Dried fish substitute

Abstract

The present invention addresses the problem of providing a dried fish substitute which is produced using a vegetable protein as a main raw material. The present invention also addresses the problem of providing a dried fish substitute which has an appearance characteristic of dried fish when made into dried fish flakes. The present invention also addresses the problem of providing a dried fish substitute which has a texture characteristic of dried fish when made into dried fish flakes.　The present invention provides a method for producing a vegetable protein-containing dried fish substitute, the method comprising: a step for obtaining a water-containing shaped product which contains a vegetable protein in an amount of 10 mass% or more and has a water content of 40-80 mass% with respect to 100 mass% of the water-containing shaped product, and has a dense structure; and a step for obtaining a dried solid material by drying the water-containing shaped product.

Description

Fish fish substitute

[0001] RELATED APPLICATIONS This application claims the benefit of priority from Application No. 2024-056785, filed with the Japan Patent Office on March 29, 2024. The priority application is hereby incorporated by reference in its entirety.

[0002] The present invention relates to a fish substitute made from vegetable protein and a method for producing the same.

[0003] Demand for alternatives to animal products is increasing due to changes in the external environment, such as shortages of animal resources and animal welfare. In particular, fish are facing problems not only with environmental changes, but also with the depletion of natural resources due to overfishing, and even in aquaculture, changes in ecosystems and environmental pollution. For this reason, fish are thought to be one of the products with particularly high demand for alternatives.

[0004] Against this background, fish meat substitutes have been investigated, and tuna substitutes using granular soy protein, etc., and fillet substitutes using mannan, etc. have been brought to market. However, no substitutes for dried fish that undergo special processing have yet been brought to market, and knowledge about them is still limited.

[0005] As a substitute for dried fish using plant-based ingredients, a dried fish shavings-like topping is disclosed in Patent Document 1. Patent Document 1 describes that a dried fish shavings-like food product is obtained by heating and gelatinizing a mixture containing grain flour and / or starch, seasoning ingredients, and water, drying the gelatinized mixture, and then shaving it.

[0006] Japanese Patent Application Laid-Open No. 2019-22474

[0007] The technology of Patent Document 1 mainly uses starches as raw materials, and compared to those made from fish such as bonito flakes, the texture in the shaved form is unnatural. Furthermore, from a nutritional standpoint, the shaved form is poor in protein, making it considered insufficient as a substitute for dried fish. An object of the present invention is to provide a dried fish substitute made primarily from vegetable protein. Another object of the present invention is to provide a dried fish substitute that, when made into shaved bonito, has the appearance characteristic of dried fish. Yet another object of the present invention is to provide a dried fish substitute that, when made into shaved bonito, has the texture characteristic of dried fish.

[0008] As a result of extensive research into the above-mentioned problems, the inventors discovered that a substitute for dried fish can be obtained by drying a hydrous shaped product composed of vegetable protein in a hydrated state with a tightly packed structure that is not swollen, and thus completed the present invention.

[0009] That is, the present invention provides: (1) a method for producing a vegetable protein-containing dried fish substitute, comprising: (a) a step of obtaining a hydrous shaped product, the hydrous shaped product being taken as 100% by mass, and containing 10% by mass or more of vegetable protein, having a moisture content of 40 to 80% by mass, and having a tightly packed structure; and (b) a step of drying the hydrous shaped product to obtain a dry solid; (2) the production method according to (1) above, in which the drying step of step (b) is carried out until the moisture content in the dry solid is 30% by mass or less; (3) (c) the production method according to (1) above, further comprising a step of adding a material that imparts a flavor or taste similar to dried fish to the hydrous shaped product or the dry solid; (4) (c) the production method according to (2) above, further comprising a step of adding a material that imparts a flavor or taste similar to dried fish to the hydrous shaped product or the dry solid; (5) (d) the production method according to (1) above, further comprising a step of slicing the dry solid into thin flakes; (6) The manufacturing method according to (2) above, further comprising the step of (d) slicing the dried solid into thin flakes; (7) The manufacturing method according to (3) above, further comprising the step of (d) slicing the dried solid into thin flakes; (8) The manufacturing method according to (4) above, further comprising the step of (d) slicing the dried solid into thin flakes; (9) A vegetable protein-containing dried fish substitute, characterized in that: (A) the shaped product forming the vegetable protein-containing dried fish substitute contains 15% by mass or more of vegetable protein in terms of solid content; (B) the shaped product has a tight structure; (C) the moisture content in the vegetable protein-containing dried fish substitute is 30% by mass or less; and (D) a dried fish-like taste or flavor is imparted to the vegetable protein-containing dried fish substitute; (10) (E) The vegetable protein-containing fish substitute according to (9), wherein the vegetable protein-containing fish substitute is thinly sliced ​​or crushed.

