CN111867386A

CN111867386A - Method for producing snack

Info

Publication number: CN111867386A
Application number: CN201880090241.6A
Authority: CN
Inventors: 渡边勲
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-02-26
Filing date: 2018-02-26
Publication date: 2020-10-30
Also published as: WO2019163148A1

Abstract

The present invention provides a snack that fits the mouthfeel of a consumer group and provides a method of making a snack that is oriented to the health of the consumer without any oil. For this purpose, the raw material is shaped into a desired thickness, a desired size, a desired shape; deactivating enzyme at a predetermined temperature for a predetermined time, gelatinizing the raw material, drying the deactivated raw material to a predetermined water content, heating and pressurizing the dried raw material at a predetermined temperature and pressure to expand the dried raw material, flavoring the expanded raw material with a thickening polysaccharide, and firing the flavored raw material.

Description

Method for producing snack

Technical Field

The present invention relates to a method for manufacturing snacks, and more particularly, to a method for manufacturing snacks that provide snacks that have a taste suitable for consumer groups and are oriented in consumer health.

Background

Conventionally, there have been puffed snacks using vegetables such as potatoes and grains as raw materials. Such snacks are generally produced by, for example, frying potato chips at a high temperature, or frying a processed product, which is formed into a desired shape by incorporating a puffing agent into a raw material, in an oil pan or the like. As noted above, most of the current puffed snacks are typically fried and high calorie foods.

The oil used herein is an edible vegetable oil or fat obtained by heating and refining a raw oil or fat for deodorization, or a hydrogenated oil or fat obtained by adding hydrogen to a vegetable oil or fat, and is excellent in oxidation stability and heat resistance as compared with a low-temperature pressed oil or an unrefined oil, and therefore has been widely used in the catering industry and processed foods as a heating and conditioning oil or fat.

When the edible vegetable oil or fat refined by heating is heated to 150 ℃ or higher in the refining process, unsaturated fatty acid and acrylamide are produced. Therefore, when a food, particularly a food containing a large amount of carbohydrates, such as a potato chip, a fried food, etc., fried with oil having a high temperature of 180 to 200 ℃ is heated with high-temperature oil, trans fatty acids and acrylamide are produced.

The united states Food and Drug Administration (FDA) has issued a guideline aimed at completely abolishing the use of "hydrogenated" foods, which are the main cause of trans-fatty acid production, and increasing the total cholesterol value or the undesirable cholesterol value in blood and the risk of developing coronary artery diseases such as obesity, myocardial infarction, angina pectoris, etc., when trans-fatty acids are ingested in large amounts over a long period of time. Therefore, the use of processed products produced by hydrogenation of vegetable oils and fats such as margarine and shortening is prohibited after 6 months in 2018. In addition, more and more countries must clearly indicate the requirements for foods containing trans fatty acids of a certain level or more.

On the other hand, acrylamide was found to be present in foods in 2002. The swedish government alleges that "in foods obtained by heating food materials containing a large amount of carbohydrates such as potato at a high temperature, acrylamide which may possibly cause genotoxicity or carcinogenicity is produced". Thereafter, various studies and investigations have been conducted, and European Food Safety Agency (EFSA) in the EU governing food safety policy calls consumers for 2005 that "acrylamide may increase the risk of cancer" to be reduced by devising cooking methods. "genetic toxicity" referred to with respect to acrylamide means toxicity to genetic materials (DNA, chromosome), and "genetic toxicity carcinogenic material" means a substance which causes mutation by damage to DNA and which may cause chromosomal abnormality and cause carcinogenesis when accumulated.

In this case, it is sufficient to provide a non-fried snack, but there is a practical problem that the preparation of a non-fried snack is not easy. For example, as shown in patent document 1, a method of producing snacks without frying is proposed. In the method, potato granules are shaped in a granule shaping step; temporarily drying the granules in a granule drying step; adjusting the water content of the particles to 14-23 wt% in the particle water content adjusting step; in the puffing step, the particles are puffed by pressurizing and heating to prepare a semi-finished product; in the flavoring step, flavoring is attached to the surface of the puffed snack by spraying oil; the puffed snack is produced by firing with far infrared rays in the firing step. In addition, in the method, snacks which do not need to be seasoned can be prepared according to materials used as raw materials. According to this method, a puffed snack having a crispy texture and a good texture peculiar to snacks can be obtained without frying.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 2010-187644

Disclosure of Invention

Technical problem to be solved by the invention

However, the method for producing snacks described in patent document 1 has the following problems.

