Method for producing soybean-containing processed food, system for producing soybean-containing processed food, and soybean-containing processed food

Abstract

[Problem] To provide a method for producing, by using soybean as a raw material, a new soybean-containing processed food having terrine-like (terrine de pate-like) appearance and taste.　[Solution] This method comprises: a dough base preparation process P10 for preparing a dough base 1 that serves as a base for a target soybean-containing processed food 10; an auxiliary material-mixing process P20 for mixing an auxiliary material 2 to the dough base 1 obtained in the dough base preparation process P10; and a post-treatment process P30 for subjecting an auxiliary material mixture 3 obtained in the auxiliary material-mixing process P20 to a post-treatment. The post-treatment process P30 includes at least a thermal treatment step P35 for the auxiliary material mixture 3. In addition, the lipid content in the ingredient composition of the dough base 1 is less than the protein content thereof, and the solid content derived from the dough base 1 in the obtained soybean-containing processed food 10 is at least 25 wt%. Furthermore, the dough base preparation process P10 includes a component separation step P15 for separating coagulated product components 04 and water-soluble components 06 by performing a coagulation treatment on soybean milk 02.　

Description

Soybean-containing processed food manufacturing method, soybean-containing processed food manufacturing system, and soybean-containing processed food

[0001] The present invention relates to a method for producing soybean-containing processed foods, a system for producing soybean-containing processed foods, and soybean-containing processed foods, and in particular to a method for producing soybean-containing processed foods using soybeans as a main ingredient, which can provide novel textures, tastes, uses, etc.

[0002] There have long been many processed foods that use soybeans as ingredients, and many new research and development projects and patent applications have been filed. For example, the applicant's patent document 1, cited below, discloses an invention that solves the problem of having to set up separate production lines for each product, such as tofu, frozen tofu, fried tofu, and yuba, by extracting necessary ingredients from soy milk and remixing them in the appropriate ratio for each product. This has resulted in the consolidation of production lines, resulting in reduced costs, space savings, improved hygiene management, and the promotion of new product development.

[0003] In addition, Patent Document 2 listed below discloses a method for producing a tofu-like food with a sea urchin flavor that is made into a paste by increasing the dietary fiber, lipid, and water content, Patent Document 3 discloses a method for producing a soybean processed food similar to processed meat food, which is produced using mountain yam and defatted soybeans or soybean protein, and Patent Document 4 discloses a method for producing a soybean processed food with a cheese-like texture by increasing the water content.

[0004] Protein bars, which are formed into a fixed shape such as wafers or crunchies, are foods that allow for easier intake of protein than amorphous powders. When soybeans are used as the raw material, they are powdered, hydrated, and then baked to a solid content of approximately 75-90%. Examples of foods formed into a fixed shape include terrine de pâté, or terrine, which is prepared by filling a mold or container with ingredients and cooking it by heating. Terrine-style prepared foods and sweets are also available on the market.

[0005] Patent No. 6,598,564 "Method for producing soybean processed foods and soybean processed product production system" (by the applicant) Patent No. 7,479,708 "Method for producing soybean paste-like foods or gel-like foods" JP 2022-128426 A "Soybean-containing processed foods and their production method" Patent No. 4,928,425 A "Soybean processed foods with a cheese texture and their production method"

[0006] As such, research and development of processed foods made from soybeans, a plant-based resource and high-protein food ingredient, is actively underway, and with diversifying consumer needs, new products are being introduced to the market at a high rate. Providers are required to continue offering new benefits to the market and consumers. For example, processed soybean foods with lower fat content meet the needs of those oriented toward maintaining and improving their health; processed soybean foods that are suitable for room-temperature distribution or freezing through retort processing, which offer advantages in terms of distribution and storage; and processed soybean foods such as terrines, which aim to improve product quality by better matching the perspectives and sensibilities of consumers.

[0007] Therefore, the problem that the present invention aims to solve is to provide, in light of the state of the prior art, a production technology for new soy-containing processed foods that can provide new textures, tastes, flavors, uses, etc., such as soybean processed foods with reduced lipid content, soybean processed foods that are suitable for distribution at room temperature or freezing after retort processing, soybean processed foods that are highly productive, or soybean processed foods that are suitable for terrine-like product forms, as well as a production technology for soy-containing processed foods that are suitable for these.

[0008] The present inventors have conducted extensive research into the above-mentioned problems. As a result, based on the separation / extraction and reconstitution method of essential components from soybean raw materials disclosed in Patent Document 1, they have devised a method for producing a solid processed food by molding, which has relatively high viscosity properties, by mixing appropriate auxiliary ingredients with the soybean raw material, homogenizing the mixture as necessary, and then heat-treating the mixture. Suitable auxiliary ingredients can be used, such as seasonings, edible polysaccharides, powdered vegetable protein, vegetable powder, confectionery powder, fish meal, dairy products such as cheese and milk powder, etc. Furthermore, they have confirmed that soybean flour, as well as soy milk, can be used as raw materials to prepare a sol-like tofu-like emulsion, which can then be used to produce terrine-like foods by adding auxiliary ingredients.

[0009] It has been confirmed that the present invention can provide processed soybean foods with reduced lipid content, processed soybean foods suitable for distribution at room temperature through retort processing or for freezing, processed soybean foods with excellent productivity, processed soybean foods suitable for terrine-like product forms as described above, processed soybean foods with novel and good texture, taste, and flavor, and processed soybean foods with new uses such as prepared dishes and confectioneries. Based on these results, the present invention has been completed. That is, the invention claimed in this application, or at least the invention disclosed therein, as a means for solving the above problems, is as follows.

