Manufacturing method of cream-mixed gochujang sauce using phase stabilization emulsion process

Abstract

The present invention relates to a technology for manufacturing a cream gochujang sauce that minimizes oil-water separation even during long-term storage by mixing fermented gochujang with **cream (animal- or vegetable-based)**. In order to suppress phase separation that occurs when the fermentation microorganisms of gochujang, capsaicin, glutamic acid, etc., and the oil content of the cream are mixed, the cream particles are fined to a level of 110 μm by using a combination of an emulsifier (lecithin, gums, etc.) + a stabilizer (protein hydrolysate, etc.) and applying **high-pressure homogenization (1,500-3,000 psi)** in two stages. In addition, the pH is adjusted to 5.0–5.5 and the water activity (Aw) to 0.90–0.93 to achieve both microbial safety and fermented flavor, and aseptic filling or pasteurization at around 85°C is introduced to minimize the destruction of the cream texture. As a result, the phase separation rate is managed to be less than 5% even during storage for at least 6 to 12 months, and the spicy taste and creamy texture are stably maintained, allowing for wide application in the fusion Korean sauce market, such as for cream tteokbokki and cream pasta.

Description

Technology Field

[0001] The present invention belongs to the field of food manufacturing and processing technology, specifically the field of fusion sauces made by combining **fermented sauces (such as gochujang)** and **cream (animal or vegetable oils)**. Specifically, in order to uniformly maintain the characteristic spicy taste and fermented aroma of fermented gochujang and the powdery and smooth texture of cream, Emulsifier and Stabilizer Formulation class High-pressure homogenization Using the process Inhibits long-term phase separation between oil and water phases doing How to make cream gochujang sauce It is about. Background Technology

[0002] 1. Growth and Necessity of the Fusion Gochujang Sauce Market

[0003] 1. Fusion Korean food trends

[0004] Due to the globalization of Korean cuisine and the K-food craze, various fusion sauces based on Korean fermented sauces (doenjang, soy sauce, gochujang, etc.) are gaining popularity in domestic and international markets.

[0005] · especially Creamy Gochujang Sauce is for consumers who have an aversion to spicy flavors, or more Soft and clean flavor It has high marketability as it can appeal to the consumer base that desires it.

[0006] 2. Characteristics of traditional gochujang

[0007] Traditional gochujang typically undergoes fermentation within a pH range of 4.5-5.5 and a salinity of approximately 8-1.2%, and Capsaicin , glutamic acid , Fermentation microorganisms The ingredients work together to form spicy and savory flavors.

[0008] · These fermentation characteristics when using gochujang alone Long-term storage Although it is excellent, when mixed with cream, the acidity of the gochujang and the oil content (animal or vegetable) of the cream Interfacial stability It can cause a collision from the side.

[0009] 3. Problems with the cream

[0010] · Cream (e.g., animal-based fresh cream, plant-based coconut cream, etc.) butterfat It has a high fat content and is prone to separating easily from moisture.

[0011] · In the production of general dressings or mayonnaise, egg yolk oil (lecithin) or protein-based stabilizers are used to maintain the emulsion, but in the case of direct mixing with gochujang Capsaicin, fermentation microorganisms, pH, salinity The back becomes an additional variable Stabilization design It becomes more complicated.

[0012] 2. Review of Prior Art

[0013] 1. Study on the interfacial stability of fermented food-fat mixed systems (Korea Food Research Institute, 2022)

[0014] · As a result of studying the conditions under which fermented pastes such as soybean paste and red pepper paste are mixed with milk fat in the pH range of 4.5 to 5.5, it was confirmed that the emulsion stability was improved by 89% with the addition of a lecithin-casein complex emulsifier (0.5% added).

[0015] · step, Retention period is 30 days It was relatively short to that extent, and Can phase separation be inhibited in the long term when the cream content is increased (30% or more)? It mentions that additional verification is needed.

[0016] 2. Rheological properties of vegetable cream-based sauces (Department of Food Engineering, Kyung Hee University, 2021)

[0017] · When an emulsion system was formulated with coconut cream and plum extract, with 0.3% guar gum + 0.2% carrageenan Viscosity 450 mPa·s Achieved a particle distribution change rate of less than 15% after heat treatment at 45℃.

