JP7194377B2 - Method for producing smoked processed food - Google Patents

Description

Application of Article 30, Paragraph 2 of the Patent Law (1) Released on March 26, 2018 at the 2018 Spring Conference of the Japanese Society of Fisheries Science, page 104 (2) March 27, 2018, Heisei Published at the 2018 Spring Meeting of the Japanese Society of Fisheries Science (3) Website (http://fish-exp.pref.shizuoka.jp/03research/pdf/2018/h30/h30-05-1 .pdf) (4) Released on November 14, 2018, on pages 42 and 43, materials of the Research Committee on Utilization and Processing Technology, Research and Development Promotion Council for Fisheries Utilization (5) November 2018 (6) December 28, 2018 website (http://fish-exp.pref.shizuoka.jp/07event/data/65th_kakouseminar.jp) pdf)

TECHNICAL FIELD The present invention relates to a method for producing smoked processed food, focusing on reduction of harmful components contained in smoke.

Adhesion of harmful ingredients to the surface of food has long been a problem. In particular, processed foods such as katsuobushi and smoked products, which are smoked, are carcinogenic, along with charcoal-cooked foods. It has been pointed out that there is a high possibility of containing PAH at a high concentration.
PAH is an abbreviation for Polycyclic Aromatic Hydrocarbons and is a chemical component that is produced when wood is burned. The upper limit of the amount is numerically regulated, which is a bottleneck when exporting smoked processed foods to these countries.

On the other hand, although there are no such regulations in Japan at the moment, PAH is positioned as a substance with a high need for administrative measures (regulation) examination in the government's regulatory science research promotion plan. , the plan states that it is necessary for manufacturers to develop viable reduction technologies.

Various countermeasures have been sought against this problem, one of which is a method using smoke that suppresses the generation of PAHs by low-temperature smoke generation, as described in Patent Document 1.
This PAH reduction method suppresses the generation of PAHs during smoking, and is highly effective because it is a fundamental solution.
Katsuobushi, which is a typical smoked food in Japan, has a unique aroma and flavor through a roasting and drying process using high-temperature smoke. Difficult to reproduce.
In addition, low-temperature smoke generation requires a dedicated smoke generation device that emits smoke at a certain temperature (425°C) or less. Even if it is easy to reproduce the above, the introduction of the smoke generating device will force the pain of the cost burden.

JP 2011-250735 A

In view of the above problems, the present invention is a relatively simple method without significantly changing the quality such as the flavor of conventional products and the manufacturing method so that manufacturers can actually easily adopt smoked processed foods such as dried bonito. It is an object of the present invention to provide a method capable of reducing PAH concentrations.

As a result of trial and error, the inventors of the present invention have found that the strength of flavor and aroma is not proportional to the amount of ingredients attached, and that depending on the food, if the amount of attachment exceeds the threshold value, sufficient flavor etc. can be felt. , On top of that, he came up with the idea of reducing the amount of PAH that adheres to food by temporarily forming a film and attaching a portion of PAH to the film during the smoking process. It must be safe to be coated, the film can be easily formed and removed, it can exist as a stable film in the smoking process, and it does not significantly impair the quality such as the flavor of the food to be coated. The present invention has been completed by finding a criterion for selecting those satisfying the above.

The invention of claim 1 of the present invention is a method for producing smoked processed foods in which foodstuffs are processed in a smoking process by hot smoking or hot smoking, in which dissolution or elution is performed by exposure to hot water or steam at 30 ° C or higher. Then, using an edible film raw material that can be reversibly formed into a film by cooling and / or drying, and forming a film by filming the film raw material on the surface of the food material, the smoking step Dissolving or eluting the film of the processed food that has been subjected to , and removing it from the surface of the food together with the harmful components contained in the smoke.

According to a second aspect of the invention, there is provided a method for producing a smoked processed food according to the first aspect, wherein the smoking step includes a roasting and drying step using katsuobushi as a food material.

The invention of claim 3 is the method of producing the smoked processed food according to claim 1 or 2 , characterized in that the coating material is formed from a dissolved or eluted state into a coating at room temperature.

The invention of claim 4 is characterized in that, in the method for producing a smoked processed food according to any one of claims 1 to 3 , the raw material for the film is mainly composed of agar, carrageenan, pectin or starch. It is a manufacturing method that

The invention of claim 5 is the method of producing the smoked processed food according to claim 4 , characterized in that the film raw material is one that gels at room temperature.