That is, according to conventional snacks, although a crispy texture unique to snacks is created by puffing pellets under pressure and heat in a puffing step, no study is made on how to make such a crispy texture. In other words, no one provides a crisp snack that corresponds to the tastes of different consumer groups. For example, children or the elderly want snacks that do not get stuck in the throat or between teeth and have a certain soft mouthfeel, but young people sometimes think that they have a certain degree of crispness and chewiness before they can eat them. Currently, there is no way to provide such snacks with varying crispy mouthfeel for a set consumer segment.

In addition, the conventional method for producing snacks has the following problems: although not fried, in the seasoning step after puffing the pellets by heating and pressurizing, a slight amount of oil is sprayed, but oil is used in a small amount, and thus it cannot be said as a snack with no oil per se. This does not provide a snack oriented sufficiently to respond to the health of the consumer.

It is therefore an object of the present invention to provide a snack that fits the mouth feel of the consumer population and to provide a method of manufacturing a snack that is oriented to the health of the consumer without any oil.

Means for solving the problems

In order to achieve the above object, the present invention provides a method for manufacturing a snack, characterized by manufacturing a snack through the steps of:

a forming step, forming the raw materials into required thickness, required size and required shape;

a blanching step of blanching the raw material molded in the molding step at a predetermined temperature for a predetermined time to gelatinize the raw material (alpha);

a drying step of drying the raw material that has been water-removed in the water-removing step to a predetermined water content; and

and a puffing step of puffing the raw material dried in the drying step by heating and pressurizing the raw material at a predetermined temperature and a predetermined pressure.

In this case, the fixation time suitable for the gelatinization is in the range of 10 to 15 minutes; characterized in that the water-removing temperature suitable for the gelatinization is in the range of 60-80 ℃.

Further, the method is characterized by comprising a seasoning step of seasoning the puffed raw material without separating oil as a subsequent step of the puffing step. Characterized in that a thickening polysaccharide is used for seasoning in the seasoning step.

Further, the seasoning step is characterized by including, as a subsequent step to the seasoning step, a firing step of firing the seasoned raw material.

ADVANTAGEOUS EFFECTS OF INVENTION

The present invention can provide a snack food which is produced by molding a raw material into a desired thickness, a desired size, and a desired shape, deactivating enzymes at a predetermined temperature for a predetermined time to gelatinize the raw material, drying the deactivated raw material to a predetermined water content, heating and pressurizing the dried raw material at a predetermined temperature and a predetermined pressure to puff the raw material, seasoning the puffed raw material with a thickening polysaccharide, and baking the seasoned raw material, and therefore, the snack food does not contain fats and oils other than those contained in the raw material and is suitable for the taste of consumer groups.

Drawings

FIG. 1 is a flow chart showing the steps of manufacturing a snack according to an embodiment of the present invention.

FIG. 2 is an SEM image showing an example of a comparative example in which puffing was carried out without deactivating enzymes.

FIG. 3 is an SEM image showing an example of the puffing process at a water temperature of 58 ℃ for 8 minutes of deactivation.

FIG. 4 is an SEM image showing an example of the puffing process at a water temperature of 62 ℃ for 8 minutes of deactivation.

FIG. 5 is an SEM image showing an example of the puffing process at a water temperature of 80 ℃ for 8 minutes of deactivation of enzymes.

FIG. 6 is an SEM image showing an example of the puffing process at a water temperature of 80 ℃ for 10 minutes of deactivation of enzymes.

FIG. 7 is an SEM image showing an example of the puffing process at a water temperature of 80 ℃ for 15 minutes of deactivation of enzymes.

FIG. 8 is an SEM image showing an example of the puffing process at a water temperature of 80 ℃ for 20 minutes of deactivation of enzymes.

Detailed Description

Hereinafter, a method for manufacturing a snack, which is an embodiment of the present invention, will be described in detail with reference to the accompanying drawings.

FIG. 1 is a flow chart showing the steps of manufacturing a snack according to an embodiment of the present invention. First, a potato (potato) is used as a raw material, and the potato is peeled and subjected to a preliminary treatment (step S1).

Next, the preliminarily processed potatoes are formed into pellets (step S2). The granules are obtained by cutting potato as a raw material into 10-20 mm square pieces.