[0018] · Since the present invention allows vegetable cream (such as coconut) to be applied to cream gochujang, Heat resistance, viscosity maintenance method It can be referenced as.

[0019] 3. pH Stabilization Strategy of Gochujang Fermentation Microorganisms (Chonnam National University, 2023)

[0020] · Inside the gochujang Bacillus subtilis In a study on the viability of the JK-108 strain in the pH range of 4.5 to 5.5, it was reported that when 0.5% sodium ascorbate was added, the viable cell count could be maintained at 10^7 CFU / g even after 60 days of storage.

[0021] · Also in cream gochujang sauce pH 5.0~5.5If adjusted to this, fermentation microorganisms (microorganisms unique to gochujang) remain, distinctive fermented aroma This serves as evidence that hygienic safety can be secured while maintaining [it].

[0022] 3. Comparison with Existing Patent Documents

[0023] 1. KR 10-2020-0034567 (Method for manufacturing emulsion-stabilized Korean sauce)

[0024] · By mixing fermented pastes such as Cheonggukjang with 2030% animal fat and achieving a particle size of 515μm through two-stage homogenization (1,500psi / 2,500psi), however, the gochujang Capsaicin class pH around 5.0 Stabilization strategies specialized for the conditions are insufficient.

[0025] 2. US 9,878,765 B2 (Hybrid Sauce Stabilization System)

[0026] · In tomato sauce (pH 4.0~4.8) Hydroxypropyl methylcellulose (HPMC) +Stabilized by a 2:1 mixture of lecithin. It differs from gochujang in pH range and fermentation components (glutamic acid, capsaicin), and high-temperature heat treatment (121℃, 2.8 min) is the cream's Thermal denaturation It is differentiated from the present invention because it can cause problems.

[0027] 3. JP 2021-567890 (Composition of vegetable emulsifying stabilizers)

[0028] · Soy protein hydrolysate + rice starch in a 3:7 ratio acts as an emulsifier. While it is possible to achieve an Aw of 0.91 at a 1% concentration, the synergy with the unique fermented components of gochujang has not been sufficiently verified. Additionally, thermal stability (in a repeated high-temperature distribution environment) is reported to be 20% lower than that of the present invention.

[0029] 4. Necessity and Purpose of the Present Invention

[0030] The mixture of gochujang and cream is Innovative fusion sauce in terms of taste and texture It can create, but Inhibits long-term phase separation Even while doing The fermented aroma of gochujang, the smooth texture characteristic of cream The technology for maintaining it still has great potential for development.

[0031] The present invention aims to solve the following technical problems.

[0032] 1. Oil-water emulsion stabilization: By lowering the interfacial tension generated when mixing cream and gochujang through high-pressure homogenization and the combined use of emulsifiers and stabilizers, and Without separation for a long period maintain.

[0033] 2. pH·Aw (water activity) control : Establish microbiologically safe conditions while preventing the fermentation microorganisms of gochujang and the capsaicin and glutamic acid components from deteriorating or denaturing (pH 5.05.5, Aw 0.900.93, etc.).

[0034] 3. Long-term storage stability : Provides a stable source that suppresses the phase separation rate to less than 5% for a minimum of 6 months and for 9 to 12 months. The problem to be solved

[0035] 1. Ensuring interfacial stability between cream (animal / vegetable) and fermented gochujang

[0036] · Even during long-term distribution To prevent the cream layer from separating Optimize high-pressure homogenization and the blending of emulsifiers and stabilizers.

[0037] 2. Simultaneously achieving microbial safety and flavor in the pH 5.0-5.5 and Aw 0.9-0.93 ranges.

[0038] · While allowing the persistence of gochujang fermentation microorganisms or umami components, pathogenic microorganisms must be suppressed.

[0039] 3. Maintains creamy and spicy flavor for 12 months

[0040] · Minimizes cream rancidity and the volatilization and decomposition of capsaicin, thereby preserving the sensory satisfaction of the final sauce for a long period. means of solving the problem

[0041] To achieve the above objective, the present invention provides the following core technology Integrates.