[0010] According to the present invention, a fish substitute made primarily from vegetable protein can be obtained. Furthermore, according to the present invention, a fish substitute that has the characteristic appearance of fish when made into shavings can be obtained. Furthermore, according to the present invention, a fish substitute that has the characteristic texture of fish when made into shavings can be obtained.

[0011] Fig. 1 is a diagram showing the hydrous shaped product produced in Production Example 1. Fig. 2 is a diagram showing the dried fish substitute produced in Production Example 2. Fig. 3 is a diagram showing the dried fish shavings substitute produced in Production Example 3. Fig. 4 is a diagram showing each dried fish shavings substitute produced in Production Example 4. Fig. 5 is a diagram showing the state of the dried fish substitute produced from each expanded granular soy protein product produced in Production Example 5 before and after cutting. All of them are powdered, and their uses as dried fish shavings substitutes are limited.

[0012] In one aspect, the present invention provides a method for producing a vegetable protein-containing fish substitute, comprising the steps of obtaining a densely structured hydrous shaped product using vegetable protein as a main ingredient, and drying the hydrous shaped product to obtain a dry solid product.

[0013] The vegetable protein used as the raw material for the hydrous shaped product of this embodiment is not particularly limited, and examples thereof include proteins derived from beans such as soybeans, peas, mung beans, lupine beans, chickpeas, kidney beans, lentil beans, and cowpeas; seeds such as sesame seeds, canola seeds, coconut seeds, and almond seeds; grains such as corn, buckwheat, wheat, and rice; vegetables; and fruits. These vegetable proteins may be used alone or in combination of two or more. In a more specific embodiment, the vegetable protein is a protein derived from beans or grains. In an even more specific embodiment, the vegetable protein is a protein derived from soybeans or wheat. As an example, soybean-derived proteins are prepared by further concentrating and processing soybean raw materials such as defatted soybeans and whole soybeans, and generally include isolated soybean proteins, concentrated soybean proteins, powdered soy milk, and various processed versions thereof.

[0014] The hydrous shaped product of this embodiment contains 10% by mass or more of vegetable protein, for example, 10 to 60% by mass, 12 to 50% by mass, 15 to 40% by mass, 17 to 35% by mass, 22 to 30% by mass, or 24 to 28% by mass, based on 100% by mass of the hydrous shaped product. In one embodiment, the hydrous shaped product contains 15% by mass or more of vegetable protein, for example, 20 to 100% by mass, for example, 30 to 100% by mass, 35 to 95% by mass, 40 to 95% by mass, 50 to 95% by mass, 60 to 95% by mass, 70 to 95% by mass, 75 to 90% by mass, 80 to 90% by mass, or 84 to 88% by mass, calculated on a solid content basis. The protein content can be measured by the official Kjeldahl method.

[0015] The hydrous shaped product of this embodiment contains 40 to 80% by mass, for example, 50 to 80% by mass, 55 to 80% by mass, 60 to 75% by mass, 65 to 75% by mass, or 68 to 72% by mass, when the hydrous shaped product is taken as 100% by mass.

