JP3768460B2 - Purine manufacturing method and manufacturing apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
TECHNICAL FIELD The present invention relates to a method and apparatus for producing pudding in a container, and more specifically, generation of voids by gas-liquid separation by hygienically irradiating ultrasonic waves to a purine base solution prepared by mixing pudding raw materials. It is related with the manufacturing method and manufacturing apparatus of a pudding which can improve a product yield.
[0002]
[Prior art]
A method for producing a pudding is known in the past by filling a container with a thermocoagulable pudding base solution prepared by mixing pudding raw materials and heating the pudding base solution by heating means such as an oven. For example, refer to Japanese Patent No. 2604481 and Japanese Patent Laid-Open No. 6-276977).
When manufacturing pudding in a container on an industrial scale, it is necessary to manufacture it sufficiently hygienically in order to maintain a quality that can be stored for a long period of time. Further, in order to increase the product yield, it is necessary to reduce the occurrence of “poor” that impairs the appearance of the product. The voids generated in the pudding are easily removed when air or other gas mixed in the pudding base liquid before heating is separated when the base liquid filled in the container is heated and remains as bubbles or cavities in the solidified pudding. In many cases, puddings with visible voids are poor in appearance and are not considered as products. If there are many voids, the product yield decreases. In order to prevent the generation of voids, it is effective to perform gas-liquid separation (degassing) before heating the purine base solution. Further, the gas-liquid separation of the purine base liquid also removes oxygen that causes quality degradation.
[0003]
One method for degassing the liquid to be treated includes a method using a vacuum degassing apparatus. However, the vacuum degassing apparatus is expensive and has a drawback that it requires a large degassing tank and a lot of auxiliary equipment, so that it is large and requires a large installation space. Therefore, there has been a demand for a device that is inexpensive and can perform gas-liquid separation efficiently.
[0004]
Other methods for degassing the liquid to be treated are described, for example, in JP-A-1-132369, JP-A-7-8170, JP-A-11-505175, and JP-A-2001-104942. As described above, a method of gas-liquid separation by irradiating a liquid to be treated with ultrasonic waves has been proposed.
A. Japanese Patent Laid-Open No. 1-132369 discloses a first step of separating a sparkling beverage through a filter by gas-liquid separation, and then placing the liquid in a tank provided with an ultrasonic oscillator and applying ultrasonic waves to the gas-liquid. A degassing method for sparkling beverages comprising a second step of separation is disclosed.
B. Japanese Patent Application Laid-Open No. 7-8170 discloses a method of removing chocolate bubbles by applying ultrasonic waves to accelerate gas-liquid separation before putting a fluid chocolate in a mold and solidifying it.
C. Japanese Patent Laid-Open No. 11-505175 discloses an apparatus for removing bubbles by flowing a liquid to be processed through an ultrasonic wave propagation tube.
D. Japanese Patent Application Laid-Open No. 2001-104942 discloses a deaeration device provided with an ultrasonic treatment chamber that performs ultrasonic irradiation that is weak enough not to cause cavitation in raw water using an ultrasonic vibrator.
[0005]
[Problems to be solved by the invention]
However, among the above-described conventional techniques using ultrasonic waves, the techniques described in the A, C, and D publications are hygienic because the liquid to be processed and the ultrasonic oscillator are directly brought into contact with each other to irradiate ultrasonic waves. The above management is difficult, and it is unsuitable for gas-liquid separation of a liquid to be treated such as a purine base liquid, which preferably eliminates the possibility that microorganisms or the like are mixed in the liquid to be treated as much as possible.
Further, the technique described in B irradiates the liquid to be processed (fluid chocolate) through the mold material, and in the pudding manufacturing method, irradiates the ultrasonic wave to the container filled with the purine base liquid. Therefore, ultrasonic irradiation can be performed hygienically. However, when filling the purine base liquid into the container, it is necessary to provide a caramel syrup layer under the purine base liquid, and when the container is irradiated with ultrasonic waves in a state where the caramel syrup and the purine base liquid are filled, There is a problem that caramel syrup is mixed into the purine base solution.
