Method for producing packed noodles

Abstract

The objective of the present invention is to provide a method for producing packed noodles that maintain moderate hardness even after long-time storage and are highly versatile.　The objective is achieved by a method for producing packed noodles, the method comprising: a step for preparing pregelatinized noodles; a step for obtaining immersion liquid-absorbing noodles by subjecting the pregelatinized noodles to an immersion treatment in an immersion liquid containing 20-50 mass % of a starch decomposed product having a DE value of 4-25 and then subjecting the same to a solid-liquid separation treatment; and a step for obtaining packed noodles by subjecting a container filled with the immersion liquid-absorbing noodles to a heat sterilization treatment.

Description

Manufacturing method for packaged noodles

[0001] The present invention relates to packaged noodles that maintain a suitable hardness even when stored for a long period of time and are highly versatile, and to a method for producing the same.

[0002] Processed foods such as pasta, udon, soba, ramen, and other cooked noodles are required to maintain a moderate firmness without falling apart when cooked. Preventing the food from falling apart and maintaining a moderate firmness are particularly difficult for products intended for long-term storage.

[0003] For example, pasta is generally made from wheat, has a dense internal structure, and has a unique texture that is smooth to the touch and has a moderate chewiness (hardness). Therefore, maintaining the unique texture of pasta in cooked processed foods that use pasta is an important factor in increasing the commercial value.

[0004] The present inventor has previously developed a method for producing packaged noodles that can maintain an appropriate hardness even when stored for a long period of time, in which a container filled with noodles that have been pre-heated and frozen and a seasoning liquid containing a specific amount of a starch hydrolysate with a specific DE value is heat-sterilized (see, for example, Patent Document 1).

[0005] Furthermore, noodles that have been pasteurized and pH-treated are known as room temperature storable heat-treated noodles (see, for example, Non-Patent Documents 1 and 2).

[0006] Patent No. 6923986

[0007] Ma Ma Boiled Spaghetti Napolitan, Nisshin Seifun Wellna [online], [Retrieved January 31, 2024], Internet <URL: https: / / www.nisshin-seifun-welna.com / index / products / 4902110344981.html> Udon with Soup, Itsuki Foods Co., Ltd. [online], [Retrieved January 31, 2024], Internet <URL: https: / / www.itsukifoods.jp / product_02_udon.html>

[0008] The method described in Patent Document 1 can maintain the noodles' appropriate firmness even when stored for a long period of time, but because the noodles and seasoning liquid are packed together in a container, there is a problem in that the variety of flavors is lacking and it is not possible to meet the diversifying tastes of consumers.

[0009] The noodles described in Non-Patent Documents 1 and 2 have the problem that they can be stored for a relatively short period of time due to the low-temperature sterilization treatment, and furthermore, the firmness (hardness) of the noodles is not sufficient.

[0010] Therefore, an object of the present invention is to provide highly versatile packaged noodles that maintain a suitable hardness even when stored for a long period of time.

[0011] In order to produce versatile packaged noodles, the present inventors attempted to eliminate as many seasoning components as possible from the seasoning liquid other than water and starch hydrolysates in the method described in Patent Document 1. However, they encountered the problem that, depending on the concentration of starch hydrolysates, the noodles could not achieve an appropriate firmness. It was presumed that this was because, even if the concentration of starch hydrolysates was the same in the method described in Patent Document 1, the absence of seasoning components inevitably increased the amount of water, and this moisture transferred to the noodles, making it impossible to maintain firmness. Generally, moisture transfer occurs from a higher moisture content to a lower moisture content. Therefore, when the moisture content of noodles is low and the moisture content of the seasoning liquid is high, the moisture from the seasoning liquid transfers to the noodles, making it difficult to maintain an appropriate firmness. Therefore, when the inventors attempted to eliminate the seasoning components and reduce the moisture content in the method described in Patent Document 1, they encountered the problem that, as the concentration of starch hydrolysates became excessively high, the viscosity of the seasoning liquid also increased, preventing the seasoning liquid from mixing with the noodles. Ultimately, they encountered the problem that the noodles could not achieve an appropriate firmness. To solve this problem, the inventors conducted extensive research, reviewing the ingredients and blending ratio of the seasoning liquid, the manufacturing process, etc. Finally, they succeeded in obtaining packaged noodles that can maintain a suitable hardness even after long-term storage by immersing noodles that have been gelatinized to a certain extent in a soaking liquid containing specific amounts of water and specific starch hydrolysates. Furthermore, because these packaged noodles contain almost no ingredients other than water and the starch hydrolysates, the seasoning liquid (including sauces, soups, dipping sauces, etc.) and ingredients can be freely selected for use with the noodles, making them highly versatile and able to meet consumer needs. The present invention was completed based on these successful examples and findings.

[0012] Therefore, according to one aspect of the present invention, the following is provided: [1] A method for producing packaged noodles, comprising the steps of: preparing pregelatinized noodles; immersing the pregelatinized noodles in a soaking liquid containing 20% ​​to 50% by mass of a starch hydrolysate with a DE value of 4 to 25, followed by solid-liquid separation to obtain soaking liquid-absorbed noodles; and sterilizing a container filled with the soaking liquid-absorbed noodles to obtain packaged noodles. [2] A method for producing packaged noodles according to [1], wherein the packaged noodles have a moisture value of 45% to 63% by mass. [3] A method for producing packaged noodles according to [1] or [2], wherein the soaking liquid has a Brix value of 20 to 50. [4] A method for producing packaged noodles according to any one of [1] to [3], wherein the noodles are at least one type selected from the group consisting of Chinese noodles, pasta, udon, and somen. [5] The method for producing packaged noodles according to any one of [1] to [4], wherein the heat sterilization treatment is retort sterilization treatment. [6] The method for producing packaged noodles according to any one of [1] to [5], wherein the soaking liquid further contains at least one component selected from the group consisting of salt and acidulants. [7] The method for producing packaged noodles according to any one of [1] to [6], wherein the packaged noodles are substantially unseasoned.

[0013] According to the present invention, it is possible to obtain packaged noodles that can maintain a suitable hardness even when stored for a long period of time and that are highly versatile.

[0014] The following describes in detail packaged noodles, which are one embodiment of the present invention, and the method for producing the same; however, the technical scope of the present invention is not limited to the items in this section, and the present invention can take various forms as long as it achieves its objectives.