According to the manufacturing method using the film of the present invention, PAH adheres to foodstuffs while significantly maintaining the same quality such as flavor as conventional products without significantly changing conventional manufacturing equipment and manufacturing methods. You can definitely reduce the amount.

FIG. 2 is an explanatory image of a test method for confirming the film-forming effect implemented in Examples. 1. It is a graph which shows the PAH reduction effect at the time of using an agar film|membrane by the test method of FIG. 1. It is a graph which shows the PAH reduction effect at the time of using a starch film|membrane by the test method of FIG. 1 is a photograph showing the state of a food material at each stage when dried bonito is actually produced by the method of the present invention (using an agar film). FIG. 5 is a photograph showing the state of foodstuffs in each stage following FIG. 4 ; FIG. FIG. 6 is a photograph showing the state of foodstuffs in each stage following FIG. 5 ; FIG. 1 is a photograph showing the state of kezuribushi when it is actually produced by a conventional method that does not use a film and does not use blanching. FIG. 8 is a graph showing the PAH reduction effect when distinguishing between male and female nodes in the examples of FIGS. 4 to 7. FIG.

A manufacturing method according to an embodiment of the present invention will be described according to the procedure.

First, the raw materials will be explained.
(ingredients)
In a general smoking process, depending on the temperature of the smoking atmosphere, it is divided into cold smoking, hot smoking, and hot smoking, and is used according to the type of smoked processed food. As will be described later, it is premised on the characteristic use of the film, so the quality is not affected by it, that is, it is planned to be processed in the smoking process by hot smoking or hot smoking.
Specifically, heated hams and sausages that undergo a washing process with hot water after the smoking process, and dried bonito (bonito flakes, mackerel flakes, etc.) that undergo steam treatment (softening treatment) to facilitate shaving are suitable. In addition, it can be applied to foods other than meat, such as boiled eggs, nuts, pickled radish, etc., whose quality does not change significantly even when immersed in warm water.

(coating raw material)
The film raw material to which the present invention can be applied is
(1) Safe to eat: and (2) Capable of forming a film:
On the premise that, furthermore, considering that the object of manufacture is smoked processed food,
(3) Before and after the smoking process, the film can be easily formed and removed, and it can exist as a stable film during the smoking process:
It satisfies all the conditions of
and preferably
(4) It should not affect the flavor of foodstuffs.

The above (2) “film formation” is <1> a solubilized state realized under constant (concentration and temperature) conditions, and has viscosity and fluidity that adhere to the food surface, <2> fluidity A decrease in the value means solidification and fixation on the surface of the food. As for the film, it is not required to completely cover the surface of the food without gaps. In particular, when the food is dried bonito, the smoking process is intended to remove moisture, so a film that completely seals the entire food is rather undesirable.

Specifically, (3) above means that dissolution or elution by exposure to hot water or steam at 30°C or higher and film formation by cooling and/or drying are reversibly realized. . That is, it means that the film fixed and solidified on the food material surface is dissolved or eluted again by exposure to hot water or water vapor of 30° C. or higher. The lower limit is set at 30°C because the melting temperature is generally 30°C or higher, although it depends on the type and grade of the target film raw material. The reason why water is used as the solvent is that it does not affect the taste of the finished smoked food.
Preferably, it forms a film at room temperature. This is for the convenience of workability.
More preferably, it gels during film formation at room temperature from a dissolved or eluted state. This is because gelation in the middle of the film develops adhesiveness, and the film more strongly adheres to the surface of the food material.

Candidates include food materials such as agar, carrageenan, pectin and starch (wafer). Carrageenan is the main component of agar and is readily available as a food additive. Pectin is the same vegetable thickening polysaccharide as carrageenan and has the same properties.
These satisfy the above (1) and (2).
These satisfy (3) above. Furthermore, since both of them preferably form a film at room temperature, they only need to be cooled to room temperature, so equipment such as a refrigerator is not required, and they are easy to handle.
In particular, when agar is used, it is possible to create a strong film that is not affected by fixation to foodstuffs even in the smoking process by utilizing the expression of stickiness due to its gelling ability.
Although starch does not have a gelling ability, it has sufficient stickiness as a starch paste, and a certain degree of fixability can be ensured by drying after cooling to room temperature.
These satisfy (4) above. In particular, agar and starch are preferable because they are nearly tasteless and odorless.

