JP7459561B2 - Method for manufacturing processed livestock product-like foods - Google Patents

Description

The present invention relates to a method for producing processed livestock foods such as sausages and hams that can be produced using only vegetable ingredients without the addition of egg whites.

In recent years, interest in global environmental protection has increased, and at the same time, food has become more diverse due to various considerations including animal welfare and health, and there has been an increase in preference for plant-based foods. Product development is also underway to use plant proteins instead of meat in livestock processed foods such as sausages, hams, and hamburgers.

Egg white is often added to these processed foods as a binder and gelling agent, and when producing products that are mainly made from plant-based ingredients, it is necessary to replace egg white, especially to achieve the unique hard and brittle texture. This can be a challenge. Technologies for egg white substitution include a composition containing gel-reinforced methylcellulose (Patent Document 1), swelling-inhibiting starch, and wheat protein (Patent Document 2), and a method using a pickle liquid containing transglutaminase and carrageenan (Patent Document 1). 3) etc. are disclosed.

Patent Document 4 is an application regarding the production of a plant-based sausage substitute by treating tofu with transglutaminase, but the product lacks the texture of meat and tissue/fiber, limiting its application as a substitute.

Japanese Patent Application Publication No. 2015-71779 International Publication No. WO2016/52712 International Publication No. WO2007/29867 Japanese Patent Application Publication No. 2001-352911

The object of the present invention is to obtain a processed livestock food-like food such as a sausage that uses vegetable protein, particularly soybean protein, as the main raw material and has good binding properties and texture without using egg white.

The present inventors have diligently studied the above-mentioned problems and first tried to utilize transglutaminase, and by incorporating it into an oil-in-water emulsion prepared using emulsified oil and fat, and using it as a reconstituted solution for granular soy protein. It was confirmed that a certain level of cohesiveness and juicy feeling could be obtained. Further investigation led to the discovery that by combining this with powdered soy protein and adjusting the heating time and various conditions, it was possible to achieve physical properties comparable to sausages made with egg whites, which could not be obtained with each component alone. , completed the invention.

The present invention is explained in detail below.

(Livestock processed foods)
In the present invention, the term "livestock processed food" refers to processed food produced by blending only plant-based raw materials or mainly plant-based raw materials without using livestock meat as the main raw material. Examples of the form include sausages such as wiener sausage, frankfurter sausage, and bologna sausage, hams such as pressed ham, hamburger steaks, meatballs, and pates. In addition, by using the method of the present invention, it is possible to produce seafood processed food without using seafood. Specifically, examples include filleted fish-like formed foods and side dishes such as fries and tempura that use these as ingredients or fillings.

(transglutaminase)
Commercially available formulations of transglutaminase can be used in the present invention. Specific examples include "Activa TG-H" and "Activa TG-H-NF" manufactured by Ajinomoto Co., Inc. The type of formulation can be appropriately selected depending on the product design, such as using a type that does not use lactose as an excipient when animal raw materials are not used. The amount used is adjusted appropriately depending on the enzyme content and activity in the formulation, but when using the above-mentioned Activa TG-H series (transglutaminase content in the formulation 0.4%), 0.0% in the oil-in-water emulsion described below is used. It is blended in an amount of .2% to 1.0% by weight, preferably 0.3 to 0.7% by weight. If the amount is less than this, the effect of the present invention may not be sufficiently obtained, and if it is added more than this, the manufacturing cost may increase without changing the effect.

(Granular vegetable protein)
The granular vegetable protein used in the present invention is obtained by blending vegetable raw materials such as soybeans, defatted soybeans, isolated soybean protein, wheat, wheat protein, peas, and pea protein, and structuring them under high temperature and pressure using a single-screw or twin-screw extruder, and has a granular or flaky shape. Granular soy protein made mainly from soybeans is suitable for the present invention. Products of any shape and size can be appropriately selected and used depending on the desired final product form. Although there are products that are distributed after being reconstituted with water, it is preferable to use a dried product (water content 10% or less) for the present invention. By reconstituting the dried product with water using an oil-in-water emulsion, the effects of the present invention can be maximized.