[0015] "Packed in a container" means filled or contained in a container. The term "content" is synonymous with "concentration" herein and refers to the ratio (e.g., mass %) of the amount (e.g., mass) of a component to the total amount (e.g., volume). "Comprise" means that elements other than those explicitly specified as being included can be added (synonymous with "comprise at least"), but also encompasses "consist of" and "essentially consisting of." That is, "comprise" can mean including the explicitly specified elements and any one or more elements, consisting of the explicitly specified elements, or essentially consisting of the explicitly specified elements. Elements include limitations such as components, steps, conditions, and parameters. The "to" in a numerical range refers to a range that includes the preceding and succeeding numbers. For example, "0% to 100%" means a range that is 0% or greater and 100% or less. "Exceeds" and "less than" refer to lower and upper limits, respectively, exclusive of the preceding number. For example, "exceeds 1" means a number greater than 1, and "less than 100" means a number less than 100. The number of digits in an integer value matches the number of significant digits. For example, 1 has one significant digit, and 10 has two significant digits. Also, the number of digits after the decimal point in a decimal value matches the number of significant digits. For example, 0.1 has one significant digit, and 0.10 has two significant digits.

[0016] One aspect of the present invention is a method for producing packaged noodles, which comprises the steps of: preparing pregelatinized noodles (hereinafter also referred to as the "pregelatinized noodle preparation step"); immersing the pregelatinized noodles in a soaking liquid containing 20% ​​to 50% by mass of a starch hydrolysate with a DE value of 4 to 25, followed by solid-liquid separation to obtain soaking liquid-absorbed noodles (hereinafter also referred to as the "soaking treatment step"); and sterilizing a container filled with the soaking liquid-absorbed noodles to obtain packaged noodles (hereinafter also referred to as the "heat sterilization treatment step").

[0017] The packaged noodles of one embodiment of the present invention are substantially unseasoned. Here, "substantially unseasoned" means that they are not seasoned with any seasoning ingredients (seasonings, ingredients, etc.) other than starch hydrolysates and, optionally, salt and acidulants, and therefore do not contain any seasoning ingredients at all, or if they are contained, they are in extremely small amounts. In other words, the packaged noodles of one embodiment of the present invention are not seasoned or cooked so that they can be eaten on their own, but are intended to be used for seasoning or cooking in combination with a seasoning liquid (including sauce, soup, broth, and other ingredients).

[0018] [Pregelatinized Noodle Preparation Step] In the pregelatinized noodle preparation step, pregelatinized noodles are prepared. In the present invention, pregelatinized noodles refer to noodles that have been prepared by heat-treating non-gelatinized noodles (dried noodles, semi-dried noodles, or fresh noodles) using a known method such as boiling or steaming, thereby pregelatinizing the starch contained in the noodles. Note that in the present invention, pregelatinized noodles also include noodles in which a portion of the starch contained in the noodles has been pregelatinized.

[0019] The degree of gelatinization of gelatinized noodles can be evaluated by the moisture content of the gelatinized noodles. In the present invention, the moisture content of noodles can be measured using a heat-dry moisture meter ("ML50", manufactured by A&D Co., Ltd., settings: standard MID, set temperature: 200°C), as described in the Examples below. Specifically, noodles are cut into pieces of 10 mm or less, and 5 g of the cut noodles are measured.

[0020] The moisture content of pregelatinized noodles can be set appropriately depending on the type, shape, thickness, etc. of the noodles, but is preferably 45% to 63% by mass, more preferably 48% to 60% by mass, and even more preferably 55% to 58% by mass. If the moisture content of pregelatinized noodles is too low, there is a risk that the noodles will stick together and form lumps during the subsequent heat sterilization treatment step. On the other hand, if the moisture content of pregelatinized noodles is too high, there is a risk that they will not be able to maintain an appropriate firmness. Furthermore, the moisture content of pregelatinized noodles is preferably 80% to 130% of the moisture content (mass %) of the packaged noodles (noodles after the heat sterilization treatment step), more preferably 85% to 120%, and even more preferably 88% to 117%. The moisture content of pregelatinized noodles can be adjusted, for example, by the time, temperature, etc. of the heat treatment.

[0021] In the gelatinized noodle preparation step, non-gelatinized noodles (dried noodles, semi-dried noodles, or fresh noodles) may be subjected to a heat treatment to obtain gelatinized noodles, or commercially available chilled noodles or frozen noodles may be used.

[0022] The conditions for the heat treatment of non-gelatinized noodles can be set appropriately depending on the type, shape, thickness, etc. of the noodles, but for example, the boiling temperature is preferably 80°C to 100°C, and the boiling time is preferably 1 minute to 10 minutes, more preferably 1 minute to 5 minutes. Also, for example, the steaming temperature is preferably 80°C to 100°C, and the steaming time is preferably 15 minutes to 100 minutes, more preferably 30 minutes to 60 minutes. Methods commonly used in food production can be used as the method for heat treatment of non-gelatinized noodles.

[0023] Non-gelatinized noodles refer to noodles that have not been subjected to heat treatment and in which the starch contained therein has not been gelatinized. Non-gelatinized noodles may be noodles formed from dough using cereal flour as a raw material, and examples thereof include Chinese noodles, udon, pasta, somen, etc. Wheat is preferably used as the noodle raw material, and wheat is more preferably used in an amount of 50% by mass or more. Furthermore, non-gelatinized noodles can be any of dried noodles, semi-dried noodles, and fresh noodles. The thickness of non-gelatinized noodles varies depending on the type of noodle, but is, for example, about 1.5 mm to 3 mm for Chinese noodles, about 1.8 mm to 4.5 mm for udon, about 1.4 mm to 2.3 mm for pasta (spaghetti), and about 0.5 mm to 1.3 mm for somen.

[0024] The moisture content of non-gelatinized noodles is generally about 30% to 40% by mass for fresh noodles, and about 10% to 15% by mass for dried noodles.

[0025] When pregelatinized noodles are obtained by heat-treating non-gelatinized noodles in the gelatinized noodle preparation step, it is preferable to rinse the noodles with water and drain them after the heat treatment. Methods commonly used in food production can be used for rinsing and draining, and examples include rinsing with running water for 5 to 60 seconds and draining the water in a punching bowl or the like. Furthermore, when frozen noodles are used as the gelatinized noodles in the gelatinized noodle preparation step, it is preferable to thaw them (preferably naturally thawed) before use.