In addition to the above, gelatin, which is a similar material, can be mentioned as a candidate.
The above (1) and (2) are satisfied, and the above (3) is also satisfied. Film formation is possible even at room temperature, but unlike agar, the strong gelling ability of gelatin is exhibited when refrigerated. However, when combined with agar, it gels even at room temperature. For example, it has been confirmed that when 25% of 1.5% agar is mixed with 10% gelatin, gelation occurs even at room temperature, and the firm stickiness derived from gelatin can be utilized. In addition, if refrigeration is permitted, it is possible to produce a film that takes advantage of the excellent film-forming properties of starch in combination with starch.
The above (4) is also satisfied. Like agar, it is particularly preferred because it is nearly tasteless and odorless.

Edible film has been used in the past, and there are various film raw materials that satisfy the above (1) and (2). .
Examples of film raw materials to which the present invention is not applicable include mannan (a component of konjac), which is a vegetable polysaccharide similar to carrageenan. Although mannan gels, it does not dissolve or elute again even when exposed to hot water of 30° C. or higher or steam. Alginic acid, which is a component of seaweed, also gels with calcium ions, but it requires an acid solution such as a citric acid solution to dissolve or elute it again. .

Next, the film forming process/removing process and the smoking process therebetween will be described.
≪Film formation process≫
A film is formed on the outer surface of the food material.
A commercially available product such as agar is obtained as a raw material for the coating, and is exposed to hot water or steam at 30° C. or higher to dissolve or elute.
Since the dissolution temperature differs depending on the type and grade of the target film raw material, specifically, it is necessary to expose the film to hot water at a temperature at least at which the film raw material can be dissolved.
However, since it is practical to carry out the coating in a liquid state, it is usually used as a coating liquid by dissolving it in hot water having a melting temperature or higher.

Regarding the concentration of the film liquid, when it is cooled and/or dried, the higher the viscosity, the stronger the adhesion to the surface of the food. decrease significantly. On the other hand, the lower the temperature, the easier it is to coat the surface of the food material, but the smaller the content of the composition, the thicker the coating must be and the more the coating operation is repeated.
Therefore, when implementing, it is necessary to make the optimum selection after considering the ease of work and work time. Incidentally, for agar and starch, which are readily available and can be used alone, tests have confirmed that the concentration range of 0.5 to 10% is the optimum range.
In addition, the coating efficiency can be improved by keeping the temperature at which the coating liquid is applied to be slightly higher than the solidification temperature, and by pre-cooling the food material.

The surface of the food material is coated with the coating liquid prepared as described above.
The method of coating is not particularly limited as long as the food can be coated, but immersing the food in the coating liquid or directly spraying the coating liquid on the food can be considered.
In the case of immersion, for example, food materials can be processed sequentially and continuously by transporting them while being submerged in a liquid tank (immersion tank) using a belt conveyor or the like, and as a result, mass processing can be easily achieved. Since this liquid bath can also be used when removing the film, if it is shared, it is possible to reduce the burden of introducing equipment for forming and removing the film.

Next, by cooling and/or drying, the coated film liquid is formed into a film (solidified) and fixed on the surface of the food material.
Once the concentration and solidification is achieved, cooling alone, drying alone, or both in parallel or sequentially may be performed. Strictly speaking, however, forced cooling causes the drying to proceed naturally, and forced drying causes the cooling to progress naturally. doing.
As a drying method, other than natural drying, ordinary methods such as wind drying and heat drying using a dryer can be used.

≪Smoke process≫
The smoking process is either hot smoking or hot smoking, and can be performed in exactly the same way as before.
Therefore, there is no need to introduce new equipment and work.
In addition, when the food material is dried bonito, it becomes a roasting and drying process.
At this stage, some of the constituents of the smoke are deposited on the coating, including PAHs.

≪Film removal process≫
The coating is removed from the coated foodstuff that has been subjected to the smoking process.
By exposing to hot water maintained at 30° C. or higher and at or above the melting temperature of the coating raw material, for example, by immersing and washing, the coating raw material dissolves and separates from the surface of the food material. If the food material is resistant to heat, it will be eluted by exposing it to high-temperature steam, and will similarly separate from the surface of the food material.
The dissolved or eluted liquid film raw material incorporates the adhering components as they are, and is thus separated and removed from the food surface together with the film raw material.