[0006]
SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances. A purine manufacturing method and a manufacturing apparatus capable of producing a high-quality purine with a high yield by reducing the generation of voids by sanitary gas-liquid separation of the purine base liquid. For the purpose of provision.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, the present invention prepares a pudding base liquid by mixing pudding raw materials, fills the container with the pudding base liquid, and then heats the pudding base liquid in the container to produce pudding. In the method, the purine base liquid is continuously flowed into the pipe line, and the liquid is separated from the pipe wall by irradiating ultrasonic waves from the outside of the pipe line, and after the separated bubbles are removed from the purine base liquid, the container is filled. A method for producing pudding is provided.
In the present invention, the gas-liquid separation may be performed by immersing the pipe in a hot water bath and irradiating the pipe with ultrasonic waves while keeping the purine base liquid in the pipe warm.
The present invention also includes a purine base liquid preparation unit for preparing a purine base liquid by mixing purine raw materials, a conduit for continuously feeding the purine base liquid prepared by the purine base liquid preparation unit, In an apparatus for producing pudding, comprising: a filling device provided at the end of a pipeline for filling a container with a pudding base solution; and an oven for firing the pudding by heating the container filled with the filling device.
A hot water bath for immersing at least a part of the pipe in hot water, an ultrasonic element for irradiating ultrasonic waves to the pipe immersed in the hot water bath, and a purine base solution provided in a pipe downstream of the hot water tank And a holding tank for temporarily holding the pudding.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
The purine raw material used in the method of the present invention may be the same as a conventionally known purine raw material composition such as custard pudding. If an example of a preferable composition of custard pudding is shown, it will be about 18-26 mass% of whole eggs, 60-72 mass% of milk, and sugar 8-16 mass%.
In the present invention, a pudding base solution is prepared by mixing pudding raw materials, the pudding base solution is filled in a container, and then the pudding base solution in the container is heated to produce pudding in the container. In the present invention, a gas-liquid separation device capable of irradiating ultrasonic waves to the liquid in the pipe in a non-contact manner through the pipe wall is used to perform gas-liquid separation of the prepared purine base liquid and then fill the container. It is said.
[0009]
FIG. 1 is a schematic configuration diagram showing an example of a pudding manufacturing apparatus according to the present invention. This pudding manufacturing apparatus includes a pudding base liquid preparation unit 1-8 for mixing pudding raw materials to prepare a pudding base liquid (a portion between the raw material agitation mixer indicated by reference numeral 1 in FIG. 1 and the cooling storage tank 8); , A gas-liquid separation device 16 for performing a gas-liquid separation process on the purine base liquid prepared by the preparation unit and heated via the heater 13, the gas-liquid separation device, and a holding tank for removing the separated bubbles 25, a degassing device 30 composed of 25, a filling device 23 for filling the container with the pudding base liquid after degassing, and an oven 28 for heating are configured as main components.
[0010]
The pudding base liquid preparation units 1 to 8 are charged with pudding raw materials such as weighed whole egg, milk, and sugar and mixed with the raw material stirring mixer 1 for stirring and mixing these raw materials. For example, a stirrer 2 that heats and stirs the purified pudding raw material to about 50 to 65 ° C., a homogenizer 7 that homogenizes the purine raw material heated and stirred by the stirrer / mixer 2 to obtain a purine base liquid, A purine base liquid homogenized by the homogenizer 7 is provided with a cooling storage tank 8 that cools the purine base liquid to, for example, 10 ° C. or less, preferably about 5 ° C. The stirring heater 2 includes a stirring blade 3 for stirring the mixed solution in the stirring tank, a heating medium jacket provided surrounding the stirring tank and having a heating medium inlet 4 and a heating medium outlet 5 such as hot water. 6. The cooling storage tank 8 includes a stirring blade 9 provided in the tank, and a refrigerant jacket 12 provided around the tank and having a refrigerant inlet 10 and a refrigerant outlet 11 such as water. Yes. The homogenizer 7 can be a conventionally known homogenizer (homogenizer) in the food manufacturing field or the pharmaceutical / cosmetics manufacturing field. For example, the pudding raw material is passed through the gap of the homogenizer valve at a high pressure (about 10 MPa) and homogenized. A homogenizer of the type to be used is preferably used.