[0016] As used herein, "having a dense structure" refers to a structure that is not porous, such as puffed tissue. More specifically, it refers to a structure in which solid content such as protein is present without gaps. Specific examples of tissues having a dense structure include animal tissues such as raw meat and raw fish. As used herein, puffed tissue refers to a porous structure, and specific examples include puffed confectionery and sponge-like structures.

[0017] In this embodiment, the hydrous shaped product having a tight structure and made primarily from vegetable protein can be obtained by heating a dough obtained by mixing protein with water and then cooling the resulting solid. Examples of heating temperatures include 70°C to 200°C, such as 100°C to 180°C, 120°C to 160°C, 70°C to 99°C, and 75°C to 95°C. Examples of cooling temperatures include -20°C to 60°C, such as -10°C to 50°C, 0°C to 40°C, and 10°C to 30°C. More specifically, the hydrous shaped product can be obtained by processing a raw material containing protein and water using an extruder equipped with a cooling die at the outlet, which is a type of extrusion molding machine. Alternatively, the hydrous shaped product can be produced using an extrusion molding machine such as a PH-100 Power Heater (Source Technology). Alternatively, the hydrous shaped product can be obtained by filling a raw material containing vegetable protein into a casing tube, followed by heating and cooling. More specifically, the textured protein material described in WO 2022 / 114013 may be used as the hydrous shaped product. In one embodiment, the hydrous shaped product is a hydrous textured product. The hydrous textured product can be obtained, for example, by the above-mentioned extrusion molding machine.

[0018] The obtained hydrous shaped product is dried to form a dry solid. The drying method is not particularly limited, and examples include ventilation drying, hot air drying, sun drying, vacuum drying, freeze drying, smoking, and roasting. In some embodiments, the smoking method is also not particularly limited, and any known method can be used as appropriate. Examples of such methods include a generator method in which smoke generated by a smoke generator is introduced into a smoking chamber to perform the smoking treatment, and a direct flame method. The drying temperature can be, for example, 40°C to 100°C, e.g., 60°C to 90°C. The drying time can be, for example, 1 hour to 2 weeks, e.g., 12 hours to 1 week, 24 hours to 5 days, or 2 days to 3 days. Drying can be performed alone, multiple times, or in combination with multiple methods, or multiple types can be performed simultaneously. Different drying methods can also be performed multiple times.

[0019] In a preferred embodiment, drying is carried out by roasting. A roasting method commonly used in the production of katsuobushi can be used. For example, the hand-made volcano roasting method, the cooked barn roasting method, the Yaizu roasting method, etc. can be used alone or in combination. The roasting conditions can be adjusted appropriately by those skilled in the art. A specific example includes arranging the wet molded products in a steamer, performing primary roasting in a Yaizu dryer for 12 to 24 hours, and then transferring them to a cooked barn and roasting for 3 to 5 days while checking the degree of dryness.

[0020] In some embodiments, the moisture content of the dried solid after drying is 30% by weight or less, 25% by weight or less, for example, 3 to 30% by weight, 5 to 25% by weight, 10 to 25% by weight, 15 to 25% by weight, etc.

[0021] In some embodiments, the dried solid product after drying can be used as a dried fish substitute as is, or in other embodiments, the tarry substance adhering to the surface of the dried solid product after drying can be scraped off with a grinder or the like and used as a dried fish substitute.

[0022] In one embodiment, the above-mentioned dried fish substitute may be molded. The mold-making method may be a method commonly used in the production of dried bonito. Specifically, for example, the method described in JP 2022-160846 A may be used.

[0023] In one embodiment, the method of this aspect further comprises a step of adding a seasoning ingredient to the hydrous shaped product or the dried solid. The seasoning ingredient is not particularly limited as long as it is a material that can impart a flavor to the dried fish substitute, and examples thereof include salt, sugars, seasonings such as soy sauce, miso, and vinegar, spices, vegetables, fruits, meat, seafood, milk, coffee, cocoa, and tea. Extracts are also possible, and materials in powder, liquid, puree, and other forms can be used. In a more specific embodiment, the seasoning ingredient imparts a dried fish-like flavor or taste. Examples of dried fish include dried bonito, dried mackerel, dried tuna, and dried round sardines. Typically, the seasoning ingredient imparts a dried bonito-like flavor or taste.