[0010] [1] A method for producing a soy-containing processed food, comprising: a dough base preparation process for preparing a dough base that serves as the basis for the target soy-containing processed food; a secondary ingredient mixing process for mixing secondary ingredients into the dough base obtained in the dough base preparation process; and a post-processing process for post-processing the secondary ingredient mixture obtained in the secondary ingredient mixing process, wherein the post-processing process includes at least a heat treatment step for the secondary ingredient mixture; the dough base has a component composition in which the lipid content is less than the protein content; and the resulting soy-containing processed food contains 25% by weight or more of solids derived from the dough base; and the dough base preparation process includes a component separation step for separating coagulated components from water-soluble components obtained by coagulation treatment of soy milk. [2] The method for producing soy-containing processed foods according to [1], characterized in that the dough base preparation process comprises a selective ingredient mixing step of mixing a water-soluble ingredient with the curd ingredients separated in the ingredient separation step, if necessary, to obtain a component mixture, and a selective homogenization step of homogenizing the curd ingredients, or the component mixture obtained by the selective ingredient mixing step if such step has been performed. [3] The method for producing soy-containing processed foods according to [2], characterized in that in the selective ingredient mixing step, the curd ingredients are mixed at a mixing ratio of 25% by weight to 100% by weight and 0% by weight to 75% by weight of the water-soluble ingredient, so that the concentration of the curd ingredients is suitable for obtaining the target soy-containing processed food. [4] A method for producing a soy-containing processed food, comprising a dough base preparation step for preparing a dough base that serves as the basis for the target soy-containing processed food; a secondary ingredient mixing step for mixing secondary ingredients into the dough base obtained in the dough base preparation step; and a post-processing step for post-processing the secondary ingredient mixture obtained in the secondary ingredient mixing step, wherein the post-processing step includes at least a heat treatment step for the secondary ingredient mixture, wherein the dough base has a component composition in which the lipid content is less than the protein content, and the resulting soy-containing processed food contains 25% by weight or more of solids derived from the dough base, and wherein the dough base preparation step obtains a tofu-like emulsion as the dough base by water extraction of soy flour.[5] The method for producing a soybean-containing processed food according to any one of [1], [2], [3], and [4], characterized in that the heat treatment in the heat treatment step is any one of the heat treatments listed in <H> below: <H> Baking in an oven, baking in a convection oven, baking in a steam oven, heat treatment in a drum dryer, boiling treatment after filling into a container or package, retort treatment after filling into a container or package, or other heat treatment (excluding baking in an oven, baking in a convection oven, baking in a steam oven, heat treatment in a drum dryer, boiling treatment after filling into a container or package, or retort treatment after filling into a container or package).

[0011] [6] The method for producing soy-containing processed foods according to [5], wherein the post-treatment process includes a molding process for molding the secondary ingredient mixture, and the molded product obtained by the molding process is subjected to heat treatment in the heat treatment process. [7] The method for producing soy-containing processed foods according to [6], wherein the post-treatment process includes a selective secondary ingredient mixture homogenization process for homogenizing the secondary ingredient mixture, if necessary, and when the selective secondary ingredient mixture homogenization process has been performed, the homogenized product obtained thereby is subjected to molding treatment in the molding process. [8] The method for producing soy-containing processed foods according to either [6] or [7], wherein the secondary ingredient is one or more of the ingredients listed in <C> below. <C> Soy protein, vegetable protein (excluding soy protein), seasonings, food polysaccharides, vegetable powder, fruit powder, confectionery powder, fish meal, dairy products, oils and fats [9] A soy-containing processed food production system comprising: a dough base preparation unit that prepares a dough base that is the basis of the target soy-containing processed food; a secondary ingredient mixing unit that mixes secondary ingredients with the dough base obtained in the dough base preparation unit; and a post-treatment unit that performs post-treatment on the secondary ingredient mixture obtained in the secondary ingredient mixing unit, wherein the post-treatment unit includes at least a heating unit for the secondary ingredient mixture, and wherein the dough base preparation unit obtains a dough base whose lipid content is less than its protein content, and the resulting soy-containing processed food contains 25% or more by weight of solids derived from the dough base.

[0012]

[10] The soy-containing processed food production system according to [9], characterized in that the dough base preparation unit comprises a component separation unit that separates coagulated components produced by a coagulation process of soy milk from water-soluble components.

[11] The soy-containing processed food production system according to

[10] , characterized in that the dough base preparation unit comprises a selective component mixing unit that mixes a water-soluble component with the coagulated components separated in the component separation unit, if necessary, to obtain a component mixture.

[12] A soy-containing processed food produced by the soy processed product production system according to any of [9],

[10] , or

[11] .

[13] A soy-containing processed food characterized in that a secondary ingredient is mixed into a dough base made from soybeans, the component composition of the dough base has a lipid content less than the protein content, and the solid content derived from the dough base in the obtained soy-containing processed food is 25% by weight or more, and the soy-containing processed food is formed through a heat treatment.

[14] The soy-containing processed food according to either

[12] or

[13] , which is formed into a specific shape like a pate for terrine de pate.

[15] The soy-containing processed food according to

[14] , which is any of the soy-containing processed foods listed in <F> below. <F> High-protein foods, side dishes, confectioneries, spreads

[16] The soy-containing processed food according to

[15] , which is a frozen food.

[0013] The soybean-containing processed food production method, soybean-containing processed food production system, and soybean-containing processed food of the present invention are configured as described above, and therefore can provide novel solid soybean-containing processed foods in terms of texture, taste / flavor, uses, etc. For example, soybean processed foods with reduced lipid content, soybean processed foods suitable for room temperature distribution or freezing after retort processing, or soybean processed foods suitable for terrine-like product forms can be provided with excellent productivity.

[0014]

[0023] FIG. 1 is a flow chart showing the basic configuration of the method for producing soy-containing processed foods of the present invention.

[0024] FIG. 2 is a flow chart showing the configuration of an example of a dough base preparation process shown in FIG. 1.

[0025] FIG. 3 is a flow chart showing an example of the configuration of a dough base preparation process in the method for producing soy-containing processed foods of the present invention, taking into account aspects such as component remixing.

[0026] FIG. 4 is an explanatory diagram showing an object that can be used as a dough base in the method for producing soy-containing processed foods of the present invention shown in FIG. 1.

[0027] FIG. 5 is a flow chart showing the basic configuration of the method for producing soy-containing processed foods of the present invention using soy flour as a raw material.

[0028] FIG. 6 is a flow chart showing the configuration of the method for producing soy-containing processed foods of the present invention, which includes a molding step in the post-treatment process.