[0011]
The prepared purine base solution is stored in the cooling storage tank 8, taken out from the tank as necessary, sent to the heater 13, and heated to, for example, 50 to 65 ° C, preferably 50 to 60 ° C, The gas-liquid separator 16 is supplied. The heating machine 13 may be a plate heat exchanger or the like that is conventionally known in the food manufacturing field. A heating medium such as hot water is passed from the heating medium inlet 14 to the heating medium outlet 15, and the pudding base liquid is passed through the heat exchanging section. It is structured to heat.
[0012]
The purine base liquid heated by the heater 13 is sent to the pipe line 18 of the gas-liquid separator 16 through the pipe line 21. In this case, a buffer tank (not shown) can be provided in the pipe line 21 to achieve stable operation of the process.
FIG. 2 is a diagram showing an example of a gas-liquid separator suitable for carrying out the method of the present invention. The gas-liquid separator 16 has a pipe 18 having one end connected to the pipe 21 on the heater 13 side and the other end connected to a pipe 22 extending to the holding tank 25 of the filling device 23. Is provided with a hot water bath 17 in which water is immersed, an ultrasonic element 19 provided in the hot water bath 17, and an oscillator 20 connected to the ultrasonic element 19 and provided outside the hot water bath 17.
[0013]
The pipe line 18 of the gas-liquid separation device 16 can continuously supply a required amount of purine base liquid to the filling device 23 side, and can irradiate with sufficient ultrasonic waves for gas-liquid separation during the supply. It is designed to have such a tube inner diameter and tube length. For example, when the flow rate of the purine base liquid is 1000 to 2000 L / hour, the pipe inner diameter of the pipe 18 may be about 40 to 55 mm, and the pipe length (submerged portion) may be about 4 to 7 m. It is desirable that the pipe line 18 be formed of stainless steel having heat resistance and chemical resistance capable of steam sterilization or chemical cleaning inside the pipe line. The ultrasonic irradiation time (holding time in the pipe line) for the purine base liquid for gas-liquid separation is preferably about 20 to 40 seconds.
[0014]
The ultrasonic element 19 and the oscillator 20 are not particularly limited as long as they can irradiate the purine base liquid flowing in the pipe line 18 with ultrasonic waves to promote gas-liquid separation. A known device can be used as a washing machine. The resonance frequency used is preferably about 20 to 40 MHz. Examples of commercially available products suitable for such an ultrasonic element 19 and an oscillator include various products of the product name “Phoenix” series manufactured by Kaijo Corporation.
[0015]
The hot water tank 17 contains a sufficient amount of hot water so that most of the pipe line 18 and the ultrasonic element 19 are submerged. The depth of the hot water bath 17 is set so that the ultrasonic wave oscillated from the ultrasonic element 19 can be efficiently propagated to the pipe line 18. The ultrasonic cleaning efficiency is optimum when the distance between the oscillation source and the object to be processed is about 15 cm, and when the ultrasonic element 19 is arranged at the bottom of the hot water bath 17, the liquid depth of the hot water bath 17 is preferably about 20 to 30 cm. . The hot water bath 17 may be provided with temperature adjusting means for keeping the hot water temperature at a predetermined temperature, for example, about 60 ° C.
[0016]
In this example, the ultrasonic element 19 is immersed in the hot water bath 17 to irradiate the pipe 18 with ultrasonic waves. However, the ultrasonic device 19 may be disposed on the bottom side of the hot water bath 17. A plurality of ultrasonic elements 17 may be immersed in the hot water bath 17 or arranged on the back side of the hot water bath 17.
