Food processing method and food processing device

Abstract

[Problem] To focus on effective practical use of a food material that is ordinarily discarded, and achieve suitable processing of the waste food material even when a large quantity thereof is produced. [Solution] Proposed is a food processing method comprising: a stirring step in which edible organic fibers that have been crushed into a powder and an alkaline solution are stirred; and a mixing step in which a refined flour and a stirred substance, which is a substance that was generated via the stirring step, are mixed in a condition in which the temperature of the stirred substance and the temperature of the refined flour are close to each other.

Description

Food processing method and food processing apparatus

[0001] The present invention relates to a method for processing food in a manner conducive to mass production and an apparatus used for such a processing method.

[0002] In the process of food processing, there are cases where processing is carried out after removing a part of the raw ingredients from the perspective of improving texture. Specifically, by removing organic fibers from the raw materials, a texture such as the dull texture or crispy texture unique to fibers is reduced.

[0003] Such organic fibers removed in the process of food ingredient processing, although originally edible, were often discarded without being used as food ingredients in many cases. Okara removed in the process of food ingredient processing using soybeans as raw materials is widely known as an example of such organic fibers.

[0004] Processing these food ingredients into new foods while reducing the demerits such as the avoidable texture etc. without discarding them can lead to effective utilization of the food ingredients and also lead to a suitable donor of the nutrients contained in the food ingredients, thus bringing great utility to general consumers.

[0005] From the above perspectives, quite a few technologies have been disclosed so far, and the practical application of processed food ingredients has been attempted. Specifically, Patent Document 1 discloses a technology related to a food processing method including kneading okara with food polysaccharides such as jelly-like tochocolten and konnyaku and then heating and coagulating, and Patent Document 2 discloses a technology related to a food processing method in which those raw materials are mixed into a paste, molded, and then heat-treated by being put into salt water.

[0006] JP-A-2007-312680 JP-A-2018-130102

[0007] However, the technology described in Patent Document 1 is unclear as to the specific process by which processed foods can be mass-produced, and the technology described in Patent Document 2 raises doubts as to whether the heat treatment method of immersion in high-temperature saline solution can uniformly sterilize the processed ingredients. As mentioned above, since the present invention focuses on effectively utilizing ingredients that would otherwise be discarded, it is desirable to process even large quantities of discarded ingredients in a suitable manner, and ingenuity in such processing processes is required with mass production in mind.

[0008] To solve the above problems, the present invention proposes a food processing method comprising: a stirring step of stirring granularly ground edible organic fiber and an alkaline solution; and a mixing step of mixing the stirred substance, which is the substance produced through the stirring step, and refined flour while the temperatures of the stirred substance and the refined flour are close.

[0009] Furthermore, in connection with the above invention, we also propose a food processing method characterized in that, in the stirring step, the temperature of the stirred substance is maintained at 20 to 50 degrees Celsius throughout the processing.

[0010] Furthermore, in relation to the above inventions, we also propose a food processing method characterized by continuously spraying an alkaline solution onto a predetermined amount of organic fiber while stirring during the stirring step.

[0011] Furthermore, in relation to the above inventions, we also propose a method for processing food ingredients characterized in that, in the mixing step, the mixing is performed while the temperature difference between the temperature of the stirred substance and the temperature of the refined flour is 45 degrees or less.

[0012] Furthermore, in relation to the above inventions, we also propose a food processing method characterized in that the refined flour used in the mixing step is pre-mixed with water and in a sol-like state.

[0013] Furthermore, in connection with the above invention, we also propose a food processing method characterized in that, in the mixing step, the temperature of the sol-like refined powder is maintained at 5 to 25 degrees Celsius throughout the processing.

[0014] Furthermore, all or part of the processes of the above-described processing method can be implemented by one or more devices, and if implemented by multiple devices, the present invention can also be realized by configuring these multiple devices as a series of systems.

[0015] Specifically, we propose a food processing apparatus comprising: a stirring section that stirs granularly ground edible organic fibers and an alkaline solution by injecting the alkaline solution into the organic fibers in unit quantities while stirring the alkaline solution itself; and a mixing section that mixes the stirred substance, which is the substance produced in the first stirring section, with refined flour while keeping the temperatures of the stirred substance and the refined flour close together.

[0016] Furthermore, in connection with the above invention, we also propose a food processing apparatus characterized in that the stirring section stirs the organic fibers while stirring them with an alkaline solution.

[0017] With the features described above, the present invention makes it possible to achieve mass production while ensuring homogeneity in food processing processes using ingredients that were previously discarded.