[0042] 1. Emulsifier / Stabilizer Complex Formulation

[0043] · Use a mixture of at least two types from lecithin (derived from soybeans or egg yolk), gum arabic, guar gum, casein (dairy products), soy protein hydrolysate, etc., in a range of 0.5 to 1.5%.

[0044] · Considering the lecithin-casein synergy presented in “Study on the Interfacial Stability of Fermented Food-Fat Mixture Systems (2022)”, the emulsion film strength is increased through interaction with glutamic acid in gochujang.

[0045] 2. High-pressure homogenization dual process

[0046] · Process in stages: 1st stage 2,000psi → 2nd stage 2,500-3,000psi. Cream particle size Uniformize to an average range of 110μm.

[0047] · Food Hydrocolloids Based on the findings presented in the (2023) paper that lecithin adsorption density increases and lipid rancidity can be inhibited when the pressure is 2,500 psi or higher, this was applied.

[0048] 3. pH 5.0-5.5, water activity 0.90-0.93 adjusted

[0049] · After mixing gochujang (usually pH 4.5-5.0) and cream (approx. pH 6.6-6.8), use a small amount of natural basic substance (e.g., sodium bicarbonate, calcium salt) or vinegar as an adjuster so that the pH is in the range of 5.0 to 5.5.

[0050] · Simultaneously achieve inhibition of microbial growth and maintenance of texture by fine-tuning sugars (oligosaccharides, etc.) and salinity to control water activity (Aw).

[0051] 4. Heat treatment and filling

[0052] · Instead of a high-temperature retort (121℃), Aseptic filling for 30–60 seconds at around 85°C or Pasteurization Ensure food safety while minimizing the destruction of the cream texture. Effects of the invention

[0053] 1. Minimizing phase separation during long-term storage

[0054] · The phase separation rate is maintained at less than 5% for at least 6 months at room temperature (20~25℃) and up to 912 months at refrigeration (5℃).

[0055] 2. Balance of spicy and creamy flavors

[0056] · The spicy and savory flavors are highlighted by capsaicin and fermented amino acids (such as glutamic acid), and the cream fat adds smoothness, providing a diverse sensory experience.

[0057] 3. Application scalability

[0058] · It is applicable to both animal and plant-based creams, and similar processes can be applied to other fermented sauces in the future, such as soybean paste and soy sauce-based cream sauces and salsa sauces.

[0059] 4. Microbial stability

[0060] · In the range of pH 5.0-5.5 and Aw 0.90-0.93 Bacillus cereus , Staphylococcus aureus The proliferation of pathogenic microorganisms is effectively inhibited, and some beneficial microorganisms in the gochujang may remain. Brief explanation of the drawing

[0061] [Fig. 1] (Process Flow Chart: Gochujang & Cream Blending → Emulsifier Addition → Primary & Secondary High-Pressure Homogenization → pH / Aw Adjustment → Aseptic Filling / Pasteurization → Storage Stability Testing) [Fig. 2] (Graph of cream particle size distribution before and after homogenization, laser diffraction particle size analysis results) [Fig. 3] (Graph showing change in phase separation rate (%) by storage period according to temperature stress test (5℃, 25℃, 35℃)) [Fig. 4] Specific details for implementing the invention

[0062] In the following, examples are provided to further clarify the present invention. More details Presented. However, this is merely an illustrative description and does not limit the technical scope of the present invention.

[0063] (Example 1) Preparation and testing of vegetable cream (coconut)-based cream gochujang sauce

[0064] 1) Ingredients and Formulation

[0065] · Gochujang (fully fermented product) : pH 4.8, salinity 10%, moisture content 35%, glutamic acid content 1.1%

[0066] · coconut cream : Fat content 22%, pH 6.6, viscosity (25℃) approx. 600 mPa·s

[0067] · Emulsifiers and stabilizers : Lecithin (derived from soybeans) 0.5 wt%, gum arabic 0.3 wt%, guar gum 0.2 wt%

[0068] · Other additives : Oligosaccharide (Brix 25°Bx) 5% by weight, natural spice (paprika powder, etc.) 0.2% by weight, small amount of pH adjuster such as sodium bicarbonate and vinegar

[0069] 2) Manufacturing process

[0070] 1. mix Pre-mix Gochujang and coconut cream in a 60:40 ratio (by weight) (stirrer 300 rpm, 10 minutes).