[0017]
The gas-liquid separation device 16 irradiates the purine base liquid continuously flowing in the pipe line 18 with ultrasonic waves emitted from the ultrasonic element 19 from outside the pipe line 18 through hot water and the pipe line 18 wall. Since the gas contained in the purine base liquid is separated from the liquid component, the purine base liquid can be gas-liquid separated hygienically. Thus, by continuously irradiating the purine base solution with ultrasonic waves in a non-contact manner, it is possible to continuously produce a pudding having a good texture and texture, little generation of voids, and a good appearance. Is possible.
[0018]
The purine base liquid subjected to the gas-liquid separation process in the gas-liquid separator 16 is then sent to the holding tank 25 of the filling device 23. The gas-liquid separator 16 and the holding tank 25 constitute a deaerator 30. The purine base liquid in the holding tank 25 is sent to the filling device 23 where the container is metered and filled. The filling device 23 is disposed on the upstream side of the transporting unit 27 in the transporting direction, and includes a transporting unit 27 having a conveyor that transports the containers in one direction in a state in which the containers are arranged vertically and horizontally, and the containers are supplied side by side on the conveyor. A container supply device 24, a fixed amount supply device 29 that is arranged downstream of the conveying direction and supplies a fixed amount of the deaerated purine base liquid sent from the holding tank 25 to the container, and the conveying direction of the fixed amount supply device 29 And a caramel tank 26 for storing caramel syrup disposed on the downstream side or the upstream side (downstream side in the illustration of FIG. 1).
In this example, using the fact that the specific gravity of caramel syrup is heavier than that of the purine base liquid, after filling the container with the purine base liquid, the caramel syrup is filled and settled at the bottom of the container. Prior to filling, the caramel syrup can be filled into a container, and the purine base solution can be filled thereon.
[0019]
The container used in the method of the present invention is not particularly limited as long as it does not have any problems in food hygiene and does not cause thermal deformation during heating in the next oven heating step, and is not limited to a synthetic resin container or a metal such as aluminum. A container etc. can be used, Preferably a synthetic resin container (cup) like a polypropylene resin is used.
[0020]
The purine base liquid supplied to the holding tank 25 is accompanied by the separated bubbles, and the accompanying bubbles are separated from the purine base liquid and float in the holding tank 25. At the time when the pudding base liquid is sent from below the holding tank 25 to the metering feeder 29, the bubbles are substantially removed.
[0021]
The container filled with the pudding base liquid and caramel syrup is transported to the inlet of the oven 28 by the transport means 27 and heated. The oven 28 only needs to be able to appropriately heat and solidify the pudding base solution, and various commercially available ovens and their partially improved products that are conventionally known in the field of food production can be used. Examples of commercially available ovens include trade name MC-LKGE3-230W manufactured by Kudensha Co., Ltd.
[0022]
In the present invention, in order to heat-treat the purine base liquid filled in the container, as described in, for example, Japanese Patent Application Laid-Open No. 2000-236831, after filling the container with the purine base liquid (purine raw material), Suspend on the inner frame provided with a container suspension hole in advance, fit the inner frame with the container suspended on a top plate pre-watered, and fit the lower side of the inner frame in a humid heat atmosphere, In the pudding manufacturing method in which the upper side is heated in a dry heat atmosphere from the lower side and the pudding raw material is heated and solidified, the inner frame and the top plate are fitted to each other with a predetermined gap formed therebetween, The pudding may be manufactured by heating while removing steam from the lower side to the upper side of the middle frame. By heating the container filled with the pudding base liquid using such a top plate with an inner frame, melting and deformation of the synthetic resin container can be prevented, and the processing cost of the inner frame can be reduced. , Investment costs can be reduced.
[0023]
The pudding heated and solidified in the oven 28 is cooled and sent to a sealing machine (not shown), and a suitable sealing film such as an aluminum-synthetic resin laminate film is thermocompression-sealed to the upper opening of the container and hermetically sealed. Furthermore, it is transported to a process necessary for commercialization and commercialized.