Next, the chopped particles are immersed in hot water for deactivation of enzymes (step S3). The purpose of this enzyme deactivation is to prevent browning of the granules (discoloration to brown over time, resulting in poor color), but not only to gelatinize (alphatize) the starch to a predetermined state, thereby giving a crispy texture.

Starches are classified into amylose and amylopectin according to their structure. Amylose is a straight chain molecule with a relatively small molecular weight. Amylopectin is a highly branched molecule with a relatively large molecular weight. Amylose and amylopectin, although different in their properties, coexist in starch.

When the starch is suspended in water and heated, the starch granules absorb water and gradually swell, but when the heating is continued, the starch granules finally disintegrate and become gel-like. This phenomenon is called gelatinization (alphatization). Gelatinization of starch is caused by the diffusion of water molecules into the gaps between starch molecules having a crystalline structure, thereby relaxing the structure and dispersing the branches in water. When the starch suspension is heated, the suspension gradually becomes transparent from a cloudy state, and the viscosity rapidly increases. When the particles absorb water to the maximum, the viscosity becomes maximum, and the viscosity is reduced by disintegration of the particles.

The degree of gelatinization of starch produced by this deactivation of enzymes is closely related to the density and thickness of air bubbles generated inside the puffed snack in the next puffing step, and the density and thickness of the air bubbles give a snack having a crispy texture.

In this embodiment, the deactivation of the enzyme of the granules is preferably carried out as follows: immersing the substrate in hot water at 60-80 deg.C for about 10-20 min. When the enzyme deactivation is carried out in hot water at 60 ℃ or lower for about 10 to 20 minutes, only a part of the starch grains are slightly gelatinized, and bubbles are not uniformly generated due to the swelling, and the thickness of the bubble film is increased. Therefore, the mouthfeel becomes a crispy mouthfeel like that of the scallop, and a crispy mouthfeel unique to snacks cannot be obtained.

On the other hand, when the enzyme deactivation is carried out in hot water of 80 ℃ or higher for about 10 to 20 minutes, starch is sufficiently gelatinized but the film thickness is reduced, and therefore, although bubbles are generated by swelling, the bubble film is broken in some places. That is, since the film of air cells is not uniform and beautiful, the taste and appearance of the snack are deteriorated.

The enzyme-removed pellets are dried by a dryer so that the moisture content of the pellets is 5 to 20%, preferably 10 to 15%, and the pellets are puffed to a desired texture (step S4). In this case, the far infrared ray burning machine can dry in a short time and can dry the pellets uniformly from the center to the end.

Next, the moisture-adjusted pellets are placed side by side on a hot plate of a bulking machine (hot press), heated and pressurized at high temperature and high pressure, and instantaneously brought to normal temperature and normal pressure (step S5).

The heating temperature in this case may be adjusted within a range of 100 to 300 ℃, and is preferably about 180 to 250 ℃. In addition, the pressure of the pressurization can be 700-3000 kg/cm²Preferably 2000 to 3000kg/cm²Left and right. The temperature and pressure of the hot plate are appropriately selected from the above ranges according to the desired texture of the snack.

The granules pressurized at high temperature and high pressure spread into a circular shape and simultaneously the moisture contained in the starch gelatinized inside is instantaneously gasified according to Boyle's-Charles law. At this time, bubbles are generated in the starch film generated in the granules, and immediately brought to normal temperature and normal pressure, whereby the solidification is instantaneously caused, and dense bubbles are uniformly generated in the semi-finished batter. Thereby, a unique crispy mouthfeel is produced.

The puffing machine is not limited to the hot press type, and can continuously puff the pellets at the above temperature and pressure by using a drum type as shown in Japanese patent laid-open No. 2005-27575.

Next, the puffed half-finished product (hereinafter, referred to as snack) is sprayed with diluted thickening polysaccharides without oil to form an adhesive, and is then seasoned by spraying seasonings such as salt, glutamic acid, various seasonings, garlic essence, and beef essence (step S6).

Examples of the thickening polysaccharides include guar gum, xanthan gum, tamarind gum (tamarind seed gum), carrageenan, agar, pectin, tamarind gum (tamarind gum), gum arabic, pullulan gum (pullulan), soybean polysaccharide, and locust bean gum. These thickening polysaccharides have characteristics such as water solubility, edibility, film-forming property, adhesiveness, and the like, and due to the above characteristics, the seasoning can be retained on the surface of the puffed snack without using oil. Therefore, a snack completely free of oil can be produced.