[0071] 2. Emulsifier addition Dissolve lecithin, gum arabic, and guar gum in a small amount of lukewarm water (about 40°C), then slowly add them to the mixture.

[0072] 3. 1st homogenization : Pressure 2,000 psi, single-pass method. Average particle size distribution (laser diffraction) 12 μm → Approx. 8 μm after primary homogenization

[0073] 4. Secondary homogenization : Pressure 2,500 psi, 2-pass type. Reduces average particle size to approximately 4.5 μm.

[0074] 5. pH control : Measure with a pH meter (error ±0.05) and add sodium bicarbonate (range 0.05–0.1%) to adjust the final pH to 5.2 ± 0.1.

[0075] 6. Aw adjustment : Readjust sugar and salt content to a range of approximately 0.91±0.01 as checked with an Aw meter (±0.01 accuracy) (add a very small amount of mild brewed soy sauce if necessary).

[0076] 7. Sterilization and charging Aseptic filling at 85℃ for 40 seconds, then packaging in a 200g PP container. After sealing, stabilize at room temperature (25℃) for 24 hours.

[0077] 3) Experimental Items and Methods

[0078] 1. Phase separation rate (%) Calculated based on the upper and lower layer volume ratio after centrifugation (3,000 rpm, 10 minutes). Indirectly evaluates the possibility of physical separation during actual product storage.

[0079] 2. Particle size distribution (μm) : Use a laser diffraction grain meter (Malvern, etc.). Report the average value of D[4,3].

[0080] 3. pH, Aw : Digital pH meter, Aw meter (Aqualab, etc.).

[0081] 4. Microbiological test : Bacillus cereus , Staphylococcus aureus , total bacterial count, lactic acid bacteria count (residual fermentation microorganisms in gochujang), etc. 7-day, 30-day, 90-day, 180-day intervals.

[0082] 5. Sensory evaluation : Based on a panel of 10 people (5 experts + 5 non-experts), on a 9-point scale (spiciness, creaminess, texture, aroma, overall preference, etc.).

[0083] 4) Results

[0084] · particle size : Average 4.5 μm after secondary homogenization (see Fig. 2).

[0085] · Phase separation rate : 3.0±0.5% for 30 days of storage at 25℃, 4.5±0.8% for 90 days, and 5.2±1.0% for 180 days. It was managed at around 5% up to the 6-month mark (Graph in Fig. 3).

[0086] · Microbial stability : 60 days Bacillus cereus , S. aureus Not detected, some lactic acid bacteria (approx. 10^5 CFU / g) remaining.

[0087] · Sensory evaluation : Score after 90 days (out of 9): Spicy 7.8, Creaminess 8.4, Texture 8.2, Overall 8.3. Spicy and sweet coconut cream gochujang favorable reviews.

[0088] (Example 2) Preparation of Animal Cream (Fresh Cream) Based Cream Gochujang Sauce and Heat Stress Test

[0089] 1) Material composition

[0090] · Fermented Gochujang : pH 4.7, salinity 11%, moisture 32%

[0091] · animal-based fresh cream : Fat content 35%, pH 6.6, Protein (casein) approximately 2%

[0092] · Emulsifiers and stabilizers : Egg yolk lecithin 0.3%, casein concentrate 0.2%, guar gum 0.1%

[0093] · additive : Oligosaccharide 4%, a small amount of refined salt (0.3%), etc.

[0094] 2) Manufacturing process

[0095] 1. Mixing ratio : Gochujang (70) : Fresh cream (30). After preliminary mixing, stir (300 rpm, 5 minutes).

[0096] 2. Primary homogenization : 2,000 psi, 1 pass.

[0097] 3. Secondary homogenization : 3,000 psi, single pass (enhanced high-pressure conditions). Average particle size approx. 3.8 μm.

[0098] 4. pH 5.1±0.1 Adjustment (add 0.05% calcium carbonate), Aw 0.90±0.01 Readjust sugar levels to maintain.