[0024]
In the present embodiment, a pipe line 18 through which the prepared purine base solution flows, a hot water tank 17 in which the pipe line 18 is immersed, an ultrasonic element 19 provided in the hot water tank 17, and the ultrasonic element 19 are connected. Using the gas-liquid separator 16 provided with the oscillator 20 provided outside the hot water tank 17, the ultrasonic wave emitted from the ultrasonic element 19 is supplied to the purine base liquid continuously flowing in the pipe 18. Since the gas contained in the purine base liquid is separated from the liquid component after being irradiated from outside the 18 wall through hot water and the pipe 18 wall, the purine base liquid is filled in the container. It is possible to produce a pudding having no occurrence and having a good texture, structure and appearance.
Further, since the generation of voids can be reduced, the number of defective appearances is reduced and the product yield is improved.
Furthermore, by performing non-contact type gas-liquid separation by irradiating ultrasonic waves while flowing the purine base liquid, which is the liquid to be treated, in the pipe line 18, the purine base liquid is not contaminated, and safety and sanitary It is easy to perform maintenance such as cleaning after manufacturing.
In addition, this gas-liquid separation device can simplify and miniaturize the device main body and incidental facilities, so that the device price is low and the investment efficiency is good.
In addition, this gas-liquid separation device is small in size, can be installed in a smaller space than conventional vacuum degassing devices, and can be easily moved and transported. Can be.
[0025]
【Example】
Purine was manufactured according to the method of the present invention using the purine manufacturing apparatus configured as shown in FIG.
The gas-liquid separator 16 includes a pipe line 18 through which the purine base solution prepared as shown in FIG. 2 flows, a hot water tank 17 in which the pipe line 18 is immersed, an ultrasonic element 19 provided in the hot water tank 17, A structure including an oscillator 20 connected to the ultrasonic element 19 and provided outside the hot water bath 17 is described in detail below.
Hot water bath: A plastic bat of 750 mm × 900 mm × height 200 mm. The bath was filled with hot water (liquid depth 200 mm).
Pipe line: A stainless steel pipe line having an outer diameter of 50 mm and an inner diameter of 48 mm is meandered in a hot water bath as shown in FIG. 2, and the length of the pipe in water is 5 to 6 m.
Ultrasonic element: an input vibrator manufactured by Kaijo Corporation, trade name Phoenix 6356N (allowable input 600 W, resonance frequency 26 kHz).
Oscillator: Kaijo Corporation Phoenix Series Oscillator, product name Phoenix 6339 (effective output 600 W, frequency 26 kHz ± 7%).
[0026]
Example 1
4.6 t of whole eggs, 2.8 t of sugar, and 12.6 t of milk were weighed, and these raw materials were put into the raw material stirring mixer 1 and stirred. The stirred pudding raw material was transferred to the heating stirrer 2 and heated to 60 ° C. with stirring. The heated pudding raw material was sent to the homogenizer 7 and homogenized at 60 ° C. and a pressure of 10 MPa to prepare a pudding base solution. The purine base solution was copied to the cooling storage tank 8 and stored at 20 ° C.
The purine base liquid was led out from the cold storage tank 8 through a pipe, heated to 50 to 60 ° C. through the heater 13, and then sent to the pipe 18 of the gas-liquid separator 16 through the pipe 21.
In the gas-liquid separator 16, the purine base liquid flowing in the pipe line was irradiated with ultrasonic waves under conditions of a hot water temperature of 51 ° C. and a frequency of 26 kHz. The purine base solution was allowed to flow through a pipe with an inner diameter of 48 mm at a flow rate of 1600 L / hour, and the holding time in the pipe (the submerged portion irradiated with ultrasonic waves) was 20 to 40 seconds.
The purine base liquid irradiated with the ultrasonic waves is discharged from the pipe line of the gas-liquid separator 16 through the pipe line 22 connected to the holding tank 25 and transferred to the holding tank. Bubbles entrained in the purine base liquid transferred to the holding tank 25 are separated from the purine base liquid and float above the holding tank 25. The purine base liquid from which bubbles were separated and floated and was substantially removed was weighed and filled into a polypropylene pudding cup (145 g), then filled with caramel syrup (5 g), and this was suspended and held on an inner frame with a top plate. In a state where hot water was arranged around the container, it was put in an oven 28 and baked for 60 minutes at 140 ° C. on the top and 200 ° C. on the bottom. After firing, the product was cooled by a known method, and the container was covered to obtain a product.