[0018] The embodiments of the present invention will now be described. First, edible organic fiber ground into granules and an alkaline solution are prepared. In the above description, okara (soy pulp) was used as an example of organic fiber, but it is not limited to this, and other materials such as cabbage cores, pumpkin seeds, sesame seeds, and grains can also be used. In addition, any edible organic fiber that has a certain degree of firmness as a food ingredient, is insoluble or sparingly soluble, and generally has the crumbly or dry texture described above as a problem can be used.

[0019] Furthermore, the organic fibers must be pre-ground into a powder. This is to facilitate efficient stirring with the alkaline solution described later and subsequent mixing with the refined flour. While it is desirable to grind them as finely as possible, it is not necessarily required to be in a specific granular shape. In this embodiment, we will describe the case where okara (soy pulp) is used as the organic fiber and is ground into a powder before use. Again, okara is merely one example of an organic fiber, and the process described below is equally applicable to other edible organic fibers.

[0020] Alkaline solutions can be aqueous solutions using, for example, calcium hydroxide, calcium carbonate, calcium bicarbonate, calcium oxide, magnesium oxide, magnesium carbonate, sodium hydroxide, sodium carbonate, or sodium bicarbonate. In addition, various substances can be used as solutes, as long as they are not alkaline substances that are harmful to the human body if ingested. In this embodiment, the explanation will be based on the premise of an aqueous solution using calcium hydroxide.

[0021] As an example of a method for producing an alkaline solution using calcium hydroxide as the solute, first, a predetermined amount of water is placed in a container, then lime is added and stirred for a predetermined time, and then the mixture is circulated. By circulating the mixture after it has been stirred to produce an alkaline solution, the alkalinity can be kept uniform, and consequently, the burden of the mixing process in the post-settlement mixing process described later can be reduced.

[0022] Incidentally, the hydrogen ion concentration (pH) of the alkaline solution produced at this time should preferably be in the range of 10.75 to 12. If the concentration is higher than this, the strong alkalinity will cause the okara to decompose over time during the stirring or mixing process, making it difficult to ensure homogeneity as a processed food. In any case, by stirring the okara with an alkaline solution of the above concentration and then mixing it with refined flour, it becomes possible to process food with a good texture.

[0023] Furthermore, the temperature of the alkaline solution should preferably be lukewarm, at least 45 to 65 degrees Celsius, when it is mixed and stirred with the okara during the stirring process. Maintaining a consistent temperature level allows for efficient stirring with the okara.

[0024] The stirring of the okara and the alkaline solution can be carried out by any method that is optimal in achieving homogeneous alkalization of the stirred substances, but one example is to continuously spray the alkaline solution onto a predetermined amount of okara. In this embodiment, if the calcium hydroxide aqueous solution is mixed irregularly with the powdered okara, the okara may clump together in some areas, resulting in inefficient stirring and potentially reducing the yield of the processed food. In this regard, for example, by going through a process in which a certain amount of alkaline solution is continuously sprayed from the top of a container in which the powdered okara is stored, it becomes easier to evenly mix the alkaline solution with the okara.

[0025] Another possible method involves adding an alkaline solution to powdered okara while applying pressure. Adopting this configuration can accelerate the alkalization of the agitated substance, thereby reducing labor and improving the efficiency of agitated substance production.

[0026] Furthermore, it is also conceivable to carry out a process in which the alkaline solution is continuously ejected in the manner described above while the container is vibrated during the stirring process. By vibrating the container, the powdered okara stored inside is also vibrated, and the ejected alkaline solution is evenly mixed into it, making it easier to avoid the problem of clumps forming in the stirred substance as described above.

[0027] Incidentally, it is desirable that the temperature of the stirred substance generated from the powdered okara and alkaline solution during the stirring process be maintained at 20 to 50 degrees Celsius throughout the stirring process. By controlling the temperature of the stirred substance throughout the stirring process, the mixing process with refined flour in the subsequent standing and mixing process can be carried out smoothly.

[0028] Furthermore, it is desirable to maintain the hydrogen ion concentration of the stirred substance at a pH of approximately 10 to 12, and more preferably at a pH of approximately 11. By maintaining this concentration and mixing it with refined flour as described later, the resulting processed food will be able to maintain a rich elasticity due to the structure of the glucomannan made from the refined flour.

[0029] In this embodiment, it is desirable to mix the stirred material produced through the above stirring process with the refined flour at temperatures as close as possible to the temperature of the refined flour. Mixing at similar temperatures stabilizes the state of the mixture (hydrogen ion concentration, shape, etc.) between the okara and the alkaline solution that constitute the mixed material, which can contribute to mass production. For example, when mixing refined flour kept at room temperature with the stirred material, it is conceivable to control the temperature of the mixed material so that it is also at room temperature before mixing it with the refined flour in the mixing process. If the refined flour has been stored refrigerated or heated, it is conceivable to control the temperature to a state close to the temperature of the refined flour, depending on the storage method, before mixing it with the refined flour in the mixing process.