The seasoned snacks are cooled at normal temperature temporarily until the baking process is performed, whereby the seasoning sprayed on the surface of each snack can be permeated. However, if the snack does not require seasoning, the seasoning step may be omitted.

The snack thus obtained is subjected to a baking treatment with far infrared rays (step S7). In the firing treatment, excess moisture remaining in the green sheet is dried and fired to have a moisture content of 3% or less. The snack is uniformly baked from the surface to the inside by the electromagnetic wave of the far infrared ray, thereby making it possible to manufacture a snack having more crispy texture, deliciousness, and aroma. The firing treatment is preferably carried out by far infrared ray, but may be carried out by other firing methods without particular limitation.

For the snacks manufactured as above, each 1 packaging bag is metered by the metering step through the sorting step (sorting step) of uniformizing the difference in shape or color. The snacks measured here are packed in a thick carton after being sealed in a packaging bag and distributed to the market.

[ examples ]

Hereinafter, the embodiment of the present invention will be specifically described in the case of using potato as a raw material. Here, semi-finished potato chips were prepared from granules prepared under different conditions of deactivation of enzymes, and the effect of gelatinization was verified by comparing the respective sections.

First, potatoes are peeled, and the peeled potatoes are cut into dice and granulated. The granules were subjected to deactivation of enzymes at a prescribed temperature for a prescribed time. FIGS. 3 to 5 are SEM images of the temperature variation with constant time to test the optimal temperature condition for enzyme deactivation; fig. 6 to 8 are SEM images of time-varying conditions for testing the optimum time conditions for deactivation with temperature being constant.

Fig. 2 is an SEM image showing an example of a comparative example in which puffing was performed without deactivating enzymes. In each of the SEM images of fig. 2 to 8, the left-hand image is an SEM image obtained by enlarging the cross section of the blanched and gelatinized pellet by 40 times, the upper right-hand image is an SEM image obtained by enlarging the cross section after puffing by 40 times, and the lower right-hand image is an SEM image obtained by enlarging the cross section after puffing by 100 times.

As shown in fig. 2, it is known that when the swelling process is performed without deactivating enzymes, the starch particles are distributed in the cells while maintaining a spherical shape (so-called β -starch state), and bubbles generated by swelling partially appear near the surface.

FIG. 3 shows an example of the puffing process when the water temperature is set at 58 ℃ for 8 minutes.

As shown in the figure, when the enzyme deactivation was carried out at a water temperature of 58 ℃, some starch particles were slightly gelatinized, but the expanded bubbles were not uniform and the bubble film was thick. Therefore, the mouthfeel becomes a thin and crisp mouthfeel like the scallop.

FIG. 4 shows an example of the puffing process when the water temperature is set at 62 ℃ and the enzyme deactivation is carried out for 8 minutes.

As shown in the figure, when the water temperature is 62 ℃ for water-removing, the gelatinization proceeds smoothly, most of the gelatinization occurs, and expanded bubbles are generated inside. In terms of mouthfeel, a crispy mouthfeel characteristic of snacks is obtained.

FIG. 5 shows an example of the puffing process when the water temperature is set at 80 ℃ and the enzyme deactivation is carried out for 8 minutes.

As shown in the figure, when the water temperature was set to 80 ℃ and the enzyme was deactivated, the whole surface was gelatinized. The expanded bubbles are generated entirely inside the film, and the film thickness is thin. In terms of texture, a clear, soft and crispy texture was obtained, but the bubble film was broken in some places, which affected the appearance.

FIG. 6 shows an example of the puffing process when the water temperature is set at 80 ℃ and the enzyme deactivation is carried out for 10 minutes.

As shown in the figure, when the water temperature was set to 80 ℃ and the enzyme deactivation was carried out for 10 minutes, the whole surface was gelatinized, and the expanded bubbles were generated in the whole surface, and the thickness was large.

FIG. 7 shows an example of the puffing process in which water is heated to 80 ℃ for 15 minutes.

As shown in the figure, when the water temperature was set to 80 ℃ and the enzyme deactivation was carried out for 15 minutes, the whole surface was gelatinized, and the expanded bubbles were generated in the whole surface of the inside, and the film thickness was thin.

FIG. 8 shows an example of the puffing process in which the water temperature is set at 80 ℃ and the enzyme deactivation is carried out for 20 minutes.