[0026] According to the gelatinized noodle preparation step, by using noodles that have been gelatinized to a certain extent, the noodles are prevented from sticking together and forming lumps during the subsequent heat sterilization treatment step.

[0027] [Soaking Treatment Step] In the soaking treatment step, the gelatinized noodles prepared in the previous step are soaked in a soaking liquid containing 20% ​​to 50% by mass of a starch hydrolysate with a DE value of 4 to 25, and then subjected to solid-liquid separation to obtain soaking liquid-absorbed noodles.

[0028] The soaking liquid contains 20% to 50% by mass of a starch hydrolysate having a DE value of 4 to 25. Specifically, the soaking liquid is a blend of 20% to 50% by mass of a starch hydrolysate having a DE value of 4 to 25 and 50% to 80% by mass of other components. Examples of other components include water, and optionally, acidulants such as salt, vinegar, and citric acid. At least one component selected from the group consisting of salt and acidulants is preferably contained in the soaking liquid at a ratio of 0.1% to 15% by mass to a level that does not interfere with the taste of seasoning liquids (including sauces, soups, dipping sauces, and other seasoning ingredients) and ingredients when consumed. The salt that may be contained in the soaking liquid may have a strong sweetness depending on the DE value and content of the starch hydrolysate used, and is therefore used to reduce the sweetness. Furthermore, the soaking liquid may contain an acidulant, which is used to adjust the pH and prevent discoloration when the noodles used are Chinese noodles containing kansui.

[0029] As described above, the soaking liquid preferably does not contain starch hydrolysates, and seasonings other than salt and acidulants as optional ingredients (soy sauce, miso, sugar, etc.), yeast extract, meat extract (chicken extract, pork extract, beef extract, fish extract, etc.), fruit juice (apple juice, etc.), vegetable juice (tomato puree, etc.), spices (ginger, chili pepper, pepper, basil, oregano, etc.), coloring agents, umami seasonings, flavors, and other seasoning ingredients, and even if they are contained, they are contained in very small amounts (for example, 0.1% by mass to 1% by mass).

[0030] The starch hydrolysate is not particularly limited as long as it has a DE value of 4 to 25 and can be used in general food products. The term "starch hydrolysate" collectively refers to starch that has been decomposed to an appropriate molecular weight using an enzyme and / or an acid. Specific examples of starch hydrolysates with a DE value of 4 to 25 include dextrin with a DE value of about 4 to 10, maltodextrin with a DE value of about 10 to 20, and powdered sugar with a DE value of about 20 to 25. Furthermore, starch hydrolysates with a DE value of 4 to 25 can be used singly or in combination of two or more.

[0031] The starch hydrolysate has a DE value of 4 to 25, preferably a DE value of 8 to 18. The smaller the DE value, the lower the sweetness and the higher the viscosity. Furthermore, the higher the DE value, the higher the sweetness and the lower the viscosity. Therefore, when a starch hydrolysate with a DE value of less than 4 is used, the high viscosity of the starch hydrolysate also increases the viscosity of the entire soaking liquid, making it difficult for the gelatinized noodles to mix with the soaking liquid. On the other hand, when a starch hydrolysate with a DE value exceeding 25 is used, the high sweetness of the starch hydrolysate also increases the sweetness of the entire soaking liquid, which may result in a loss of taste for the packaged noodles obtained.

[0032] The soaking liquid contains 20% to 50% by mass, and preferably 25% to 40% by mass, of starch hydrolysates with a DE value of 4 to 25. If the starch hydrolysate content is less than 20% by mass, an appropriate amount of the starch hydrolysate will not be absorbed by the pregelatinized noodles during the soaking treatment, and as a result, the noodles may not be able to maintain an appropriate level of firmness. On the other hand, if the starch hydrolysate content exceeds 50% by mass, the viscosity of the entire soaking liquid will increase, making it difficult for the pregelatinized noodles to mix with the soaking liquid.

[0033] The Brix value of the soaking liquid is preferably 20 to 50, and more preferably 27 to 43. If the Brix value is too low, an appropriate amount of starch hydrolysates will not be absorbed by the pregelatinized noodles, and as a result, the noodles may not be able to maintain an appropriate hardness. On the other hand, if the Brix value is too high, the viscosity of the soaking liquid as a whole will increase, making it difficult for the pregelatinized noodles to mix with the soaking liquid. Note that, since some of the dextrin in the soaking liquid penetrates into the inside of the noodles during the soaking treatment, the Brix value of the soaking liquid after the soaking treatment will likely be lower than 20 to 50. In light of the examples described below, the Brix value of the soaking liquid after the soaking treatment will be approximately 18 to 43.

[0034] In the present invention, the Brix value refers to the reading of a sugar refractometer at a sample temperature of 20°C. The Brix value can be adjusted by adjusting the content of starch hydrolysates in the soaking liquid. For example, when 10 g of dextrin is dissolved in 100 g of water, the Brix value is approximately 9.5 to 10. Therefore, even if the soaking liquid contains components other than starch hydrolysates, the amount is very small.

[0035] The method for preparing the soaking liquid is not particularly limited, but it can be prepared by measuring and mixing a starch hydrolyzate having a DE value of 4 to 25, water, and optionally salt, an acidulant, etc., and heating the mixture as necessary.

[0036] The soaking method is not particularly limited, but examples include a method in which the gelatinized noodles are placed in a container filled with a soaking liquid and allowed to stand.

[0037] There are no particular limitations on the blend ratio of the gelatinized noodles to the soaking liquid, so long as the gelatinized noodles are sufficiently immersed in the soaking liquid. For example, the mass ratio (gelatinized noodles:soaking liquid) is preferably 1:0.5 to 1:10, and more preferably 1:0.5 to 1:1.5.

[0038] The soaking treatment conditions can be appropriately set depending on the type, shape, thickness, etc. of the noodles. The soaking time is, for example, preferably 10 minutes to 24 hours, more preferably 30 minutes to 15 hours, and even more preferably 30 minutes to 3 hours. The soaking liquid temperature is, for example, preferably 1°C to 30°C, and more preferably 5°C to 10°C.