[0024] In some embodiments, the method of this aspect may or may not include a step of adding other ingredients to the wet shaped product or dry solid product to the extent that the addition does not impair its functionality. Examples of other ingredients include acidulants, sweeteners, spices, coloring agents, flavorings, salts, sugars, antioxidants, vitamins, stabilizers, thickeners, carriers, excipients, lubricants, surfactants, propellants, preservatives, chelating agents, pH adjusters, etc.

[0025] The timing of adding the seasoning material or other raw materials is not particularly limited, and may be at any stage, such as the stage of mixing the raw materials, the stage after heating and before cooling, the stage after cooling and before drying, during the drying process, or the stage after drying. The method of addition is also not particularly limited, and examples include adding the seasoning material or other raw materials directly during mixing, preparing a solution and spraying it, or preparing a solution and injecting it.

[0026] In some embodiments, the method of this aspect further comprises a step of slicing the dried fish substitute obtained above into thin flakes. The equipment used for slicing is not limited, and for example, a shaving machine typically used in producing dried bonito flakes can be used. In some embodiments, the thickness of the flakes is 10 μm to 2 mm, for example, 20 μm to 1 mm, 30 μm to 500 μm, 40 μm to 200 μm, 50 μm to 100 μm, etc. In some embodiments, the width of the flakes is 3 mm or more, for example, 3 mm to 5 cm, 5 mm to 3 cm, 1 cm to 2 cm, etc. In some embodiments, the method of this aspect further comprises a step of powdering the dried fish substitute obtained above.

[0027] In one embodiment, the obtained fish substitute may be eaten as a food product as is, or may be added to various foods.

[0028] In one aspect, the present invention provides a vegetable protein-containing fish substitute. Typically, the vegetable protein-containing fish substitute of this aspect can be produced by the manufacturing method of the above aspect. Therefore, all of the items specified in the manufacturing method aspect above can be applied to this aspect.

[0029] In one embodiment, the shaped product forming the fish substitute of this embodiment contains 15% or more, for example, 20 to 100% by mass, for example, 30 to 100% by mass, 35 to 95% by mass, 40 to 95% by mass, 50 to 95% by mass, 60 to 95% by mass, 70 to 95% by mass, 75 to 90% by mass, 80 to 90% by mass, or 84 to 88% by mass of vegetable protein in terms of solid content based on 100% of the shaped product.

[0030] In some embodiments, the extrusions forming the fish flake substitute of this embodiment have a tightly textured structure.

[0031] In one embodiment, the moisture content in the dried fish substitute of this embodiment is 30% by mass or less, 25% by mass or less, for example, 3 to 30% by mass, 5 to 25% by mass, 10 to 25% by mass, 15 to 25% by mass, etc.

[0032] In one embodiment, the fish substitute of this embodiment is imparted with a fish-dried taste or flavor. Examples of fish include dried bonito, mackerel, tuna, and round urume. Typically, the food of this embodiment is imparted with a bonito-like flavor or flavor. In another embodiment, the fish substitute of this embodiment may be flavored with salt, sugar, seasonings such as soy sauce, miso, and vinegar, spices, vegetables, fruits, meat, seafood, milk, coffee, cocoa, tea, and the like.

[0033] In one embodiment, the fish flakes substitute of this aspect is a fish shavings substitute. The fish shavings substitute of this embodiment is in the form of flakes or powder. Specific examples of the thickness and width of the flakes are as described above.

[0034] The fish shavings substitute of this embodiment has a texture equivalent to that of commercially available fish shavings such as bonito flakes when eaten. Furthermore, when used as a topping for foods such as okonomiyaki, it can exhibit a so-called "dancing" movement, similar to that of commercially available fish shavings.