(Powdered vegetable protein)
The powdered vegetable protein used in the present invention can be appropriately selected from commercially available products manufactured from vegetable raw materials such as soybeans, wheat, and peas. Among them, it is preferable to use a product having gel forming properties used in livestock processed food applications and fish paste products, since it can obtain a moderate binding property. The blending amount is 30 parts by weight or more and 80 parts by weight or less, more preferably 35 parts by weight or more and 70 parts by weight or less, per 100 parts by weight of granular vegetable protein (dried product). If the blending amount is less than this amount, the binding in the final product may be weak, and if the blending amount is more than this amount, the meat grain texture and texture of livestock processed products may be insufficient. In the present invention, it is preferable to use powdered soybean protein derived from soybeans. Powdered soybean protein is soybean protein extracted, recovered, and powdered to a high purity.

(Oils and fats)
In the present invention, any edible oil or fat can be appropriately used. Examples of such oils and fats include vegetable oils and fats such as rapeseed oil, soybean oil, sunflower seed oil, cottonseed oil, peanut oil, rice bran oil, corn oil, safflower oil, olive oil, kapok oil, sesame oil, evening primrose oil, palm oil, palm kernel oil, coconut oil, etc., as well as animal oils and fats such as milk fat, beef tallow, lard, fish oil, whale oil, etc. Examples of such oils and fats include single or mixed oils of these oils and fats, or hardened fractionated oils thereof, as well as processed oils and fats that have been subjected to enzymatic interesterification, random interesterification using a catalyst, etc.

(emulsifier)
In the present invention, an emulsifier capable of preparing an oil-in-water emulsion can be appropriately used. Examples of such an emulsifier include polyglycerol fatty acid esters, glycerol fatty acid esters, sucrose fatty acid esters, sorbitan fatty acid esters, propylene glycol fatty acid esters, phospholipids including lecithin and its partial hydrolysate lysolecithin, glycolipids, saponin, and proteins including soybean protein and sodium caseinate.

(emulsified fat)
Although the above-mentioned fats and oils and emulsifiers can be blended individually, it is preferable to use emulsified fats and oils containing these because it is possible to easily create an emulsion. As the emulsified fat, any commercially available product for confectionery/bread making or for delicatessen dishes can be used.More specifically, the "Unishort" and "Palming" product groups (both manufactured by Fuji Oil Co., Ltd.) I can give an example.

(Oil-in-water emulsion)
In the present invention, an oil-in-water (O/W) emulsion containing at least transglutaminase, fats and oils, and an emulsifier is prepared. The emulsion may be prepared according to a conventional method, and may be prepared by mixing raw materials with a homomixer or a propeller stirrer. When emulsified fats and oils are used, the emulsion can be prepared by simple stirring, and may be mixed and stirred using a spatula or the like. The proportion of fats and oils or emulsified fats and oils in the emulsion is 5 to 50% by weight, more preferably 10 to 30% by weight, and most preferably 15 to 25% by weight. If the proportion is less than this, the final product may lack juiciness, and if the proportion is more than this, the stability of the oil-in-water emulsion may be impaired, or the final product may have oil floating or oil stains.

(starch)
In the present invention, better binding properties can be obtained by further mixing starch. As the starch, any edible starch can be used; for example, one or more types selected from tapioca starch, potato starch, wheat starch, corn starch, and/or these processed starches may be used alone or in appropriate combinations. Can be used. The blending amount is 20 to 60 parts by weight, more preferably 30 to 50 parts by weight, per 100 parts by weight of granular vegetable protein (dry product). If it is less than this, the binding in the final product may become weak, and if it is more than this, the texture derived from starch may become stronger.

(Other raw materials)
In addition to the above, the present invention also includes salts, sugars, thickening stabilizers, seasonings, spices, acidulants, colorants, preservatives, color formers, pH adjusters, antioxidants, etc., which are commonly used in livestock processed products. The raw materials to be blended can be used as appropriate within a range that does not impede the effects of the present invention. However, salts such as table salt may inhibit the solubility of powdered vegetable protein, so they should not be added to the oil-in-water emulsion, but should be added in a step after mixing the powdered vegetable protein. is desirable.