[0039] As a solid-liquid separation method, a method commonly used in food production can be used, such as a method of draining noodles that have absorbed soaking liquid using a centrifugal dehydrator or a punching bowl.

[0040] The solid-liquid separation treatment conditions can be appropriately set depending on the type, shape, thickness, etc. of the noodles, but the solid-liquid separation time is, for example, preferably 5 to 60 minutes, and more preferably 8 to 20 minutes.

[0041] The moisture content of the gelatinized noodles after solid-liquid separation, i.e., the soaking liquid-absorbed noodles, is preferably 45% to 63% by mass, more preferably 48% to 60% by mass, and even more preferably 55% to 58% by mass. If the moisture content of the soaking liquid-absorbed noodles is too low, the noodles may stick together and form lumps during the subsequent heat sterilization treatment. On the other hand, if the moisture content of the soaking liquid-absorbed noodles is too high, the noodles themselves may become soggy, and the texture may be impaired. It is preferable that the moisture content of the soaking liquid-absorbed noodles is the same as the moisture content (% by mass) of the packaged noodles (noodles after the heat sterilization treatment). The moisture content of the soaking liquid-absorbed noodles can be adjusted by, for example, the soaking time, the temperature of the soaking liquid, the moisture content of the soaking liquid, etc.

[0042] In this soaking treatment step, the soaking treatment involves immersing the gelatinized noodles in a soaking liquid, which causes the soaking liquid to be absorbed through the surface of the gelatinized noodles and allows starch hydrolysates in the soaking liquid to penetrate into the interior of the noodles, allowing the water retention capacity of the interior of the noodles to be maintained in the subsequent heat sterilization treatment step.The solid-liquid separation treatment involves draining the soaking liquid-absorbed noodles that have absorbed the soaking liquid, thereby removing excess water from the surface of the noodles and eliminating as much water as possible that may transfer to the noodles in the subsequent heat sterilization treatment step.

[0043] [Heat Sterilization Step] In the heat sterilization step, the container filled with the soaking liquid-absorbed noodles is subjected to heat sterilization to obtain packaged noodles.

[0044] In the heat sterilization process, the soaking liquid-absorbed noodles are filled into a container, but it is preferable that other ingredients (food ingredients, seasonings, etc.) are not filled, or if they are, they are filled in very small amounts. Other ingredients are those that do not interfere with the taste of the noodles, the seasoning liquid (including sauces, soups, dipping sauces, and other ingredients) or the ingredients that are added when eating, and examples of such ingredients include oils and emulsifiers. The amount of other ingredients blended is, for example, 0.1% to 1.0% by mass of the soaking liquid-absorbed noodles.

[0045] The heat sterilization method can be any heat sterilization method commonly used in food manufacturing. Specifically, the soaking liquid-absorbed noodles are filled into a predetermined container, sealed, and then heat sterilized.

[0046] The heat sterilization conditions can be set appropriately depending on the type of noodles, filling amount, type of container, etc., but for example, when the heat sterilization is retort sterilization, it is carried out under pressure at 100°C to 130°C, preferably about 125°C, for 6 to 15 minutes, preferably 6 to 9 minutes, and the F value, which is an index of sterilization strength, is 4 or more, preferably 5 to 10. Known devices and methods for retort sterilization can be used.

[0047] The container used in the heat sterilization treatment is not particularly limited as long as it is made of a material and has a shape that can withstand the heat sterilization treatment and can be sealed, and examples thereof include packaging containers such as pouches, sachets, bottles, trays, cans, and jars made from metals such as aluminum, plastics such as PET and PTP, single-layer or laminated films, glass, etc. In particular, when a retort container is used, specific examples include containers made of a laminated film having an inner heat-sealable resin layer made of an olefin resin such as polypropylene or polyethylene, and an outer layer made of a resin with high gas barrier properties such as polyester or polyamide and / or aluminum foil.

[0048] The moisture content of packaged noodles is, for example, preferably 45% by mass to 63% by mass, more preferably 48% by mass to 60% by mass, and even more preferably 55% by mass to 58% by mass.

[0049] The method for producing packaged noodles of the present invention does not exclude the incorporation of other steps before or after each of the gelatinized noodle preparation step, the soaking step, and the heat sterilization step, as long as the object of the present invention can be achieved.

[0050] As described above, the method for producing packaged noodles of one embodiment of the present invention produces packaged noodles that maintain a suitable firmness even after long-term storage and are highly versatile. The reason for this effect is not entirely clear, but is thought to be based on the following principle. However, this principle is not intended to unduly limit the technical scope of the present invention. Specifically, by performing an immersion treatment step using an immersion liquid containing a specific DE value and a specific amount of starch hydrolysates, the immersion liquid is absorbed and penetrated into the noodles, resulting in the starch hydrolysates, which have water-retaining capacity, being uniformly dispersed within the noodles. This inhibits the migration of excess water even during the heat sterilization treatment step, and as a result, the noodles are thought to be able to maintain a suitable firmness. Furthermore, the method for producing packaged noodles of one embodiment of the present invention contains almost no seasoning ingredients other than starch hydrolysates, and is therefore essentially unseasoned. Therefore, seasoning liquids (including sauces, soups, dipping sauces, and the like) and ingredients can be freely selected for the noodles, making them highly versatile and able to meet consumer needs.

[0051] Packaged noodles according to one embodiment of the present invention can be stored for long periods at room temperature. In particular, packaged noodles according to one embodiment of the present invention can maintain a suitable firmness even when retort sterilization is used as the heat sterilization treatment, and therefore can be stored for a longer period than packaged noodles that have been subjected to low-temperature sterilization. Furthermore, packaged noodles according to one embodiment of the present invention can be stored for a longer period than packaged noodles described in Patent Document 1, for example, because seasoning ingredients and ingredients other than starch hydrolysates are eliminated as much as possible. The storage period is, for example, 8 months to 6 years. The method of seasoning or cooking using packaged noodles according to one embodiment of the present invention is not particularly limited. For example, packaged noodles can be seasoned or cooked by heating them in a hot water bath or microwave oven and combining them with a pre-prepared seasoning liquid (including sauce, soup, dipping sauce, and the like).

[0052] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples, and the present invention can take various forms as long as the object of the present invention can be achieved.