[0029] FIG. 7 is a flow chart showing the main configuration of the method for producing soy-containing processed foods of the present invention, which includes a homogenization step in the post-treatment process.

[0029] FIG. 8 is an explanatory diagram showing objects that can be subjected to the heat treatment step in the method for producing soy-containing processed foods of the present invention shown in FIG. 3.

[0029] FIG. 9 is a second explanatory diagram showing objects that can be subjected to the heat treatment step in the method for producing soy-containing processed foods of the present invention shown in FIG. 3.

[0029] FIG. 10 is a conceptual diagram showing the basic configuration of the system for producing soy-containing processed foods of the present invention.

[0029] FIG. 11 is a conceptual diagram showing the configuration of the system for producing soy-containing processed foods of the present invention, which uses soy milk as a raw material. FIG. 1 is an explanatory diagram conceptually showing the formation of the shape of the soybean-containing processed food of the present invention.

[0015] The present invention will be described in detail below with reference to the drawings. FIG. 1 is a flow chart showing the basic configuration of the method for producing soybean-containing processed foods of the present invention. FIGS. 1-2 are flow charts showing the configuration of an example of the dough base preparation process shown in FIG. 1. As shown in these figures, the production method flow basically comprises a dough base preparation process P10 for preparing a dough base 1 that forms the basis of the target soybean-containing processed food 10; a secondary ingredient mixing process P20 for mixing secondary ingredients 2 with the dough base 1 obtained in the dough base preparation process P10; and a post-processing process P30 for post-processing the secondary ingredient mixture 3 obtained in the secondary ingredient mixing process P20. The post-processing process P30 is basically configured to include at least a heat treatment process P38 of the secondary ingredient mixture 3.

[0016] The dough base 1 used in the dough base preparation process P10 has a component composition in which the lipid content is less than the protein content, and the solid content derived from the dough base 1 in the resulting soybean-containing processed food 10 is 25% by weight or more.Furthermore, as shown in Figure 1-2, the dough base preparation process P10 mainly comprises a component separation process P15 in which the coagulated component 04 and the water-soluble component 06 obtained by coagulating the raw material soy milk 02 in the coagulation process P13 are separated.

[0017] According to the present method for producing soybean-containing processed foods configured as described above, first, a dough base 1 that is the basis of the target soybean-containing processed food 10 is prepared in a dough base preparation step P10, in which soy milk 02 is used as a raw material, as shown in Figure 1-2. Specifically, in a coagulation treatment step P13, the soy milk 02 is subjected to a coagulation treatment to obtain a coagulated component 04 and a water-soluble component 06, and then in a component separation step P15, the coagulated component 04 and the water-soluble component 06 are separated.

[0018] The coagulation method in the coagulation step P13 may be the addition of a coagulant, and the separation method in the component separation step P15 may be centrifugation, which are conventionally known methods for the production of tofu, etc. How the coagulated component 04 and the water-soluble component 06 separated in this manner are used will be described later with reference to FIG.

[0019] The component composition of the dough base 1 finally obtained in the dough base preparation step P10 of the method for producing soybean-containing processed foods of the present invention is such that the lipid content is less than the protein content. That is, preparation to achieve such a component composition is carried out in the dough base preparation step P10.

[0020] The dough base 1 obtained in the dough base preparation process P10 is then subjected to a secondary ingredient mixing process P20, in which a secondary ingredient 2 is mixed into the dough base 1 to obtain a secondary ingredient mixture 3. The range of secondary ingredients 2 that can be mixed is wide, but specific details will be described later. The obtained secondary ingredient mixture 3 is then subjected to a post-treatment process P30, in which the secondary ingredient mixture 3 is subjected to post-treatment, which includes at least a heat treatment process P38 of the secondary ingredient mixture 3.

[0021] That is, the secondary ingredient mixture 3 is subjected to a heat treatment using an appropriate heating method to ultimately obtain the target soybean-containing processed food 10. The soybean-containing processed food 10 thus obtained is characterized by the production method of the present invention in that the solid content derived from the dough base 1 is 25% by weight or more. The more desirable solid content ratio of the resulting soybean-containing processed food 10 is 30 to 75% by weight.

[0022] The applicant has previously disclosed techniques for producing soybean processed products, in which a coagulated component produced by a coagulation treatment of starting soy milk is separated from a water-soluble component, and the two components are then remixed at a mixing ratio appropriate for the target product (Patent Nos. 6541509, 6598564, 6605258, and 6757126). For example, the remixing ratio is approximately 14% by weight solids for the target product such as firm tofu, approximately 18% by weight solids for frozen tofu, approximately 25% by weight solids for membrane-like soybean processed foods such as yuba, crepes, and laver, and approximately 30% by weight solids for meat-like soybean processed foods such as hamburger steaks, fish paste, and scrambled eggs.

[0023] Meanwhile, one of the objectives of the present invention is to produce a final product in a terrine-like product form. That is, the soy-containing processed food is formed into a specific pâté-like shape, such as a terrine de pâté, regardless of whether it is intended for use as a prepared dish or confectionery. Such pâté-like, or so-called terrine-like, forms also include more fixed product forms, such as protein bars. The preferred range of solids in a terrine-like final product is 30 to 75% by weight, and the remixing ratio of the coagulated component 04 and the water-soluble component 06 after the coagulation process of the soy milk 02 can be determined accordingly.

[0024] Figure 1-3 is a flow diagram of an example of the dough base preparation process in the soybean-containing processed food production method of the present invention, taking into account aspects such as component remixing. As shown in the figure, in the soybean-containing processed food production method of the present invention, in which soy milk 02 is used as the raw material, a selective component mixing process P16 can be added to the dough base preparation process P10. In this process P16, the water-soluble component 06 is remixed with the curd component 04 separated from the water-soluble component 06 in the component separation process P15 as needed to obtain a component mixture 08. Because the phrase "if necessary" is used, remixing may not be necessary if it is not necessary to achieve the final product specifications. Furthermore, even when the curd component 04 and the water-soluble component 06 are remixed, the mixing ratio can be appropriately designed depending on the final product specifications.