In the case of dried bonito, in many cases, the smoked dried bonito (arabushi) is sold as a product to bonito shavings manufacturers. In order to obtain beautiful shavings, the shavings manufacturers heat the shavings with steam or the like immediately before shaving, so this process can be combined with the above-mentioned film removal process.

In the case of heated hams and sausages, there is a step of washing the product with warm water or hot water shower after the smoking step in order to remove dirt from the surface.

(final product)
It has been confirmed that the amount of PAH adhered to the smoked processed food produced through the above steps can be reduced to about 1/2 to 1/3 of that produced by a conventional method that does not use a film.
On the other hand, the flavor and aroma are evaluated to be comparable to those produced by the conventional method that does not use a film.

[Effect of reducing PAH adhesion amount in actual bonito production]
Using a method similar to the image diagram in FIG. 1, the amounts of PAHs adhered were compared between a test section (method of the present invention) and a control section (existing method) by an actual katsuobushi production method. PAH analysis is by standard methods (chromatographic methods) in this field.
Divide the 2.5 kg of bonito into 4 sections (male section + female section) so that the ingredients have almost the same shape. did. Katsuobushi was produced according to the usual production method except for the formation and removal of the film. In the roasting and drying process, smoking was carried out for 8 hours every day for 12 days, for a total of 96 hours, using conventional combustion and smoking (450°C).
As shown in the graphs of FIGS. 2 and 3, both the agar coating and the starch coating showed numerically the effect of reducing PAH.

4 to 6 are photographs showing the state of foodstuffs at each stage when katsuobushi is actually produced by the method of the present invention (using an agar film).
FIG. 7 is a photograph showing the state of kezuribushi when it is actually produced by a conventional method that does not use a film and does not use blanching. It was confirmed that the shavings of FIG. 6 had the same color as the shavings of FIG.
As shown in the graph of FIG. 8, there was no difference in the PAH reduction effect even when male and female nodes were distinguished.

[sensory evaluation]
Filmed knots (test section) produced as shown in FIGS. 4 and 5, conventional knots (arabushi) actually produced by a method that does not use a film and does not blanch, and conventional knots (honkarebushi) A sensory evaluation was performed on a monitor, and the following results were obtained.
Honkarebushi is produced by shaving the surface of rough bonito and adding mold to it, giving it a unique mature aroma. .
Since the removal of the skin film in the kekebushi is similar to the surface scraping of the rough knot in this karebushi, the pungent odor of kekrobushi is suppressed as in this karebushi, while a moderate smoky odor is maintained. However, the odor was slightly inferior. This evaluation is the result of having them mention the difference, and in the comprehensive evaluation, we obtained the endorsement that the Himekabushi can be handled as a product equivalent to the Arabushi.

PAHs in smoked processed foods are subject to regulation overseas, and regulations are being considered in the future in Japan as well. On the other hand, the reduction technologies that have been put into practical use greatly reduce the temperature at which smoke is generated, which greatly changes the conventional manufacturing conditions, alters the quality of food such as flavor, and also entails a large cost for the introduction of equipment. On the other hand, in the present invention, although not dramatic, a certain reduction effect can be expected without greatly changing the conventional manufacturing method and quality, so the hurdles for introducing the technology are low. Furthermore, since it can be implemented by simply adding some equipment and processes to conventional production lines and methods, it is required in the government's regulatory science research promotion plan in terms of both technical level and introduction cost. Match the mitigation techniques available to the manufacturer.

Claims (5)

In a method for producing a smoked processed food in which ingredients are processed in a smoking process by hot smoking or hot smoking,
Using an edible film raw material that reversibly achieves dissolution or elution by exposure to hot water or steam of 30 ° C or higher and film formation by cooling and / or drying,
After forming a film by filming the film raw material on the surface of the food, dissolving or eluting the film of the processed food that has been subjected to the smoking process, and containing it in the smoke attached from the food surface. A manufacturing method characterized in that it is removed together with harmful components that are released . In the method for producing smoked processed food according to claim 1,
A production method characterized by carrying out a roasting and drying process using dried bonito as a smoking process . In the method for producing a smoked processed food according to claim 1 or 2,
A manufacturing method characterized in that a coating raw material is formed into a coating at room temperature from a dissolved or eluted state . In the method for producing smoked processed food according to any one of claims 1 to 3,
A production method characterized in that the film raw material is composed mainly of agar, carrageenan, pectin or starch . In the method for producing smoked processed food according to claim 4 ,
A manufacturing method, wherein the film raw material is one that gels at room temperature .

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