[0053] 1. Production of packaged noodles (pasta)] 1-1. Preparation of pregelatinized noodles 100 g of dried pasta ("Spaghetti Golden 1.6 mm", manufactured by Hagoromo Foods Co., Ltd., moisture content 11.8% by mass (measured value), noodle thickness 1.6 mm) as non-gelatinized noodles was placed in boiling water and boiled for 5 minutes while loosening, then lightly rinsed with water and drained to obtain 198 g of pregelatinized noodles.

[0054] 1-2. Preparation of Immersion Solution Immersion solutions were prepared by adding dextrins with DE values ​​of 4, 8, 25, and 40 to water to concentrations of 15 mass%, 20 mass%, 25 mass%, 30 mass%, 40 mass%, 50 mass%, and 60 mass%, respectively. The dextrins used are as follows: Dextrin with a DE value of 4: "Pinedices #100", manufactured by Matsutani Chemical Industry Co., Ltd. Dextrin with a DE value of 8: "Pinedices #1", manufactured by Matsutani Chemical Industry Co., Ltd. Dextrin with a DE value of 25: "Pinedices #3", manufactured by Matsutani Chemical Industry Co., Ltd. Dextrin with a DE value of 40: "Pinedices #6", manufactured by Matsutani Chemical Industry Co., Ltd.

[0055] 1-3. Immersion treatment and solid-liquid separation treatment The boiled and drained gelatinized noodles were then immersed in each of the immersion liquids (0°C to 20°C) for 4 hours, and then left to stand in a punching bowl for 10 minutes to drain the liquid (solid-liquid separation treatment), yielding noodles that had absorbed the soaking liquid.

[0056] 1-4. Heat sterilization treatment 100 g of the soaking liquid-absorbed noodles were packed into a retort container ("retort-compatible bag", 130 mm x 170 mm, manufactured by Toppan Printing Co., Ltd.), the opening of the retort container was sealed using a vacuum packaging machine ("Kashiwagi-type vacuum packaging machine", manufactured by NPC Corporation), and the noodles were heat sterilized using a spray-type retort sterilizer (manufactured by Hisaka Works, Ltd.) to produce packaged noodles A. The pressure heat sterilization treatment conditions were a setting of 125°C, a maximum pressure of 0.25 MPa, heating for 6 minutes after the temperature inside the device reached 125°C, and an F value of 6.5.

[0057] [2. Measurement and Evaluation] 2-1. Measurement of Breaking Strength The breaking strength of the samples (unit: N (Newton)) was measured using a rheometer CR-500DX manufactured by Sun Scientific Co., Ltd. (plunger used: No. 10 (for shear force)). Measurements were performed five times and the average value was calculated. Specifically, the packaged noodles A produced in 1 above were stored at room temperature for two weeks, then placed in boiling water for 10 minutes, and the noodles were cut into pieces of approximately 30 mm immediately after opening the container, and measured as a sample. The results are shown in Table 1. As a comparative sample, dried pasta similar to the dried pasta used in 1 above was placed in boiling water and boiled for seven minutes while loosening (normally heated noodles a), which was then drained and cut into pieces of approximately 30 mm, and measured as a comparative sample. The result was 0.335. In Table 1, a breaking strength smaller than "the breaking strength of normally heated noodles - 0.05" was assigned a score of "0," a breaking strength greater than "the breaking strength of normally heated noodles + 0.15" was assigned a score of "1," and a breaking strength between "the breaking strength of normally heated noodles - 0.05" and "the breaking strength of normally heated noodles + 0.15" was assigned a score of "2."

[0058] 2-2. Moisture Value Measurement The moisture value (mass%) of the sample was measured using a heat-dry moisture meter (ML50, manufactured by A&D, settings: Standard MID, set temperature: 200°C). The measurement was performed three times and the average value was calculated. Specifically, the packaged noodles A prepared in 1 above were stored at room temperature for two weeks, and then the noodles were cut into pieces of 10 mm or less immediately after opening the container and 5 g of the noodles were measured as a sample. The results are shown in Table 1.

[0059] 2-3. Measurement of Brix Value The Brix value of the sample at a temperature of 20°C was measured using a handheld refractometer "MASTER-TH50" (manufactured by AS ONE) (measurement range 0 to 50) as a Brix meter. The measurement was carried out three times and the average value was calculated. In the present invention, when the scale of the handheld refractometer could not be visually confirmed due to the condition of the sample, the measurement was carried out using a pocket-sized digital sugar content meter "MASTER-80H" (manufactured by Atago) (measurement range 30 to 80). Specifically, the Brix values ​​of the immersion liquid before and after immersion in the immersion treatment step described above in 1-3 were measured. The results are shown in Table 1.

[0060] 2-4. Sensory Evaluation Packaged noodles A were stored at room temperature for two weeks, then immersed in boiling water for 10 minutes. Immediately after opening the container, the noodles were evaluated by three panelists with discernment abilities according to the following evaluation criteria. The average scores for each item are shown in Table 1. <Browning> 2 points: No browning 1 point: Partial browning 0 point: Browning <Unravelling> 2 points: Unravelling 1 point: Slightly difficult to unravelling 0 point: Not unravelling <Sweetness> 2 points: Not noticeable 1 point: Slightly sweet 0 point: Sweet, with an unpleasant taste The overall score was calculated by adding this to the score for breaking strength measured in 2-1 above. A score of 6 or more out of a maximum of 8 points was considered a pass.

[0061] Table 1 also shows the weights (g) of the non-gelatinized noodles (labeled "before boiling"), the gelatinized noodles (labeled "before soaking"), and the noodles that have absorbed the soaking liquid (labeled "after soaking").