(Soaking process of granular vegetable protein)
Granular vegetable protein (dried product) is added to the above-mentioned oil-in-water emulsion and soaked. The water content in the oil-in-water emulsion is preferably 200 to 800 parts by weight, more preferably 250 to 700 parts by weight, per 100 parts by weight of granular vegetable protein. If the water content is less than this, swelling may be insufficient, and if the water content is more than this, the final product may not be sufficiently bound, or may be too soft or watery. The soaking time depends on the scale of the work and the shape and water absorption of the granular vegetable protein, but is preferably 1 to 24 hours. If the soaking time is too short, water absorption may be insufficient, and if the soaking time is too long, the enzyme reaction may proceed too much. The soaking temperature is preferably in the refrigeration temperature range (3 to 10°C). If the soaking time is above room temperature, the enzyme reaction may proceed too much, making it difficult to carry out subsequent work or sufficient binding may not be obtained.

(Powdered vegetable protein, starch mix)
Powdered vegetable protein is added to the soaked and swollen granular vegetable protein and mixed uniformly. Starch can also be mixed in. The starch can be mixed in the process before molding, and can be added before, at the same time as, or after mixing with the powdered vegetable protein. It can also be added in several portions, but it is most efficient to add and mix after mixing with the powdered vegetable protein.

The mixing means and the structure of the resulting livestock processed food-like food will be explained in more detail. When stirring and mixing while kneading the whole using a mixer, Kenwood mixer, etc., the shape of the granular vegetable protein remains and a coarsely ground-like structure is obtained. The mixture may be kneaded while being shredded using a silent cutter, RoboCoop, etc. In this case, the granular vegetable protein is cut into small pieces and a texture similar to silk milling is obtained. These can be manufactured by appropriately using or combining them.

(molding)
The dough is further shaped into a casing according to a conventional method depending on the desired product form.

(Transglutaminase Cross-Linking Reaction)
Next, transglutaminase is used to cause an enzymatic reaction, i.e., a cross-linking reaction, to bind the tissue. The reaction proceeds even at a low temperature range of 3 to 10°C, but it is preferable to heat the tissue in order to improve work efficiency and obtain stronger binding properties. The heating conditions can be appropriately adjusted depending on the shape and size of the product, but from the viewpoint of efficiency, it is preferable to heat the tissue at 40 to 65°C for 10 minutes or more, and more preferably at 45 to 60°C for 10 to 100 minutes.

(Heating process)
After the crosslinking reaction in the previous section, the mixture is heated at 70°C or higher for at least 5 minutes, preferably at 70-130°C for 5-60 minutes, and more preferably at 80-125°C for 5-50 minutes. Retort heating may also be used. This heating inactivates the enzyme and at the same time promotes gelation by the powdered vegetable protein, resulting in stronger binding properties. If the temperature or time is lower than this range, the enzyme may not be sufficiently inactivated or the binding properties may be weak.

Furthermore, the method of the present invention allows for production without the use of animal-derived ingredients such as meat, seafood, eggs, egg whites/powdered egg whites, or dairy products, making it possible to provide foods that meet the needs of vegetarians and vegans.

(Example)
The present invention will be described in more detail below. In the text, all parts and percentages are by weight unless otherwise specified.