[0099] 5. charge : Pasteurize at 80℃ for 60 seconds, then fill into a PP bottle (300g) and seal.

[0100] 3) Heat stress test

[0101] 1. method :

[0102] · One cycle of 9 days in total, consisting of high temperature cycle (35℃, 3 days) → 25℃ (3 days) → 5℃ (3 days). Repeat this 4 times (36 days).

[0103] · Monitoring of phase separation, harmful microorganisms, and sensory changes.

[0104] 2. result :

[0105] · Phase separation rate after 1 cycle 2.5±0.4%, after 4 repetitions (after 36 days) 3.8±0.6%.

[0106] · Sensory evaluation (at 36 days): Creaminess 8.2 / 9, Spiciness 7.9 / 9, Overall preference 8.1 / 9.

[0107] · Microorganisms ( Bacillus cereus , S. aureus Etc.) Not detected, pH change (5.1 → 5.0) minimal.

[0108] 3. Additional 6 months of storage : Stored for an additional 4 months at room temperature of 25℃ (total 6 months). Final phase separation rate was 5.1±1.2%, maintaining around 5%, indicating good stability.

[0109] (Example 3) Comparison of separation stability according to differences in pH range (4.8–5.5) and homogenization pressure (1,500–3,000 psi)

[0110] 1. purpose

[0111] · By setting the pH to four ranges of 4.8, 5.0, 5.2, and 5.5, and the homogenization pressure to four ranges of 1,500 psi, 2,000 psi, 2,500 psi, and 3,000 psi, Phase separation rate over 90 days under each condition and Sensory characteristics Compare changes.

[0112] 2. Experimental design

[0113] · A total of 16 combinations (e.g., pH 4.8 + homogenization pressure 1,500 psi, pH 4.8 + homogenization pressure 2,000 psi, etc.).

[0114] · Gochujang (65) : Coconut cream (35) basic ratio, lecithin (0.5%), gum arabic (0.2%), and guar gum (0.2%) are used equally.

[0115] 3. Results Summary

[0116] · When the pH is 4.8, some cream denaturation occurs (especially coagulation in animal creams), and the phase separation rate is relatively high at 7.5~10%.

[0117] · Most stable at pH 5.2±0.1 (3.0~4.5%), excellent balance of fermented scent and creamy texture.

[0118] · At a homogenization pressure of 1,500 psi, the average particle size is 10 μm or larger, and the separation rate is high at 8~9%.

[0119] · 90-day storage in the 2,500-3,000 psi pressure range with a separation rate of 34% optimal .

[0120] · Sensory evaluation scores (creamyness, overall preference) are highest when homogenized to pH 5.2±0.1 & 2,500 psi or higher (8.0 or higher / 9 points).

[0121] Overall pH 5.0~5.5 and 2,000~3,000 psi It was reconfirmed that the range is advantageous for emulsion stability.

[0122] (Example 4) Long-term monitoring of microbial safety (12 months)

[0123] 1) Purpose

[0124] · Creamy Gochujang sauce 12 months Observe the occurrence of pathogenic microorganisms, the presence of fermenting microorganisms, and changes in sensory quality during long-term storage.

[0125] 2) Method

[0126] · Based on vegetable cream (coconut, 40%) + gochujang (60%) recipe, pH 5.2, Aw 0.91, aseptic filling at 85℃ after secondary homogenization at 2,500 psi.

[0127] · Storage temperature: 50 bottles each at 25℃ room temperature and 5℃ refrigerated (total 100 bottles).

[0128] · Sampling at 1, 2, 3, 6, 9, and 12 months Microbiological testing (total bacterial count, B. cereus, S. aureus, lactic acid bacteria count, etc.), pH, color, phase separation rate, sensory evaluation progress.

[0129] 3) Result

[0130] 1. Microbiological test

[0131] · B. cereus , S. aureusAll were undetectable for 12 months (<10 CFU / g).

[0132] · Lactic acid bacteria gradually decrease from an initial level of about 10^6 CFU / g to 10^5 at 6 months and 10^4 at 12 months, but help maintain the fermented flavor.