[0062]

[0063] As shown in Table 1, in the examples where noodles were immersed in an immersion liquid containing 20% ​​to 50% by mass of dextrin with a DE value of 4 to 25 (packaged noodles A-1b to A-1f, A-2b to A-2f, A-3b to A-3f), it was found that the noodles had a breaking strength equivalent to that of conventionally heated noodles a, and were free of browning, had good loosening, and were not sweet. On the other hand, in the examples where noodles were immersed in an immersion liquid containing 60% by mass of dextrin with a DE value of 4 to 8 (packaged noodles A-1a and A-2a), the viscosity of the immersion liquid became too high, making it impossible to produce packaged noodles. Furthermore, in the examples where noodles were immersed in an immersion liquid containing 15% by mass of dextrin with a DE value of 8 to 25 (packaged noodles A-2g and A-3g), sufficient breaking strength was not obtained. Furthermore, in the cases where the noodles were immersed in an immersion liquid containing 40% by mass or more of dextrin with a DE value of 40 (packaged noodles A-4a to A-4c), the noodles had a strong sweetness and browning due to the Maillard reaction of the dextrin occurred. In the cases where the noodles were immersed in an immersion liquid containing 15% to 20% by mass of dextrin with a DE value of 40 (packaged noodles A-4f to A-4g), sufficient breaking strength was not obtained. In the cases where the noodles were immersed in an immersion liquid containing 15% to 30% by mass of dextrin with a DE value of 40 (packaged noodles A-4d to A-4g), the noodles did not disintegrate well. This is thought to be because the DE value of the dextrin is too high, which results in a small molecular weight and low viscosity of the dextrin, which allows the dextrin to penetrate the noodles excessively, resulting in the noodles being gelatinized (heat sterilization treatment) without being coated on the surface of the noodles, causing the noodles to stick together when in contact with each other and becoming difficult to separate.

[0064] 3. Production, Measurement, and Evaluation of Packaged Noodles (Chinese Noodles)] 3-1. Preparation of Pregelatinized Noodles As non-gelatinized noodles, 605 g of fresh Chinese noodles ("No. 1584", manufactured by Nishiyama Seimen Co., Ltd., moisture content 32.9% by mass (measured value), noodle thickness 1.4 to 2.5 mm) were placed in boiling water and boiled for 1 minute while loosening, then lightly rinsed with water and drained to obtain 856 g of pregelatinized noodles.

[0065] 3-2. Preparation of Immersion Solution An immersion solution was prepared containing 40% by mass of water, 2% by mass of salt, 10% by mass of brewed vinegar, and 40% by mass of dextrin with a DE value of 8 ("Pinex #1", manufactured by Matsutani Chemical Industry Co., Ltd.).

[0066] 3-3. Soaking treatment and solid-liquid separation treatment The boiled and drained gelatinized noodles were soaked in a soaking liquid (0°C to 20°C) for 3 hours, and then left to stand in a punching bowl for 10 minutes to drain the liquid (solid-liquid separation treatment), yielding 993 g of soaking liquid-absorbed noodles.

[0067] 200 g of the soaking liquid-absorbed noodles were packed into a retort container ("retort-compatible bag", 150 mm x 200 mm, manufactured by Toppan Printing Co., Ltd.), the opening of the retort container was sealed using a vacuum packaging machine ("Kashiwagi-type vacuum packaging machine", manufactured by NPC Corporation), and the noodles were heat-sterilized using a spray-type retort sterilizer (manufactured by Hisaka Works, Ltd.) to produce packaged noodles B. The pressurized heat-sterilization conditions were a setting of 125°C, a maximum pressure of 0.25 MPa, heating for 6 minutes after the temperature inside the device reached 125°C, and an F value of 6.8.

[0068] 3-5. Measurement of Breaking Strength The breaking strength of packaged noodles B was measured using the same method as described in 2-1 above. The results are shown in Table 2. As a comparative sample, fresh Chinese noodles similar to those used in 3-1 above were placed in boiling water, loosened, and boiled for 2 minutes (normally heated noodles b), drained, and cut into pieces of approximately 30 mm, and the breaking strength was measured. The result was 0.459.

[0069] The moisture content of packaged noodles B was measured in the same manner as in 2-2 above. The results are shown in Table 2.

[0070] 3-7. Measurement of Brix Value The Brix values ​​of the immersion liquid before and after immersion in the immersion treatment step 3-3 were measured in the same manner as in the measurement method described in 2-3 above. The results are shown in Table 2.

[0071] Sensory evaluation was carried out on packaged noodles B in the same manner as in 2-4 above. The results are shown in Table 2.

[0072] Table 2 also shows the weights (g) of the non-gelatinized noodles (labeled "before boiling"), the gelatinized noodles (labeled "before soaking"), and the noodles that had absorbed the soaking liquid (labeled "after soaking").

[0073]

[0074] 4. Production, Measurement, and Evaluation of Packaged Noodles (Somen) 4-1. Preparation of Pregelatinized Noodles 254 g of dried somen noodles ("Hand-stretched Somen Ibonoito (High-grade)", Hyogo Prefecture Hand-stretched Somen Cooperative Association, moisture content 13.2% by mass (measured value), noodle thickness 0.7 to 0.9 mm) were used as non-gelatinized noodles, and were placed in boiling water and heated by boiling for 1 minute while loosening the noodles, followed by lightly rinsing with water and draining to obtain 600 g of pregelatinized noodles.

[0075] 4-2. Preparation of Immersion Solution An immersion solution was prepared containing 48% by mass of water, 2% by mass of brewed vinegar, and 50% by mass of dextrin having a DE value of 8 ("Pinexedex #1", manufactured by Matsutani Chemical Industry Co., Ltd.).

[0076] 4-3. Immersion treatment and solid-liquid separation treatment The boiled and drained gelatinized noodles were then immersed in a soaking liquid (0°C to 20°C) for 30 minutes, and then left to stand in a punching bowl for 10 minutes to drain the liquid (solid-liquid separation treatment), yielding 618 g of soaking liquid-absorbed noodles.

[0077] 100 g of the soaking liquid-absorbed noodles were packed into a retort container ("retort-compatible bag", 130 mm x 170 mm, manufactured by Toppan Printing Co., Ltd.), the opening of the retort container was sealed using a vacuum packaging machine ("Kashiwagi-type vacuum packaging machine", manufactured by NPC Corporation), and the noodles were heat-sterilized using a spray-type retort sterilizer (manufactured by Hisaka Works, Ltd.) to produce packaged noodles C. The pressurized heat-sterilization conditions were a setting of 125°C, a maximum pressure of 0.25 MPa, heating for 6 minutes after the temperature inside the device reached 125°C, and an F-value of 6.8.

[0078] 4-5. Breaking Strength Measurement The breaking strength of packaged noodles C was measured in the same manner as in the measurement method described in 2-1 above, except that after storing packaged noodles C at room temperature for two weeks, they were placed in boiling water for 10 minutes, and after opening, the noodles were washed under running water for 30 seconds and drained. The results are shown in Table 3. As a comparative sample, dried somen noodles similar to those used in 4-1 above were placed in boiling water, boiled for 1 minute 30 seconds while loosening, washed under running water for 30 seconds, drained, and cut into pieces of approximately 30 mm (normally heated noodles c), which were then measured. The resulting value was 0.12.