[0025] As shown in the figure, this flow can also be configured to include a selective homogenization step P18. In this step P18, the coagulated component 04, or the component mixture 08 obtained when the components were remixed in the selective component mixing step P16, is homogenized as needed to obtain a dough base level homogenized product 09. Since the phrase "if necessary" is used, homogenization may not be performed if it is not necessary to achieve the specifications of the final product. Note that the specific method for homogenization can be designed appropriately depending on the specifications of the final product.

[0026] Figure 1-4 is an explanatory diagram showing materials that can be used as the dough base in the method for producing soybean-containing processed foods of the present invention shown in Figure 1. As shown in the figure, a plurality of materials can be used as the dough base 1 obtained in the dough base preparation step P10 of this method for producing soybean-containing processed foods using soy milk 02 as a raw material. That is, any of the coagulated component 04 obtained in the component separation step P15, the component mixture 08 obtained in the selective component mixing step P16, and the homogenized material 09 obtained during dough base preparation in the selective homogenization step P18 can be used as the dough base 1 and subjected to subsequent processes.

[0027] In the selective component mixing step P16, the remixing process can be configured to be performed at a mixing ratio of 25% by weight to 100% by weight of the coagulum component and 0% by weight to 75% by weight of the water-soluble component so that the concentration of the coagulum component 04 is suitable for obtaining the target soybean-containing processed food. By using these remixing ratios, it is possible to obtain a soybean-containing processed food of the present invention with a solids content of 30 to 75% by weight, which is the more desirable ratio mentioned above.

[0028] FIG. 2 is a flow chart showing the basic configuration of the method for producing soybean-containing processed foods of the present invention using soybean flour as a raw material. As shown in the figure, this method for producing soy-containing processed foods using soy flour 03 as a raw material has a basic structure consisting of a dough base preparation process P210 for preparing a dough base 21 that forms the basis of the target soy-containing processed food 210, a secondary ingredient mixing process P220 for mixing secondary ingredients 22 with the dough base 21 obtained in the dough base preparation process P210, and a post-processing process P230 for post-processing the secondary ingredient mixture 23 obtained in the secondary ingredient mixing process P220.The post-processing process P230 has in common with the production method of the present invention using soy milk 02 as a raw material shown in Figure 1, etc. in that the dough base 21 has a lipid content that is less than the protein content, and the resulting soy-containing processed food 210 contains 25% by weight or more of solids derived from the dough base 21.However, it differs in that in the dough base preparation process P210, a tofu-like emulsion obtained by water extraction of soy flour 03 is obtained as the dough base 21.

[0029] That is, in the dough base preparation process P210, a tofu-like emulsion obtained by water extraction of soy flour 03 is used as dough base 21 and subjected to the subsequent processes, but processes P220 and P230 are carried out with the same variations as the production method using soy milk 02 as the raw material described in Figures 1, 1-3, and 1-4. In this way, by preparing a sol-like tofu-like emulsion from soy flour 03 and adding auxiliary ingredients, a soy-containing processed food 210 can be obtained, as in the case of the soy milk raw material shown in Figure 1, etc., and a terrine-like final product can also be obtained. Note that, of course, the characteristic feature of showing component separation based on the coagulation treatment of soy milk 02, as described using Figure 1-3, is not present in this flow using soy flour 03 as the raw material.

[0030] Regardless of whether the raw material is soy milk 02 or soy flour 03, the heat treatment carried out in the heat treatment step of the post-processing process can be various heating methods and conditions, including baking in an oven, convection oven, or steam oven, heat treatment in a drum dryer, boiling or retort treatment after filling into a container or package, etc., as long as it can reduce the moisture content of the final product to the desired solids ratio. In the present invention, a heat treatment step by one of these methods is essential as a post-processing process.

[0031] If this step is not carried out sufficiently, the final product will be in a paste or slurry state, and the terrine-like processed food with a high solids content that is the main form of the final product envisioned by this invention will not be obtained. Therefore, it is important that the degree of heating in the heat treatment be at least sufficient to achieve such a high solids content in the final product, depending on the specific treatment method. For example, if the boiling treatment is carried out after filling into a container or package, if the degree is too low, the final product will become paste-like, so it is important to carry out a sufficient boiling treatment. A high solids content in the final soybean-containing processed food product is also significant in making it a product more suitable for distribution.

[0032] 3 is a flow chart showing the configuration of the method for producing soy-containing processed foods of the present invention, which includes a molding step in the post-processing steps. As shown in the figure, in this method for producing soy-containing processed foods, regardless of whether soy milk or soy flour is used as the soy-containing processed food raw material 01, the post-processing step P330 to which the secondary ingredient mixture 33 obtained through the dough base preparation step P310 and the secondary ingredient mixing step P320 is supplied can be configured to include a molding step P336 for molding the secondary ingredient mixture 33.

[0033] According to this flow having such a configuration, the secondary material mixture 33 is subjected to a forming step P336 in the post-processing process P330 to obtain a shaped product 38. For the forming process in the forming step P336, any suitable forming means for forming the desired shape of the shaped product 38, such as a molding machine or a filling machine, can be used. The shaped product 38 is then subjected to a heat treatment step P338 to obtain a soybean-containing processed food 310 shaped into the desired shape.

[0034] 3-2 is a flow chart showing the main components of the method for producing soy-containing processed foods of the present invention, which includes a homogenization step in the post-processing steps. As shown in the figure, in this method for producing soy-containing processed foods, regardless of whether the soy-containing processed food raw material 01 is soy milk or soy flour, the post-processing step P330, to which the secondary ingredient mixture 33 obtained through the dough base preparation step and the secondary ingredient mixing step is subjected, can be configured to include a selective secondary ingredient mixture homogenization step P335, where the secondary ingredient mixture 33 is homogenized, if necessary.