(Example 1)
100 parts of water, 0.9 parts of a commercially available transglutaminase preparation (Activa TG-H-NF, manufactured by Ajinomoto Co., Inc.), and 0.15 parts of gardenia pigment were mixed with a spatula, followed by commercially available emulsified fats and oils (Unishort EF, 25 parts (manufactured by Fuji Oil Co., Ltd.) were added and mixed to prepare an oil-in-water emulsion. To 126 parts of this oil-in-water emulsion, 25 parts of flake-shaped granular soy protein (Apex 650, manufactured by Fuji Oil Co., Ltd.) was added and immersed, and the mixture was allowed to stand in a refrigerator for 1 hour. 15 parts of powdered soybean protein (FujiPro 748, manufactured by Fuji Oil Co., Ltd.) was added to this, and mixed uniformly while being shredded with a Robocup. Subsequently, 1.2 parts of salt, 10 parts of starch (trade name: RK-08, processed starch derived from tapioca, manufactured by Glico Nutritional Foods Co., Ltd.), sugar, and seasonings/spices were added and further mixed. In addition, no animal ingredients were used for seasonings and spices. The mixture was filled into a sausage casing, degassed under vacuum, and heated at 50° C. for 60 minutes to carry out a transglutaminase crosslinking reaction. Subsequently, the mixture was heated at 90°C for 30 minutes to obtain a minced silk sausage-like food. After cooling, some samples were stored in the refrigerator, and others were quickly frozen. The next day, the frozen product was boiled and subjected to sensory evaluation along with the refrigerated product.

(Sensory evaluation criteria)
The sensory evaluation was conducted by five experienced panelists, who mainly evaluated the texture, and made a consensus decision.
◎: Particularly good, comparable to normal sausages ○: Good as a sausage-like food without any problems △: Slightly inferior ×: Poor as a sausage-like food

Example 2
15 parts of the granular soy protein of Example 1 (Apex 650) were added to 10 parts of granular soy protein New Fujinic 80N (manufactured by Fuji Oil Co., Ltd.), and mixed in a Kenwood mixer to obtain a coarsely ground sausage-like food.

Example 3
A sausage-like food was obtained in the same manner as in Example 1, except that the amount of emulsified oil was changed to 15 parts.

(Example 4)
A sausage-like food was obtained using the same process as in Example 1 except that 15 parts of emulsified oil and fat, 10 parts of powdered soybean protein, and 8 parts of starch were used.

(Comparative example 1)
During the blending process of Example 1, the powdered soybean protein was not added and mixed, but the other steps were the same.

(Comparative example 2)
In the formulation of Example 1, an oil-in-water emulsion was prepared without adding the transglutaminase preparation, and the other steps were the same.

(result)
In all of the examples, good sausage-like foods were obtained. In Example 2, the product that was frozen and thawed after heating and cooling had a juicy feel and was evaluated as more preferable than the refrigerated product. It was estimated that a part of the oil-in-water emulsion held in the tissue of the granular soy protein remaining in the form of coarsely ground meat was demulsified, which may be responsible for the juiciness. Examples 3 and 4 were slightly less juicy than Examples 1 and 2, and Example 4 was slightly soft, but both were good as sausage-like foods. On the other hand, Comparative Example 1 was only loosely held together and did not bind, and had a brittle, sticky texture. Comparative Example 2 was bound, but was powdery and lacked elasticity, and had a texture that was inferior to that of a sausage-like food.

(Table 1)

(Examples 5 and 6)
It was produced in the same manner as in Examples 1 and 2, but with the same formulation, except that the immersion time of the granular soybean protein was changed to 15 hours. The quality (physical properties, flavor, color tone) of the obtained sausage-like food was good, with no major difference from Examples 1 and 2.

(Examples 7 and 8)
The same composition as in Examples 1 and 2 was used, but the soaking time of the granular soy protein was changed to 15 hours, and the heating after molding was changed to 121°C for 10 minutes (retort heating), and similar production was carried out. The obtained sausage-like food was slightly duller in color than in Examples 1 and 2, but the flavor tended to be improved. In any case, it was a good sausage-like food without any problems.

Claims (3)

A method for producing a processed livestock food, comprising the following steps:
(1) A step of soaking granular vegetable protein in an oil-in-water emulsion containing transglutaminase, oil and an emulsifier.
(2) A step of mixing powdered vegetable protein with (1).
(3) A step of forming (2) and cross-linking it with transglutaminase
(4) Heating (3) at 70°C or higher for 5 minutes or more The manufacturing method according to claim 1, in which the oil and fat of the oil-in-water emulsion and the emulsifier are mixed as an emulsified oil and fat. The method according to claims 1 or 2, further comprising the step of mixing starch.