[0035] The dried fish substitute of this embodiment can be sprinkled directly on foods such as rice, noodles, salads, tofu, meat, simmered dishes, grilled fish, takoyaki, and okonomiyaki, or can be used as an ingredient in processed rice products such as rice balls.It can also be used by being incorporated into toppings for the above-mentioned foods.

[0036] Hereinafter, the embodiments of the present invention will be described in more detail with reference to examples, etc. Unless otherwise specified, "%" and the like in the examples are based on mass.

[0037] Production Example 1: Production of hydrous shaped product The raw materials were mixed according to the formulation in Table 1 below, and a hydrous shaped product, a textured product, was prepared using an extruder (KEI-45-25, manufactured by Kowa Kogyo Co., Ltd.). The extruder was operated at a rotation speed of 200 rpm and a dough temperature of approximately 140°C. After extrusion, the dough was cooled and solidified using a cooling die. The obtained hydrous shaped product is shown in Figure 1. The obtained hydrous shaped product had a moisture content of 69.5% (30.5% solids), protein of 26.2% (86.0% of solids), lipids of 1.0% (3.3% of solids), carbohydrates of 2.4% (7.9% of solids), and ash of 0.9% (2.8% of solids). The obtained hydrous shaped product was stored frozen.

[0038] 1: (Protein content 86.0%, moisture 5.0%) 2: (Protein content 78.9%, moisture 4.8%)

[0039] Production Example 2: Production of dried fish substitute After thawing, the hydrous molded products obtained above were placed in a bamboo steamer and subjected to primary roasting for 12 hours at a temperature of 80-100°C in a Yaizu-type dryer. The primary roasted molded products were then transferred to a cooking barn and subjected to secondary roasting for approximately 4 days at a temperature of 70-90°C, adjusting the time as needed while checking the degree of dryness. The moisture content of the final product was adjusted to approximately 20-30%, yielding a dried solid as a dried fish substitute. The dried solid is shown in Figure 2.

[0040] Production Example 3: Production of a substitute for shaved dried fish flakes The dried solid obtained above was cut to obtain a substitute for shaved dried fish flakes 1. The substitute for shaved dried fish flakes 1 is shown in Figure 3.

[0041] Evaluation of the dried bonito flakes substitute The dried bonito flakes substitute 1 obtained above was compared with commercially available dried bonito flakes to confirm differences in texture, shape, and overall evaluation. Five panelists well trained in sensory evaluation were asked to evaluate the product and provide scores by consensus. The scores are as follows: Texture was evaluated based on mouthfeel and chewing sensation, and shape was evaluated based on whether it could be cut into large chunks like "flowers." All commercially available dried bonito flakes were given a score of 5. 1: The texture and shape are significantly different from those of dried bonito flakes. 2: The texture and shape are different from those of dried bonito flakes. 3: The texture and shape are slightly different from those of dried bonito flakes. 4: The texture and shape are not significantly different from those of dried bonito flakes. 5: The texture and shape are the same as those of dried bonito flakes. The results are shown in Table 2.

[0042]

[0043] As described above, a substitute for dried bonito flakes comparable to commercially available dried bonito flakes was obtained.

[0044] Production Example 4: Study using soy protein gel According to the formulation shown in Table 3, the raw materials were mixed in a Robocup (FMI) to prepare a kneaded dough, which was then vacuum degassed in a vacuum packaging machine (WEBOMATIC). The dough was then placed in a casing and heated at 80°C for 45 minutes in a water bath (THOMAS), and then frozen. The resulting hydrous molded product was roasted, dried, and cut in the same manner as in Production Examples 2 and 3 to obtain dried fish flakes substitutes 2 to 6. Dried fish flakes substitutes 2 to 6 are shown in Figure 4.