[0035] According to this flow having such a configuration, the secondary ingredient mixture 33 is subjected to a selective secondary ingredient mixture homogenization step P335 in the post-processing process P330, and if homogenization is performed here as necessary, a homogenized product 35 is obtained. The homogenized product 35 is then subjected to a shaping process in a shaping step P336 to obtain a shaped product 38. The shaped product 38 is then subjected to a heat treatment step P338 to obtain a soy-containing processed food 310 shaped into the desired form.

[0036] Figure 3-3 is an explanatory diagram showing materials that can be subjected to the heat treatment step in the soybean-containing processed food production method of the present invention shown in Figure 3. As shown in the figure, multiple materials can be used as the object to be subjected to the heat treatment step P338. That is, any of the following can be subjected to the heat treatment step P338: the secondary ingredient mixture 33 obtained in the secondary ingredient mixing step P320, the homogenized product 35 obtained in the selective secondary ingredient mixture homogenization step P335, and the shaped product 38 obtained in the shaping step P336. However, one of the main objectives of the present invention is to produce a terrine-like product. Therefore, a more desirable configuration would require the shaping step P336. From this perspective, we will now provide an explanation.

[0037] Figure 3-4 is a second explanatory diagram showing materials that can be subjected to the heat treatment step in the soybean-containing processed food production method of the present invention shown in Figure 3, assuming that the molding step is required. As shown in the figure, both the secondary ingredient mixture 33 obtained in the secondary ingredient mixing step P320 and the homogenized product 35 obtained when homogenization is performed in the selective secondary ingredient mixture homogenization step P335 (indicated by the "Y" arrow in the figure) must be molded in the molding step P336 to form a molded product 38 before being subjected to the heat treatment step P338. If homogenization is not selected in the selective secondary ingredient mixture homogenization step P335 (indicated by the "N" arrow in the figure), the material subjected to the molding step P336 is the secondary ingredient mixture 33.

[0038] The auxiliary materials used in the method for producing soybean-containing processed foods of the present invention are not particularly limited and can include a wide range of materials. In particular, any one of the following, or an appropriate combination of two or more of the following, can be suitably used as auxiliary materials: soy protein, vegetable protein other than soy protein, seasonings, food polysaccharides, vegetable powder, fruit powder, confectionery powder, fish meal, dairy products (cheese, milk powder, etc.), and oils and fats. Since the final soybean-containing processed food product has a high solids content and high viscosity, it is desirable to use a device with a strong mixing force, such as a food processor, cutter mixer, or shear mixer, for production.

[0039] 4 is a conceptual diagram showing the basic configuration of the soy-containing processed food production system of the present invention. As shown in the figure, the soy-containing processed food production system S1000 comprises a dough base preparation section S100 for preparing a dough base that forms the basis of the target soy-containing processed food, a secondary ingredient mixing section S200 for mixing secondary ingredients with the dough base obtained in the dough base preparation section S100, and a post-treatment section S300 for post-processing the secondary ingredient mixture obtained in the secondary ingredient mixing section S200. The post-treatment section S300 includes at least a heating section S380 for the secondary ingredient mixture, and is mainly configured to obtain a dough base whose lipid content is less than its protein content, and in which the solid content derived from the dough base accounts for 25% by weight or more of the solid content in the soy-containing processed food obtained as the final product.

[0040] In the soybean-containing processed food production system S1000 of the present invention configured as described above, a dough base that is the basis for the target soybean-containing processed food is first prepared in the dough base preparation section S100, and the dough base prepared here has a lipid content less than the protein content and has properties such that the solid content derived from the dough base in the soybean-containing processed food obtained as the final product is 25% by weight or more, more preferably 30% by weight or more and 75% by weight or less.

[0041] The dough base is mixed with the secondary ingredients in the secondary ingredient mixing section S200 to form a secondary ingredient mixture. As in the above-described method for producing soy-containing processed foods of the present invention, various secondary ingredients can be used depending on the intended use of the final product. The resulting secondary ingredient mixture is subjected to post-processing in the post-processing section S300 to obtain the final soy-containing processed food product. In the post-processing section S300, at least the secondary ingredient mixture is subjected to a heat treatment in the heat treatment section S380. The heat treatment method in the heat treatment section S380 can be any suitable method known in the art, as in the above-described method for producing soy-containing processed foods of the present invention.

[0042] Figure 5 is a conceptual diagram showing the configuration of the soy-containing processed food production system of the present invention, which uses soy milk as a raw material. As shown in the figure, this soy-containing processed food production system S1000X can be configured so that, in addition to the components described using Figure 4, the dough base preparation unit S100X is equipped with a component separation unit S115X that separates the curd components resulting from the coagulation treatment of the soy milk from the water-soluble components. That is, this soy-containing processed food production system S1000X uses soy milk as a production raw material, and in the dough base preparation unit S100X, the component separation unit S115X separates the curd components resulting from the coagulation treatment of the soy milk from the water-soluble components.

[0043] The dough base obtained through separation of the soy milk components in the component separation section S115X is mixed with the component in the component mixing section S200X to form a component mixture, which is then subjected to post-processing in the post-processing section S300X, including at least a heat treatment in the heat treatment section S380, to obtain the final soy-containing processed food product. Note that the dough base preparation section S100X can output the coagulated component separated in the component separation section S115X as the dough base, but other dough base compositions are also possible.

[0044] That is, by providing a selective component mixing section S116X downstream of the component separation section S115X as shown in the figure, the dough base preparation section S100X can be configured to remix the separated components in an appropriate ratio. That is, the selective component mixing section S116X has the function of mixing a water-soluble component with the coagulum component separated in the component separation section S115X as needed, and remixing the two components to obtain a component mixture. Since the phrase "if necessary" is used, remixing may not be necessary to achieve the final product specifications. The specific method and mixing ratio for remixing can be designed appropriately depending on the final product specifications.

[0045] The scope of the present invention also includes soybean-containing processed foods themselves produced by any of the soybean processed product production systems S1000, etc. Furthermore, the production means is not limited to the soybean processed product production system S1000, etc. Soybean-containing processed foods formed by mixing auxiliary ingredients with a dough base made from soybeans, the dough base has a component composition in which the lipid content is less than the protein content, and the solid content derived from the dough base in the resulting soybean-containing processed food is 25% by weight or more, and are formed through a heat treatment, are also within the scope of the present invention.