[0030] Various methods can be considered for controlling the temperature of the stirred material. One approach is to measure the temperature of the milled flour in parallel with the stirring process and perform heating or cooling treatment to control the temperature of the stirred material to approximate the temperature of the milled flour. Another approach is to allow the stirred material to stand for a predetermined time after the stirring process to bring its temperature closer to room temperature.

[0031] However, even when using a configuration that allows the agitated material to stand, it is advisable to avoid leaving it standing for excessively long periods. Even at room temperature, if left standing for more than 10 minutes, for example, the water contained in the agitated material will evaporate and hardening will begin, which will prolong the subsequent mixing process with the refined flour and may cause lumps to form in the processed food.

[0032] Furthermore, in order to efficiently achieve the mixing process between the stirring substance and the refined flour, it is desirable to have a configuration in which the mixing takes place when the temperature difference between the temperature of the stirring substance and the temperature of the refined flour is 45 degrees Celsius or less, and more preferably when it is kept to around 35 degrees Celsius or less. Since the stirring substance is likely to be at a higher temperature than the refined flour due to its production process, if the temperature difference is at least 45 degrees Celsius or less, the hydrogen ion concentration will not change erratically during the mixing process, and homogenization of the processed food will be easily achieved.

[0033] Incidentally, the refined flour used in the mixing process contains mannan, a water-soluble polysaccharide derived from konjac root, and it is desirable that it be pre-mixed with water to form a sol (paste-like) consistency before being mixed with the stirring material. By making the refined flour a sol, it becomes easier to mix with the stirring material, making it possible to mix a large amount of the mixing material in a short time.

[0034] One possible process for turning the above-mentioned refined powder into a sol is to store water in a container and then add the refined powder to the container while circulating the water either throughout the container or only within the container, and to agitate it for a predetermined time. When the agitated refined powder is left to stand for a predetermined time, the water-containing refined powder swells and becomes a sol.

[0035] At this time, it is desirable that the water used for swelling be at a temperature of around 12 degrees Celsius, and that the temperature of the sol-like refined flour be maintained at 5 to 25 degrees Celsius throughout the process under this water temperature. By maintaining and adjusting the temperature of the refined flour to a certain extent, swelling can be delayed, and gelation (hardening) of the refined flour or the mixture of refined flour and the agitated substance can be suppressed due to the mixing process continuing for a predetermined time, thereby facilitating the subsequent molding process of processed foods and ultimately enabling more efficient mass production.

[0036] The present invention will be described in more detail below with reference to examples. These examples are not intended to limit the scope of the present invention in any way.

[0037] First, we will describe a configuration in which the temperature of the stirred substance, generated from powdered okara and an alkaline solution through the stirring process, is controlled to maintain a temperature of 20 to 50 degrees Celsius throughout the stirring process. In all of the Examples 1 described below, the okara, alkaline solution, and refined flour are of the same mass, and apart from the differences in conditions described in each example, the ambient temperature, humidity, and other external environmental factors are the same.

[0038] (Example 1-1) First, the applicant stirred powdered okara and an alkaline solution for several minutes, controlling the temperature so that the temperature of the stirred substance remained at 20 degrees Celsius. In this case, the stirred substance did not have any particular texture issues, and no lumps formed in the processed food obtained by mixing the stirred substance with refined flour.

[0039] (Examples 1-2) Next, the applicant controlled the temperature to maintain the temperature of the stirred substance at 50 degrees Celsius. This was achieved by heating the okara (soy pulp) and performing the stirring process with a higher water temperature in the alkaline solution compared to the case of Example 1, thereby controlling the temperature to maintain the above temperature (similar control was performed for Examples 3 and 4). In this case as well, there was no particular difference in texture or other characteristics of the stirred substance, and no lumps formed in the processed food obtained by mixing the stirred substance with the refined flour.

[0040] (Examples 1-3) Furthermore, the applicant controlled the temperature to maintain the temperature of the stirred substance at 10 degrees Celsius. In this case, clumps formed in some of the stirred substance, or dryness was observed on the surface. When this was mixed with refined flour, clumps formed in the processed food ingredients, resulting in a certain quantity of defective products that were difficult to commercialize.

[0041] (Example 1-4) Finally, the applicant controlled the temperature of the stirred material to maintain a temperature of 60 degrees Celsius. In this case, the stirred material had a generally viscous texture, and variations in moisture content were observed in different parts. When this stirred material was mixed with refined flour, partial browning occurred in the processed food product, resulting in defective products that were difficult to commercialize.