As shown in the figure, when the water temperature was set to 80 ℃ and the enzyme deactivation was carried out for 20 minutes, the entire surface was gelatinized and the expanded bubbles were generated on the entire inner surface, but the film thickness was too thin, and therefore, the bubble film was broken and voids were generated.

From the above, it was concluded that in the case of slicing potatoes into granules, de-enzyming is best carried out at a water temperature in the range of 60 ℃ to 80 ℃ and for a time in the range of 10 minutes to 15 minutes.

< summary of the present embodiment >

As described above, gelatinization of raw materials is essential for the puffing process, and a pretreatment called enzyme deactivation needs to be performed at an appropriate temperature for an appropriate time in order to generate air bubbles in the batter mix.

The starch gelatinization state of the raw material granules has a close relationship with the density and thickness of the air bubbles generated inside the snack manufactured by puffing. Therefore, by changing the combination of the gelatinization conditions and the puffing conditions, a snack which is puffed beautifully and has a crispy texture suitable for consumers of each group can be produced.

In addition, by using a diluted thickening polysaccharide as a binder in the seasoning step, the seasoning can be retained on the surface of the puffed snack without using oil. Thus, a snack free of any fat can be provided that is oriented in the health of the consumer.

In the present invention, although potatoes are used as a raw material, the raw material is not necessarily limited to potatoes, and may be other potatoes, potatoes such as sweet potatoes and the like. In addition, the food can be made from various food materials such as grains, vegetables, fruits, fish, shellfish, and meat, without being limited to potato and taro.

Instead of making granules from solid raw materials such as potatoes, granules may be made from powdery raw materials (potato granule slices, potato flakes, mashed potatoes, rice flour, wheat flour, soybean flour, etc.) as the main components. In the case of the main raw material monomer, the amount of starch required for proper expansion is added to the main raw material for steaming. In addition, when other auxiliary materials (powdery or pasty vegetables and fruits) are added to the powdery main material alone or a mixture of plural kinds of materials and steamed, various kinds of raw material pellets can be produced.

By adding the auxiliary material, gelatinization of starch necessary for producing good bubbles and chain-linking of the material can be optimized, whereby a crispy texture can be produced. By cooking, gelatinization of the starch is caused under the action of appropriate moisture and heat. In addition, gluten is produced in the case of wheat flour.

When granules are produced from powdery raw materials or the like, instead of the process shown in fig. 1, a primary process is performed by kneading a single main raw material, a mixture of a plurality of main raw materials, or one or both of them with other auxiliary raw materials in step S1, and the raw material subjected to the primary process is formed (rolled) into a sheet having a desired thickness by a roll press or the like in step S2, and then subjected to a mold release process or a cutting process to have a desired size and a desired shape, and formed into granules. For processing the raw material into pellets, a kneading extruder or the like may be used. The processing after step S3 is the same as the case of the processing of potatoes.

The important point is the gelatinization of the starch granules contained in the raw material, and suitable moisture and heating are necessary to cause gelatinization. The moisture enclosed in the gelatinized starch and gluten is instantaneously gasified and expanded at high temperature and high pressure to cause puffing. The moisture content of the raw material is an important factor in causing puffing with good taste.

Further, the shape of the pellets is not necessarily dice depending on the characteristics and the matching of the raw materials, and snack foods having the same texture can be produced by making the shape and the size suitable for the mechanism of the puffing machine.

Claims

1. A method of manufacturing a snack, characterized in that a snack is manufactured by the steps of:

a water-removing step of removing water from the raw material molded in the molding step at a predetermined temperature for a predetermined time to gelatinize the raw material;

a drying step of drying the raw material that has been water-removed in the water-removing step to a predetermined moisture content; and

2. The snack manufacturing method according to claim 1,

the water-removing time suitable for gelatinization is within the range of 10-15 minutes.

3. The method of manufacturing a snack according to claim 1 or 2,

the water-removing temperature suitable for gelatinization is in the range of 60-80 ℃.

4. A method of manufacturing a snack according to any of claims 1 to 3,

as a later step of the puffing step, a seasoning step of seasoning the puffed raw material in a moisture-free manner is included.

5. The snack manufacturing method according to claim 4,

in the seasoning step, a thickening polysaccharide is used for seasoning.

6. The method of manufacturing a snack according to any of claims 1 to 5,

the latter step of the seasoning step includes a firing step of firing the seasoned raw material.