[0046] 6 is an explanatory diagram conceptually showing the shaping of the soybean-containing processed food of the present invention. As shown in the figure, the soybean-containing processed food 610 is filled into an appropriate mold structure 65 of a specific shape for forming, thereby obtaining a specific form as the soybean-containing processed food p610 before being removed from the mold structure ((a) in the figure), and is finally removed from the mold structure 65 to obtain the soybean-containing processed food 610 shaped into a specific shape like a pâté terrine ((b) in the figure).

[0047] The soybean-containing processed food of the present invention is produced with a solids content of 25% by weight or more, more preferably 30% to 75% by weight or less, and is a low-fat, natural food due to the use of natural emulsions. Its uses are not limited. For example, it can be used as a high-protein food, prepared dish, confectionery, etc., and, when the solids content is low, it can also be used as a spread food. Furthermore, because the soybean-containing processed food has a high solids content and low moisture content, it is suitable for distribution at room temperature through retort processing, or for production, distribution, and sale as a frozen food regardless of its intended use.

[0048] Examples of the present invention are described below, but the present invention is not limited to these examples. Percentages are by weight. <1. Production of soybean processed composition (= dough base)> Soy milk produced in a tofu factory according to a conventional method was used for the test. This soy milk was obtained by soaking Canadian soybeans overnight, grinding them in a grinder while adding water, heating them directly in a steamer, and separating the soybean lees using a screw press. Water was added to adjust the solids content of the soy milk to 10%, and the soy milk was heated to 80°C in a hot water bath.

[0049] To 500 g of soy milk, 17.5 mL of a 10% aqueous solution of magnesium chloride hexahydrate (Kanto Chemical Co., Ltd.) was added, stirred with a rubber spatula, and allowed to stand for 10 minutes. The mixture was separated into a coagulated product and an aqueous solution using a tabletop centrifuge (H-112, Kokusan Co., Ltd.) at 5,000 rpm. The solid content of the separated coagulated product was 24%.

[0050] <2. Physical Property Measurement Method (Viscosity)> Viscosity measurements were performed on unheated samples at 25°C. A rheometer (Anton Paar, MCR-302e) was used for the measurements, with a 12 mm diameter parallel plate spindle (Anton Paar, PP12) used as the plunger. To obtain rheological profiles using RheoCompass software, the rheometer was set to oscillation mode at an angular frequency of 10 (1 / s), with a gap of 3 mm, and 25 data points were collected while the strain increased from 0.01% to 100% on a logarithmic scale. Shear strain (%), shear stress (Pa), storage modulus (Pa), loss modulus (Pa), loss tangent (-), torque (μNm), complex viscosity (Pa s), and normal force (N) were recorded. Complex viscosity (Pa s) at a shear strain of 0.1% was also recorded.

[0051] <3. Method for Measuring Physical Properties (Rupture Stress)> The rupture stress was measured by carrying out a penetration test at three locations on a sample cut to a thickness of 1.5 cm and kept at 25° C. For the measurement, a rheometer (Sun Scientific Co., Ltd., CR-500DX) was used, and a circular plunger with a diameter of 10 mm was used. The penetration rate was 1.0 mm / min, and the average value of the first peak of the load was evaluated as the rupture stress.

[0052] <4 Comparative Examples> Comparative Example 1 (Plain) 100 g of dough base alone was homogeneously dispersed in a food processor (MK-K48P, Panasonic Corporation) without using any secondary ingredients. This was filled into a container and subjected to a heat treatment in a constant temperature water bath at 90°C for 20 minutes to obtain a soybean processed product (soybean-containing processed food). This was designated as Comparative Example 1.

[0053] Comparative Example 2 (Low Protein) 97.5 g of dough base and 2.5 g of 90% soy protein (Bioactives Japan) as a secondary ingredient were weighed and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and heat-treated in a constant-temperature water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Comparative Example 2.

[0054] 5. Examples - High-Nutrition Foods Example 1 (Medium Protein) 94 g of dough base and 6 g of 90% soy protein (Bioactives Japan) as a secondary ingredient were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and heat-treated in a constant-temperature water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated Example 1.

[0055] Example 2 (High Protein) 89 g of dough base and 11 g of 90% soy protein (Bioactives Japan) as a secondary ingredient were weighed and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and heat-treated in a constant temperature water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 2.

[0056] Example 3 (High-Protein Retort) 89 g of dough base and 11 g of 90% soy protein (Bioactives Japan) as a secondary ingredient were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and subjected to a retort process (Hirayama Manufacturing Co., Ltd.) at 121°C for 20 minutes to obtain a soybean processed product, which was designated as Example 3.

[0057] Example 4 (ultra-high protein) 84 g of dough base and 16 g of 90% soy protein (Bioactives Japan) as a secondary ingredient were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic). The resulting mixture was filled into a container and heat-treated in a constant temperature water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 4.

[0058] 6. Examples - Prepared Dishes Example 5 (Komatsuna Spread, Low Temperature) 90 g of dough base and 8 g of komatsuna powder (Mikasa Sangyo Co., Ltd.) as secondary ingredients, 1 g of consommé powder, and 1 g of edible oil were weighed and homogeneously dispersed in a food processor (MK-K48P, Panasonic Corporation). The resulting mixture was filled into a container and heat-treated in a 65°C constant temperature water bath for 90 minutes to obtain a soybean processed product, which was designated as Example 5.

[0059] Example 6 (Komatsuna terrine, high temperature) 90 g of dough base and 8 g of komatsuna powder (Mikasa Sangyo Co., Ltd.) as secondary ingredients, 1 g of consommé powder, and 1 g of edible oil were weighed and homogeneously dispersed in a food processor (MK-K48P, Panasonic Corporation). The resulting mixture was filled into a container and heat-treated in a constant-temperature water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 6.