[0042] Next, a configuration in which mixing is performed in a state where the temperature difference between the temperature of the stirring substance and the temperature of the refined flour is within 45 degrees will be described. In both Example 2 and Example 3 described below, the stirring substance formed by stirring okara and an alkaline solution and the refined flour have the same mass. The refined flour is made to contain moisture and swell into a sol state. Except for the differences in the conditions described in each example, the atmospheric temperature, humidity, and other external environments are the same.

[0043] (Example 2-1) First, the applicant adjusted the temperature of the stirring substance to 60 degrees and the temperature of the refined flour to 5 degrees, that is, adjusted the temperature difference between the two to 55 degrees, and then performed a mixing process. As a result, due to the occurrence of temperature unevenness in the sol, unevenness occurred in the curing rate of the sol. Even after mixing and kneading, the processed food had variations in elasticity and texture, and an inhomogeneous state occurred such as partial browning.

[0044] (Example 2-2) Next, the applicant adjusted the temperature of the stirring substance to 50 degrees and the temperature of the refined flour to 5 degrees, that is, adjusted the temperature difference between the two to 45 degrees, and then performed a mixing process. As a result, the inconveniences in the mixing process as described in Example 2-1 did not occur, and a homogeneous processed food could be produced in terms of color, elasticity, and texture.

[0045] (Example 2-3) As a precaution, while keeping the temperature of the stirring substance at 50 degrees, the temperature of the refined flour was adjusted to 25 degrees so that the temperature difference between the two was 25 degrees, and then the same mixing process was performed. As a result, compared with the case of Example 2-2, it became less likely to form lumps, and favorable results were obtained.

[0046] Furthermore, a configuration in which the temperature of the sol-like refined flour is maintained at 5 degrees to 25 degrees throughout the process will be described.

[0047] (Example 3-1) First, the applicant performed a mixing process for a predetermined time while controlling the temperature so that the temperature of the sol-like refined flour was maintained at about 2 degrees throughout the process. In such a low-temperature case, since the refined flour and moisture were not well stirred, even though it was in a sol state, it was not possible to expect a function that could be suitably mixed with the stirring substance, and the binding with the organic fiber was partially poor. Therefore, a non-uniform processed food with brittle parts was produced.

[0048] (Example 3-2) Next, the applicant carried out a mixing process for a predetermined time while controlling the temperature so that the temperature of the sol-like refined powder was maintained at about 5 degrees throughout the process. As a result, the elasticity problem as described in Example 3-1 was considerably resolved, and no problems such as the occurrence of lumps through the mixing process occurred.

[0049] (Example 3-3) Further, the applicant increased the temperature of the moisture added to the refined powder and carried out a mixing process for a predetermined time while controlling the temperature so that the temperature of the sol-like refined powder was maintained at about 25 degrees throughout the process. As a result, the refined powder and the stirring substance were suitably bound, and sufficient elasticity as a processed food material could be maintained.

[0050] (Example 3-4) Finally, the applicant further increased the temperature of the moisture and carried out a mixing process for a predetermined time while controlling the temperature so that the temperature of the sol-like refined powder was maintained at about 30 degrees throughout the process. Then, the refined powder no longer had the suitable viscosity as before and became in a state that could even be said to be slightly hard. When mixing with the stirring substance under such a viscosity, uneven kneading occurred, and quality defects such as partial cracks and cavities occurred during molding as a processed food material.

Claims

1. A food processing method comprising: a stirring step of stirring granularly ground edible organic fiber and an alkaline solution; and a mixing step of mixing the stirred substance, which is the substance produced through the stirring step, and refined flour while the temperatures of the stirred substance and the refined flour are close to each other.

2. The food processing method according to claim 1, characterized in that the stirring step maintains the temperature of the stirred substance at 20 to 50 degrees Celsius throughout the processing.

3. The food processing method according to claim 1, characterized in that the stirring step involves stirring while continuously spraying an alkaline solution onto a predetermined amount of organic fiber.

4. The method for processing food ingredients according to claim 1, characterized in that the mixing step is performed while the temperature difference between the temperature of the agitated substance and the temperature of the refined flour is 45 degrees or less.

5. The food processing method according to claim 1, characterized in that the refined flour used in the mixing step is pre-mixed with water and in a sol-like state.

6. The food processing method according to claim 5, characterized in that the mixing step maintains the temperature of the sol-like refined powder at 5 to 25 degrees Celsius throughout the processing.

7. A food processing apparatus comprising: a stirring unit that stirs granularly ground edible organic fibers and an alkaline solution by injecting the alkaline solution into the organic fibers in unit quantities while stirring the alkaline solution itself; and a mixing unit that mixes the stirred substance, which is the substance produced in the stirring unit, with refined flour while keeping the temperatures of the stirred substance and the refined flour close together.

8. The food processing apparatus according to claim 7, characterized in that the stirring section stirs the organic fibers while stirring them with an alkaline solution.