[0079] The moisture content of packaged noodles C was measured in the same manner as in 2-2 above. The results are shown in Table 3.

[0080] 4-7. Measurement of Brix Value The Brix values ​​of the immersion liquid before and after immersion in 4-3. immersion treatment step were measured in the same manner as in 2-3 above. The results are shown in Table 3.

[0081] Sensory evaluation was carried out on packaged noodles C in the same manner as in 2-4 above. The results are shown in Table 3.

[0082] Table 3 also shows the weights (g) of the non-gelatinized noodles (labeled "before boiling"), the gelatinized noodles (labeled "before soaking"), and the noodles that had absorbed the soaking liquid (labeled "after soaking").

[0083]

[0084] 5. Production, Measurement, and Evaluation of Packaged Noodles (Udon) 5-1. Preparation of Pregelatinized Noodles 1,312 g of frozen udon noodles ("Menippon Udon", manufactured by Takara Foods Co., Ltd., moisture content 67.4% by mass (measured value), noodle thickness 3.0 mm (according to specifications), cutting blade count no. 8) was allowed to thaw naturally, yielding 1,312 g of pregelatinized noodles.

[0085] 5-2. Preparation of Immersion Solution An immersion solution was prepared containing 58% by mass of water, 2% by mass of salt, and 40% by mass of dextrin having a DE value of 8 ("Pine Index #1", manufactured by Matsutani Chemical Industry Co., Ltd.).

[0086] 5-3. Soaking treatment and solid-liquid separation treatment The gelatinized noodles were soaked in a soaking liquid (0°C to 20°C) for 2 hours and 30 minutes, and then left to stand for 10 minutes in a punching bowl to drain the liquid (solid-liquid separation treatment), yielding 1,283 g of soaking liquid-absorbed noodles.

[0087] 100 g of the soaking liquid-absorbed noodles were packed into a retort container ("retort-compatible bag", 130 mm x 170 mm, manufactured by Toppan Printing Co., Ltd.), the opening of the retort container was sealed using a vacuum packaging machine ("Kashiwagi-type vacuum packaging machine", manufactured by NPC Corporation), and the noodles were heat-sterilized using a spray-type retort sterilizer (manufactured by Hisaka Works, Ltd.) to produce packaged noodles D. The pressure-heat sterilization conditions were a setting of 125°C, a maximum pressure of 0.25 MPa, heating for 6 minutes after the temperature inside the device reached 125°C, and an F-value of 7.

[0088] 5-5. Measurement of Breaking Strength The breaking strength of packaged noodles D was measured using the same method as described in 2-1 above. The results are shown in Table 4. As a comparative sample, frozen udon noodles similar to those used in 5-1 above were placed in boiling water while still frozen, and boiled for 1 minute while loosening them (normally heated noodles d), then drained and cut into pieces of approximately 30 mm, and the breaking strength was measured. The result was 0.662.

[0089] The moisture content of packaged noodles D was measured in the same manner as in 2-2 above. The results are shown in Table 4.

[0090] 5-7. Measurement of Brix Value The Brix values ​​of the immersion liquid before and after immersion in 5-3. immersion treatment step were measured in the same manner as in 2-3 above. The results are shown in Table 4.

[0091] Sensory evaluation was carried out on packaged noodles D in the same manner as in 2-4 above. The results are shown in Table 4.

[0092] Table 4 also shows the weights (g) of the naturally thawed gelatinized noodles (labeled "after thawing" and "before immersion") and the noodles that had absorbed the soaking liquid (labeled "after immersion").

[0093]

[0094] 6. Production, Measurement, and Evaluation of Packaged Noodles (Pasta)] 6-1. Preparation of Pregelatinized Noodles 174 g of dried pasta ("Penne", manufactured by DiBella, moisture content 12.3% by mass (measured value)) was placed in boiling water and heated by boiling for 5 minutes, then lightly rinsed with water and drained to obtain 288 g of pregelatinized noodles.

[0095] 6-2. Preparation of Immersion Solution An immersion solution was prepared containing 58% by mass of water, 2% by mass of salt, and 40% by mass of dextrin with a DE value of 8 ("Pine Index #1", manufactured by Matsutani Chemical Industry Co., Ltd.).

[0096] 6-3. Soaking treatment and solid-liquid separation treatment The gelatinized noodles were soaked in a soaking liquid (0°C to 20°C) for 17 hours, and then left to stand for 10 minutes in a punching bowl to drain the liquid (solid-liquid separation treatment), yielding 330 g of soaking liquid-absorbed noodles.

[0097] 180 g of the soaking liquid-absorbed noodles were packed into a retort container ("retort-compatible bag", 150 mm x 200 mm, manufactured by Toppan Printing Co., Ltd.), the opening of the retort container was sealed using a vacuum packaging machine ("Kashiwagi-type vacuum packaging machine", manufactured by NPC Corporation), and the noodles were heat-sterilized using a spray-type retort sterilizer (manufactured by Hisaka Works, Ltd.) to produce packaged noodles E. The pressure-heat sterilization conditions were a setting of 125°C, a maximum pressure of 0.25 MPa, heating for 6 minutes after the temperature inside the device reached 125°C, and an F value of 6.5.

[0098] 6-5. Breaking Strength Measurement The breaking strength of packaged noodles E was measured using the same method as described in 2-1 above, except that the noodles were drained and cut into quarters as samples. The results are shown in Table 5. As a comparative sample, dried pasta similar to that used in 6-1 above was placed in boiling water and boiled for 12 minutes (normally heated noodles e), drained, cut into quarters, and then measured. The resulting value was 1.62.

[0099] Measurement of Moisture Value The moisture value of packaged noodles E was measured in the same manner as in 2-2 above. The results are shown in Table 5.

[0100] The Brix values ​​of the immersion liquid before and after immersion in the immersion treatment step 5-3 were measured in the same manner as in the measurement method described in 2-3 above. The results are shown in Table 5.

[0101] Sensory evaluation was carried out for packaged noodles E in the same manner as in 2-4 above. The results are shown in Table 5.