[0060] 7 Example - Confectionery Example 7 (Matcha Terrine Boiled) 72.5 g of dough base and 20 g of sugar, 5 g of modified starch (Showa Sangyo Co., Ltd.), and 2.5 g of matcha powder as secondary ingredients were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic Corporation). The resulting mixture was filled into a container and heat-treated in a constant-temperature water bath at 90°C for 20 minutes to obtain a soybean processed product, which was designated as Example 7.

[0061] Example 8 (Retort Matcha Terrine) 72.5 g of dough base and 20 g of sugar, 5 g of modified starch (Showa Sangyo Co., Ltd.), and 2.5 g of matcha powder as secondary ingredients were weighed out and homogeneously dispersed in a food processor (MK-K48P, Panasonic Corporation). The resulting mixture was filled into a container and subjected to a retort process (Hirayama Seisakusho Co., Ltd.) at 121°C for 20 minutes to obtain a soybean processed product, which was designated as Example 8.

[0062] <8. Measurement and Evaluation Methods> a. Moisture content (%) Measured by a heating and drying method at 105°C under normal pressure.

[0063] b. Texture Texture was judged by a panel sensory evaluation using the following criteria, with a score of 0 or higher being considered acceptable: ◎: Very good ○: Good ×: Poor

[0064] c Complex viscosity before heating (Pa·s) The complex viscosity (Pa·s) at a shear strain of 0.1% was recorded. d Breaking stress after heating (gf / cm) ２ The breaking stress was measured by a penetration test using a rheometer.

[0065] e Protein % Measured using a total nitrogen analyzer by the combustion method (Sumika Chemical Analysis Center, SUMIGRAPH (registered trademark) NC-220F) and calculated using a nitrogen conversion factor of 5.71. f Lipid % The lipid content was measured by extracting lipids using a chloroform-methanol mixed liquid extraction method.

[0066] g Texture after freezing and thawing The frozen products were slowly frozen in a freezer (Shibata Scientific Co., Ltd.) at -20°C, stored for 24 hours, thawed at room temperature, and subjected to sensory evaluation. The texture was judged by a panel using the following criteria in a sensory evaluation, with a score of 0 or higher being considered acceptable. ◎: The texture before freezing was maintained. ○: The texture before freezing was maintained, although it was inferior to ◎. ×: The texture before freezing was lost.

[0067] <9. Results and Discussion> The results of measurements and evaluations for Examples 1 to 8 and Comparative Examples 1 and 2 are summarized in Table 1.

[0068]

[0069] The difference between the production conditions of Example 1 (medium protein) and Comparative Example 1 (plain) is the presence or absence of the secondary ingredient soy protein. The difference between the production conditions of Example 1 (medium protein) and Comparative Example 2 (low protein) is the amount of secondary ingredient soy protein added. As a result, Comparative Example 1, which did not contain any secondary ingredients, and Comparative Example 2, which contained a small amount, lost texture after freezing and thawing, whereas Example 1 maintained this texture, resulting in a high-quality soybean processed product (soybean-containing processed food). It was estimated that when using vegetable protein (at least when using soy protein), the amount of secondary ingredient added should preferably be at least about 5% of the total.

[0070] The difference between the manufacturing conditions of Example 1 (medium protein) and Example 2 (high protein) is the amount of soy protein added as a secondary ingredient. As a result, even in Example 2, where the amount added was increased to about 10% of the total, the texture after freezing and thawing was maintained, and a soybean product of good quality was obtained. Furthermore, in Example 2, the protein content was increased and the lipid content was reduced, resulting in a result that is more in line with the trend toward low-fat foods.

[0071] The difference between the production conditions of Example 2 (high protein) and Example 3 (high protein retort) is the method and temperature of the heat treatment, with the former being a boiling treatment at 90° C. and the latter being a retort treatment at 121° C. As a result, in Example 3, which was subjected to heat treatment at a higher temperature, the texture of the soybean processed product obtained was extremely good, and furthermore, the texture after freezing and thawing was maintained better than in Example 2, and a soybean processed product of excellent quality was obtained.

[0072] In Example 4 (ultra-high protein), the production conditions were the same as in Examples 1 and 2, but the amount of soy protein added as a secondary ingredient was increased to over 15% of the total. In this example, the texture after freezing and thawing was maintained, and a high-quality soybean product was obtained. Furthermore, the fat content could be further reduced along with the increased protein content, which is in line with the trend toward low-fat foods.

[0073] Both Example 5 (Komatsuna spread, low temperature) and Example 6 (Komatsuna terrine, high temperature) are soybean processed foods prepared as side dishes using komatsuna powder and other secondary ingredients, but the heating temperatures are different. The former is 65°C, and the latter is 90°C. As a result, Example 5, which was heated at a lower temperature, produced a soybean processed food in the form of a spreadable food (soybean-containing processed food). However, a freeze-thaw test was not conducted on this product.

[0074] On the other hand, in Example 6, which was heated at a higher temperature, a terrine-like soybean product with a high solid content was obtained. The texture was also well maintained after freezing and thawing, and a soybean product of excellent quality was obtained.

[0075] Both Example 7 (boiled matcha terrine) and Example 8 (retort matcha terrine) are processed soybean products in the form of confectionery, using matcha powder and sweeteners as secondary ingredients, but the heat treatment method and temperature are different. The former is boiled at 90°C, while the latter is retort-treated at 121°C. As a result, both examples demonstrated a good texture and maintained texture after freezing and thawing, yielding soybean products of good quality. In particular, Example 8, which was heat-treated at a higher temperature, produced excellent results.

[0076] The soybean-containing processed food production method, soybean-containing processed food production system, and soybean-containing processed food of the present invention can provide novel solid soybean-containing processed foods with excellent productivity in terms of texture, taste, flavor, applications, etc. Therefore, this invention has high industrial applicability in the food production field and all related industrial and technical fields.