[0045] 1: Fujipro FM, Fuji Oil Co., Ltd. (protein content 86.0%, moisture 5.0%) 2: Fujipro AL, Fuji Oil Co., Ltd. (protein content 86.3%, moisture 5.5%) 3: A-Glu WP, Glyco Nutrition Foods Co., Ltd. (protein content 78.9%, moisture 4.8%) 4: RK08, Glyco Nutrition Foods Co., Ltd. 5: Cornstarch Y, Sanwa Shoji Co., Ltd. 6: Palm Ace, Fuji Oil Co., Ltd. 7: Super 04, Fuji Foods Industry Co., Ltd.

[0046] The resulting dried fish flakes substitutes 2 to 6 were evaluated in the same manner as in the evaluation of the above-mentioned dried fish flakes substitutes. The results are shown in Table 4.

[0047]

[0048] Dried fish shavings substitutes 2 and 3 were unsuitable, with a hard, crunchy texture. Furthermore, the shape was also unsuitable, as they did not form a "flower" shape but were rather curly. Dried fish shavings substitutes 4 to 6 melted easily in the mouth, and although there was a slight difference compared to conventional dried bonito flakes, which remain in the mouth, they were still within the range of usability as dried fish shavings substitutes. Of these, dried fish shavings substitute 6 had the closest mouthfeel to dried bonito flakes. Furthermore, the shape tended to be slightly smaller, but was within the acceptable range. This indicates that preferable results can be obtained with a hydrated molded product with a moisture content of 80% or less. However, all of dried fish shavings substitutes 2 to 6 were inferior to the textured dried fish shavings substitute 1, and it was found that preferable results can be obtained by texturing the protein.

[0049] Production Example 5: Study using expanded granular soy protein products "Apex 950," "Apex 1300," and "Apex 2000SP" (all manufactured by Fuji Oil Co., Ltd.) were each supplied with water, and then subjected to primary roasting in a Yaizu-type dryer in the same manner as in Production Examples 2 and 3, followed by secondary roasting in a cooking barn. The moisture content of the final product was adjusted to approximately 10%, and then the product was cut. The obtained dried fish substitutes are shown in Figure 5. When all of the dried fish substitutes were cut, they became powdery, and their uses as a substitute for dried fish flakes were limited.

[0050] According to the present invention, a substitute for dried fish made mainly from vegetable protein can be obtained. The present invention can be used in the food industry, etc.

Claims

1. A method for producing a vegetable protein-containing fish substitute, comprising: (a) obtaining a hydrous shaped product that contains 10% by mass or more of vegetable protein, has a moisture content of 40 to 80% by mass, and has a tightly packed structure, when the hydrous shaped product is taken as 100% by mass; and (b) drying the hydrous shaped product to obtain a dry solid.

2. The method according to claim 1, wherein the drying step (b) is carried out until the moisture content of the dried solid is 30% by weight or less.

3. The method according to claim 1, further comprising the step of (c) adding a material that imparts a fish-dried-like flavor to the hydrous shaped product or the dry solid product.

4. The method according to claim 2, further comprising the step of (c) adding a material that imparts a fish-dried-like flavor to the hydrous shaped product or the dry solid product.

5. The method of claim 1, further comprising the step of: (d) slicing the dried solid into thin slices.

6. The method of claim 2, further comprising the step of: (d) slicing the dried solid into thin slices.

7. The method of claim 3, further comprising the step of: (d) slicing the dried solid into thin slices.

8. The method of claim 4, further comprising the step of: (d) slicing the dried solid into thin slices.

9. A vegetable protein-containing, dried fish substitute characterized in that: (A) the shaped product forming the vegetable protein-containing, dried fish substitute contains 15% or more by mass of vegetable protein in terms of solid content; (B) the shaped product has a tightly packed structure; (C) the moisture content in the vegetable protein-containing, dried fish substitute is 30% or less by mass; and (D) the vegetable protein-containing, dried fish substitute is imparted with a taste or flavor similar to dried fish.

10. (E) The vegetable protein-containing fish substitute according to claim 9, wherein the vegetable protein-containing fish substitute is thinly sliced ​​or crushed.

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