of claims 1 to 4.

6. The aforementioned waste material is part or all of one or more materials selected from the group consisting of oranges, edamame, pumpkins, cabbage, onions, Chinese cabbage, bananas, broccoli, maitake mushrooms, Iyokan oranges, coffee beans, sea lettuce, strawberries, crab shells, spinach, and purple sweet potatoes. The method according to any one of claims 1 to 5.

7. The aforementioned waste material contains sugar, The predetermined temperature is above the melting point of the sugar in the waste material. The method according to any one of claims 1 to 6.

8. In the step of forming the molded body, the pressure applied to the dry powder is 20 MPa or more and 50 MPa or less. The method according to any one of claims 1 to 7.

9. The above step of preparing the dried powder is, The steps include drying the aforementioned waste material, The process includes the step of crushing the dried waste material to prepare a dried powder, The method according to any one of claims 1 to 8.

10. The step of drying the waste material includes a step of freeze-drying the waste material. The method according to claim 9.

11. In the step of forming a molded body, the dried powder is mixed with the seasoning and then heat-compressed. The method according to any one of claims 1 to 10.

12. The molded body consists solely of the waste material, or solely of the waste material and edible clay. The method according to any one of claims 1 to 10.

13. The method according to claim 1, wherein the thermal compression in (a) to (c) above is performed at a temperature of 50°C to 200°C and a pressure of 20 MPa to 50 MPa.

14. The aforementioned waste materials are selected from the group consisting of oranges, edamame, pumpkins, cabbage, onions, Chinese cabbage, bananas, broccoli, maitake mushrooms, Iyokan oranges, coffee beans, sea lettuce, strawberries, crab shells, spinach, and purple sweet potatoes. If the waste material is part or all of a pumpkin, the thermal compression in (a) above is performed at a temperature of 120°C to 200°C and a pressure of 20 MPa to 50 MPa. If the waste material is part or all of a cabbage, the thermal compression in (a) above is carried out at a temperature of 60°C to 80°C and a pressure of 20 MPa to 50 MPa. If the waste material is part or all of a banana, the thermal compression in (a) above is performed at a temperature of 80°C to 100°C and a pressure of 20 MPa to 50 MPa. If the waste material is part or all of broccoli, the thermal compression in (a) above is performed at a temperature of 60°C to 80°C and a pressure of 20 MPa to 50 MPa. If the waste material is part or all of a maitake mushroom, the thermal compression in (a) above is carried out at a temperature of 80°C to 120°C and a pressure of 20 MPa to 50 MPa. If the aforementioned waste material is part or all of the sea lettuce, the thermal compression in (a) above shall be carried out at a temperature of 120°C to 180°C and a pressure of 20 MPa to 50 MPa. If the waste material is part or all of a crab shell, the thermal compression in (a) above is performed at a temperature of 80°C to 100°C and a pressure of 20 MPa to 50 MPa. The method according to claim 13.

15. A heat-compressed molded body made from waste materials, comprising at least one of food waste and seaweed, The three-point bending strength is 3 MPa or more. The content of at least one of the aforementioned food waste and seaweed is 60% by weight or more. It consists solely of the aforementioned waste materials, or solely of the aforementioned waste and seasonings, or solely of the aforementioned waste materials and edible clay. A heat-compressed molded body.

16. The aforementioned waste material is part or all of one or more materials selected from the group consisting of oranges, edamame, pumpkins, cabbage, onions, Chinese cabbage, bananas, broccoli, maitake mushrooms, Iyokan oranges, coffee beans, sea lettuce, strawberries, crab shells, spinach, and purple sweet potatoes. The heat-compressed molded article according to claim 15.

17. Building materials, structures, furniture, carpets, containers, interior accessories, tableware, or decorative items, including the heat-compressed molded body according to claim 15 or 16.

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