[0077] 01...Soy-containing processed food ingredients 02...Soy milk 03...Soy flour 04...Coagulated component 06...Water-soluble component 08...Component mixture 09...Homogenized product during dough base preparation 1, 31...Dough base 2, 22, 32...Secondary ingredient 3, 23, 33...Secondary ingredient mixture 10, 210, 310, 610...Soy-containing processed food 21...Dough base (tofu-like emulsion) 35...Homogenized product during post-processing process 38...Shaped product 65...Mold structure for shaping p610...Soy-containing processed food before removal from mold structure P10, P210, P310...Dough base preparation process P13...Coagulation treatment process P15...Component separation process P16...Selective ingredient mixing process P18...Selective homogenization process P20, P220, P320...Secondary ingredient mixing process P30, P230, P330... Post-processing process P38, P238, P338... Heat treatment process P335... Selective secondary ingredient mixture homogenization process P336... Forming process S100, S100X... Dough base preparation section S115X... Ingredient separation section S116X... Selective ingredient mixing section S200, S200X... Secondary ingredient mixing section S300, S300X... Post-processing section S380, S380X... Heat treatment section S1000, S1000X... Soy-containing processed food manufacturing system

Claims

1. A method for producing a soy-containing processed food, comprising: a dough base preparation process for preparing a dough base that is the basis of the target soy-containing processed food; a secondary ingredient mixing process for mixing secondary ingredients with the dough base obtained in the dough base preparation process; and a post-processing process for subjecting the secondary ingredient mixture obtained in the secondary ingredient mixing process to post-processing, said post-processing process including at least a heat treatment process for the secondary ingredient mixture, said dough base having a component composition in which the lipid content is less than the protein content, and said dough base contains 25% by weight or more of solids in the obtained soy-containing processed food, and said dough base preparation process includes a component separation process for separating coagulated components produced by the coagulation process of soy milk from water-soluble components.

2. The method for producing soy-containing processed foods as described in claim 1, characterized in that the dough base preparation process comprises a selective component mixing process in which, if necessary, a water-soluble component is mixed with the coagulated component separated in the component separation process to obtain a component mixture, and a selective homogenization process in which, if necessary, a homogenization treatment is performed on the coagulated component or, if the selective component mixing process has been performed, on the component mixture obtained thereby.

3. A method for producing soy-containing processed foods as described in claim 2, characterized in that in the selective component mixing process, the processing is carried out at a mixing ratio of 25% by weight or more and 100% by weight or less of the coagulated component and 0% by weight or more and 75% by weight or less of the water-soluble component so that the concentration of the coagulated component is a concentration suitable for obtaining the target soy-containing processed food.

4. A method for producing a soy-containing processed food, comprising a dough base preparation process for preparing a dough base that is the basis of the target soy-containing processed food, a secondary ingredient mixing process for mixing secondary ingredients with the dough base obtained in the dough base preparation process, and a post-processing process for subjecting the secondary ingredient mixture obtained in the secondary ingredient mixing process to post-processing, said post-processing process including at least a heat treatment step for the secondary ingredient mixture, said dough base having a component composition in which the lipid content is less than the protein content, and said dough base accounts for 25% by weight or more of the solids in the obtained soy-containing processed food, and said dough base preparation process includes obtaining a tofu-like emulsion by water extraction of soy flour as the dough base.

5. A method for producing a soybean-containing processed food according to any one of claims 1, 2, 3 and 4, characterized in that the heat treatment in the heat treatment step is any one of the following listed in <H>: <H> Baking in an oven, baking in a convection oven, baking in a steam oven, heat treatment in a drum dryer, boiling treatment after filling in a container or package, retort treatment after filling in a container or package, other heat treatment (excluding baking in an oven, baking in a convection oven, baking in a steam oven, heat treatment in a drum dryer, boiling treatment after filling in a container or package, or retort treatment after filling in a container or package).

6. A method for producing a soy-containing processed food as described in claim 5, characterized in that the post-processing process includes a molding process for molding the secondary material mixture, and the molded product obtained by the molding process is subjected to heat treatment in the heat treatment process.

7. The method for producing a soy-containing processed food as described in claim 6, characterized in that the post-processing step includes a selective secondary ingredient mixture homogenization step of homogenizing the secondary ingredient mixture as necessary, and when the selective secondary ingredient mixture homogenization step has been performed, the homogenized product obtained thereby is subjected to a molding process in the molding step.

8. The method for producing soybean-containing processed foods according to claim 6 or 7, characterized in that the secondary ingredients are one or more of the following listed in <C>: <C> Soybean protein, vegetable protein (excluding soybean protein), seasonings, food polysaccharides, vegetable powder, fruit powder, confectionery powder, fish meal, dairy products, oils and fats 9. A soy-containing processed food manufacturing system comprising a dough base preparation section which prepares a dough base that is the basis of the target soy-containing processed food, a secondary ingredient mixing section which mixes secondary ingredients with the dough base obtained in the dough base preparation section, and a post-processing section which applies post-processing to the secondary ingredient mixture obtained in the secondary ingredient mixing section, the post-processing section including at least a heat processing section for the secondary ingredient mixture, and the dough base preparation section producing a dough base having a lipid content less than its protein content, and in which the resulting soy-containing processed food contains 25% or more by weight of solids derived from the dough base.

10. The soy-containing processed food manufacturing system according to claim 9, wherein the dough base preparation unit is provided with a component separation unit that separates the coagulated components produced by the coagulation process of soy milk from the water-soluble components.

11. The soy-containing processed food manufacturing system of claim 10, wherein the dough base preparation section is provided with a selective ingredient mixing section which, if necessary, mixes a water-soluble ingredient with the coagulated component separated in the ingredient separation section to obtain an ingredient mixture.

12. A soybean-containing processed food produced by the soybean processed product production system according to any one of claims 9, 10 and 11.

13. A soy-containing processed food, characterized in that a secondary ingredient is mixed into a dough base made from soybeans, the dough base has a composition in which the lipid content is less than the protein content, and the solid content of the obtained soy-containing processed food derived from the dough base is 25% by weight or more, and the food is formed through a heat treatment.

14. A soybean-containing processed food according to claim 12 or 13, characterized in that it is formed into a specific shape like a pate for a terrine de pate.

15. The soybean-containing processed food according to claim 14, which is any one of the following listed in <F>. <F> High protein foods, side dishes, confectioneries, spreads 16. The soybean-containing processed food according to claim 15, which is a frozen food.

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