[0102] Table 5 also shows the weights (g) of the non-gelatinized noodles (labeled "before boiling"), the gelatinized noodles (labeled "before soaking"), and the noodles that had absorbed the soaking liquid (labeled "after soaking").

[0103]

[0104] As shown in the results in Tables 2 to 5, in the examples (packaged noodles B to E) in which noodles were immersed in an immersion liquid containing 20% ​​to 50% by mass of dextrin with a DE value of 4 to 25, it was found that, regardless of the type of noodle, the noodles achieved breaking strength equivalent to that of noodles b to e that had been conventionally heated, did not turn brown, disintegrated well, and had no sweetness.

[0105] 7. Production, measurement, and evaluation of comparative packaged noodles (pasta)] 7-1. Preparation of pregelatinized noodles 100 g of dried pasta ("Spaghetti Golden 1.6 mm", manufactured by Hagoromo Foods Co., Ltd., moisture content 11.8% by mass (measured value), noodle thickness 1.6 mm) as non-gelatinized noodles was placed in boiling water and boiled for 7 minutes while loosening, then lightly rinsed with water and drained to obtain 225 g of pregelatinized noodles.

[0106] 7-2. Heat sterilization treatment 100 g of pregelatinized noodles were filled into a retort container ("retort-compatible bag", 130 mm x 170 mm, manufactured by Toppan Printing Co., Ltd.), the opening of the retort container was sealed using a vacuum packaging machine ("Kashiwagi-type vacuum packaging machine", manufactured by NPC Corporation), and the noodles were heat sterilized using a spray-type retort sterilizer (manufactured by Hisaka Works, Ltd.) to produce comparative containerized noodles F. The pressurized heat sterilization treatment conditions were a setting of 125°C, a maximum pressure of 0.25 MPa, heating for 6 minutes after the temperature inside the device reached 125°C, and an F value of 6.5.

[0107] Measurement of breaking strength The breaking strength of comparative packaged noodles F was measured in the same manner as in 2-1 above. The results are shown in Table 6.

[0108] Measurement of Moisture Value The moisture value of the noodles of comparative packaged noodles F was measured in the same manner as in 2-2 above. The results are shown in Table 6.

[0109] Sensory evaluation was carried out on comparative packaged noodles F in the same manner as in 2-4 above. The results are shown in Table 6.

[0110] Table 6 also shows the weights (g) of the non-gelatinized noodles (labeled "before boiling") and the gelatinized noodles (labeled "after boiling").

[0111]

[0112] As shown in the results in Table 6, comparative packaged noodles F, which did not undergo a soaking treatment step, had lower breaking strength than packaged noodles A (packaged noodles A-1b to A-1f, A-2b to A-2f, A-3b to A-3f), which were soaked in a soaking liquid containing 20% ​​to 50% by mass of dextrin with a DE value of 4 to 25. Furthermore, comparative packaged noodles F showed that the noodles stuck together and did not separate well.

[0113] 8. Production, measurement, and evaluation of comparative packaged noodles (udon)] 8-1. Preparation of pregelatinized noodles 522 g of frozen udon noodles ("Menippon Udon", manufactured by Takara Foods Co., Ltd., moisture content 67.4% by mass (measured value), noodle thickness 3.0 mm (according to specifications), cutting blade count 8) was boiled in hot water for 1 minute while still frozen, then lightly rinsed with water and drained to obtain 577 g of pregelatinized noodles.

[0114] 100 g of pregelatinized noodles were filled into a retort container ("retort-compatible bag", 130 mm x 170 mm, manufactured by Toppan Printing Co., Ltd.), the opening of the retort container was sealed using a vacuum packaging machine ("Kashiwagi-type vacuum packaging machine", manufactured by NPC Corporation), and the noodles were heat-sterilized using a spray-type retort sterilizer (manufactured by Hisaka Works, Ltd.) to produce comparative containerized noodles G. The pressurized heat-sterilization conditions were a setting of 125°C, a maximum pressure of 0.25 MPa, heating for 6 minutes after the temperature inside the device reached 125°C, and an F-value of 7.

[0115] Measurement of breaking strength The breaking strength of comparative packaged noodles G was measured in the same manner as in 2-1 above. The results are shown in Table 7.

[0116] The moisture content of the comparative packaged noodles G was measured in the same manner as in 2-2 above. The results are shown in Table 7.

[0117] Sensory evaluation was carried out on the comparative packaged noodles G in the same manner as in 2-4 above. The results are shown in Table 7.

[0118] Table 7 also shows the weights (g) of the non-gelatinized noodles (labeled "before boiling") and the gelatinized noodles (labeled "after boiling").

[0119]

[0120] As shown in the results in Table 7, comparative packaged noodles G, which did not undergo a soaking treatment step, had a lower breaking strength than packaged noodles D, which were soaked in a soaking liquid containing 20% ​​to 50% by mass of dextrin with a DE value of 4 to 25. Furthermore, comparative packaged noodles G showed that the noodles stuck together and did not separate well.

[0121] The packaged noodles of one embodiment of the present invention maintain a suitable hardness even when stored for a long period of time and are highly versatile, thereby adding value as a new processed food.

Claims

1. A method for producing packaged noodles, comprising the steps of: preparing pregelatinized noodles; immersing the pregelatinized noodles in a soaking liquid containing 20% to 50% by mass of a starch hydrolysate having a DE value of 4 to 25, followed by solid-liquid separation to obtain soaking liquid-absorbed noodles; and sterilizing a container filled with the soaking liquid-absorbed noodles to obtain packaged noodles.

2. The method for producing packaged noodles according to claim 1, wherein the moisture content of the packaged noodles is 45% to 63% by mass.

3. The method for producing packaged noodles according to claim 1, wherein the Brix value of the soaking liquid is 20 to 50.

4. The method for producing packaged noodles according to claim 1, wherein the noodles are at least one type selected from the group consisting of Chinese noodles, pasta, udon, and somen.

5. The method for producing packaged noodles according to claim 1, wherein the heat sterilization treatment is a retort sterilization treatment.

6. The method for producing packaged noodles according to claim 1, wherein the soaking liquid further contains at least one component selected from the group consisting of salt and acidulant.

7. The method for producing packaged noodles according to claim 1, wherein the packaged noodles are substantially unseasoned.

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