[0027]
Under the conditions described above, 100,000 puddings were produced, and the ratio of defective product appearance due to the occurrence of voids (percentage of defective products relative to the total number of products) was determined. As a result, the ratio of defective products was 0.62% (620 pieces).
[0028]
(Comparative example)
Purines were produced in the same manner as in Example 1 except that no gas-liquid separator was used.
When the gas-liquid separator was not used, the ratio of defective product appearance due to the occurrence of voids was 2.13% (2130).
That is, in the comparative example in which the ratio of product appearance defective products due to the generation of voids is high, the purine base liquid was subjected to gas-liquid separation by irradiating ultrasonic waves. It was found that the product yield was significantly improved.
[0029]
(Example 2)
Pudding was produced in the same manner as in Example 1 except that 4.0 t of whole eggs, 2.0 t of sugar and 14.0 t of milk were used as the pudding materials instead of the pudding materials in Example 1.
As a result, the proportion of product appearance defects due to the occurrence of voids was at the same level as in Example 1.
[0030]
【The invention's effect】
According to the present invention, after purifying the purine base liquid by non-contact type ultrasonic irradiation and gas-liquid separation, the purine base liquid is filled in the container, so there is no generation of voids, texture, tissue and appearance, etc. Can produce good pudding.
Further, since the generation of voids can be reduced, the number of defective appearances is reduced and the product yield is improved.
In addition, purine base liquid is not contaminated by non-contact type gas-liquid separation by irradiating ultrasonic waves while flowing the purine base liquid, which is the liquid to be treated, in the pipeline, and it is safe and sanitary. And maintenance such as cleaning after manufacture is easy.
Further, this gas-liquid separator can simplify and miniaturize the apparatus main body and incidental facilities, so that the apparatus price is low and the investment efficiency is good.
In addition, this gas-liquid separation device is small in size, can be installed in a smaller space than conventional vacuum degassing devices, and can be easily moved and transported. Can be.
[Brief description of the drawings]
FIG. 1 is a configuration diagram of a pudding production apparatus suitable for carrying out the method of the present invention.
FIG. 2 is a perspective view illustrating a gas-liquid separation apparatus for purine base liquid suitable for carrying out the method of the present invention.
[Explanation of symbols]
1-8 Purine Base Liquid Preparation Unit 16 Gas-Liquid Separator 17 Hot Water Bath 18, 21, 22 Pipe 19 Ultrasonic Element 20 Oscillator 23 Filling Device 25 Holding Tank 28 Oven

Claims (3)

In a method of producing a pudding by mixing a pudding raw material to prepare a pudding base liquid, filling the pudding base liquid into a container, and then heating the pudding base liquid in the container.
While purine base liquid is continuously flowing in the pipeline, it is separated into gas and liquid by irradiating ultrasonic waves from the outside of the pipeline wall, and after the separated bubbles are removed from the purine base liquid, the container is filled. A method for producing pudding. The method for producing pudding according to claim 1, wherein the gas-liquid separation is performed by immersing the pipe in a hot water bath and irradiating the pipe with ultrasonic waves while keeping the purine base liquid in the pipe warm. . A purine base liquid preparation unit for preparing a purine base liquid by mixing pudding raw materials, a pipe line for continuously feeding the purine base liquid prepared by the purine base liquid preparation part, and an end of the pipe line In a pudding manufacturing apparatus comprising: a filling device that fills a container with a pudding base liquid; and an oven that heats the container filled with the filling device and bakes pudding.
A hot water bath for immersing at least a part of the pipe in hot water, an ultrasonic element for irradiating ultrasonic waves to the pipe immersed in the hot water bath, and a purine base solution provided in a pipe downstream of the hot water tank And a holding tank for temporarily holding the pudding.

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