[0133] 2. pH change

[0134] · Initial 5.2 → After 12 months 5.1±0.1 (no significant change)

[0135] 3. Phase separation rate

[0136] · Room temperature (25℃): 6.0±1.5% at 12 months

[0137] · Refrigerated (5℃): 4.5±1.0% at 12 months

[0138] · Overall, less than 6%, and no noticeable separation phenomenon was observed (Comparison photo in Fig. 4).

[0139] 4. Sensory evaluation (at 12 months)

[0140] · (Room Temperature) Creaminess 7.6 / 9, Spicy 7.5 / 9, Overall 7.8 / 9

[0141] · (Refrigerated) Creaminess 7.9 / 9, Spicy 7.6 / 9, Overall 8.0 / 9

[0142] · Although there is a slight drop in score, excellent sensory quality is still maintained.

[0143] Abnormal result, Store for 12 months Even in the poem Maintenance and separation stability and Microbial safety This is good, Practicality as a fusion sauce I confirmed that this is very high. Industrial applicability

[0144] 1. Food Service and Foodservice Industry

[0145] · Can be used in cream tteokbokki, cream pasta, cream ramen, various risottos, premium salad dressings, etc.

[0146] · Easy product standardization with a separation-free 'Cream Gochujang' formula for on-the-spot manufacturing (franchise).

[0147] 2. Home Meal Replacement (HMR) and Export Markets

[0148] · Since it can be distributed at room temperature or refrigerated after filling into retort pouches or PP containers, it is advantageous for online sales and international export.

[0149] · Vegan (vegetable cream) and General use (Animal cream) can be expanded into the lineup.

[0150] 3. Technology licensing

[0151] · The present invention Emulsifier and Stabilizer Formulation and High pressure homogenization The know-how can also be applied to the development of various sauces, including other fermented sauces (soybean paste, soy sauce).

[0152] · Food companies can license the technology of the present invention to launch a premium cream sauce line under their own brand.

[0153] 4. creation of high added value

[0154] · Cream Gochujang sauce can be premium positioned as a 'mild spicy flavor' product differentiated from the existing spicy sauce market.

[0155] · When entering overseas markets (USA, Europe, Southeast Asia, etc.), a unique USP (Unique Selling Point) is formed through the fusion of European mayonnaise and cream sauces with Korean sauces. Explanation of the symbols

[0156] · Fig. 1: Flowchart of the cream gochujang sauce manufacturing process · Fig. 2: Graph of cream particle size distribution (laser diffraction) before and after high-pressure homogenization · Fig. 3: Graph of change in phase separation rate by temperature stress (max. 6 months) · Fig. 4: Comparison photos of the separation status of the control group vs. the invention-applied group after 3, 6, and 12 months of storage. · Fig. 5: Radar chart of sensory evaluation results (spiciness, creaminess, texture, overall preference)

Claims

Claim 1 A method for manufacturing a cream-mixed type gochujang sauce using an oil-water phase stabilized emulsion process comprises:

1. mixing fermented gochujang (glutamic acid content 0.81.5%, pH 4.55.0) and cream (animal or vegetable, fat content 10~35%) in a weight ratio of 50:50 to 70:30; 2. adding two or more of lecithin, gum arabic, guar gum, and protein-based stabilizers (casein, egg yolk oil, etc.) in a total weight of 0.51.5% to adjust the pH to a range of 5.05.5 and the water activity (Aw) to a range of 0.90~0.93; and 3. A method for manufacturing a cream-mixed gochujang sauce, characterized by performing a high-pressure homogenization process in two stages, wherein the first stage is treated at 1,500-2,000 psi and the second stage at 2,500-3,000 psi to finely reduce the average size of the cream particles to a range of 1 to 10 μm, and then performing an aseptic filling or pasteurization process for 30 to 60 seconds at a temperature range of 80 to 90°C to fill and package the product into a container, and wherein the phase separation rate is maintained at less than 5% even when stored for more than 6 months under room temperature (20 to 25°C) or refrigeration (5°C) conditions, and the fermented flavor of the gochujang and the soft texture of the cream are stably maintained.

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