JPS6255067A - Production of edible dough using twin-screw extruder and device - Google Patents

Abstract

PURPOSE:To produce edible dough having the same water content as dumpling and rice cake, by treating a raw material starch by a pre-heating process, a cooking process, a cooling process and a molding process in a twin-screw extruder. CONSTITUTION:In a twin-screw extruder, a raw material starch and water are fed from the raw material feeder 2 and the water feeding mechanism 11 to the raw material feed barrel B1 and then the raw material is kneaded under heating by the preheating barrel B2 at a relatively low temperature until it becomes an underdone state. In the following barrel B3 for cooling, the raw material in an underdone state is kneaded under pressure at relatively high temperature and the hydrated raw material is completely impasted. Then, in the cooling barrels B4-B6, the impasted raw material dough is gradually cooled and the cooled dough is extruded into a desired shape by the die D and molded. Consequently, the edible dough having the same water content as dumpling and rice cake can be continuously produced in a short time.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention uses a twin-screw extruder to turn nH flour containing coarsely ground rice flour into dough similar to dango or mochi in an extremely short period of time. It is intended for use in the production of edible dough for production.

[Conventional technology]

Conventionally, it has been common practice to obtain dough for dumplings or mochi using grain flour such as rice flour. This method involved mixing the ingredients, passing them through a steamer several times, and then extruding them from a twisting machine, which required the complicated means of adding auxiliary materials each time the mixture passed through the steamer. When manufacturing rice cake-like dough, it is a so-called batch method, in which raw rice that has been washed and soaked in water is crushed using a crusher, then steamed using a steamer, and then kneaded using an extruder to produce steamed dough. The method was to store the dough in a container, stabilize it for 70 hours, and then cut it into the desired shape and dry it.It took more than three days from inputting the raw materials to obtaining the product dough. Ta. A mochi dough processing method using a uniaxial extruder was developed to solve the time-consuming drawbacks of the batch method, but it had several drawbacks.

[Problem that the invention seeks to solve]

The following points have been pointed out as the disadvantages of the conventional uniaxial extruder described above: 1) The processing principle of the axial extruder is that the raw material to be processed is caused by friction between the barrel wall surface and the raw material. Since the raw material is forced forward while being prevented from co-rotating with the screw, if the water content in the raw material increases, it will slip on the barrel wall, making forward extrusion unstable.

Therefore, the limit of allowable moisture in the raw material is about 30 to 40%. ■There is a lot of energy loss due to friction, which consumes a lot of power. ■In general, the barrel wall of a uniaxial extruder is not a smooth surface but has grooves cut into it, and the clearance between the screw flight and the barrel wall is large, so if there is a lot of moisture in the raw material, the raw material will overcome the screw flight and flow backwards. Therefore, high pressure cannot be expected.

That is the problem.

[Means for solving problems]

The present invention focuses on the fact that by using a twin-screw extruder, raw materials can be hydrated, mixed, heated, and cooled without any special troubles. By skillfully combining the incorporated screw patterns, rice flour and other grain flours, including coarsely ground rice flour, can be mixed in a short period of time, preferably close to "instantaneous", without adding excess moisture. In this method, the gelatinized raw materials are gelatinized by heating and steaming during the production process, and the gelatinized raw materials are quickly cooled, thereby solving many of the problems associated with conventional manufacturing methods and equipment. It is something.

Furthermore, according to the method and apparatus of the present invention, those products should be able to have extremely high quality,
Furthermore, products manufactured by such means should be able to bring about significant reductions in manufacturing costs. The present inventors have eliminated the drawbacks of the prior art described above by using a twin-screw extruder, and in particular by skillfully combining the patterns of several types of screw elements installed in the twin-screw extruder according to their functions. However, it is an object of the present invention to achieve the intended effects.

The above objects of the present invention can be achieved by heating and cooling a mixture of raw flour and a required amount of water using a twin-screw extruder.

The twin-screw extruder used in the present invention consists of a feeder for supplying raw materials, several barrels, two-wheeled screw elements installed in each of the several barrels, and a die attached to the tip of the barrel. The several barrels described above are combined to form a raw material input zone, a high heat treatment zone, and a cooling treatment zone. The raw material input zone has a raw material input port and a water supply port.The high heat treatment zone has a preheating zone that heats and stirs the raw material transferred from the raw material input zone and water while mixing it, and a preheating zone that has a sufficient amount of water. The cooling zone consists of a cooking zone that compresses and pulverizes the heated raw materials and gelatinizes the starch in the raw materials using the heat supplied from the barrel.The cooling zone also includes a cooling zone that compresses and crushes the raw materials that have been heat-treated in the high-heat treatment zone. It is constructed so that it is gradually cooled and then connected to an extrusion die attached to the rear end. The above-mentioned two-screw extruder is made up of two screw shafts that are rotatably attached to the inside of the barrel, and screw elements that have functions according to the purpose are fitted in combination. A two-shaft device that is rotationally driven and configured as a device that can perform all processes such as mixing, grinding, kneading, compression, shearing, heating, and sterilization sequentially and continuously within one mechanism. As an example of a specific structure of the mold extruder, a co-rotating twin screw extruder TEM50B manufactured by Toshiba Machine Co., Ltd. was suitable.

[Effect]

The operation of the present invention will be explained below with reference to the drawings of a twin-screw extruder used for manufacturing the same. The twin-screw extruder used to demonstrate the effects of the present invention is a twin-screw extruder TEM50B manufactured by Toshiba Machine Co., Ltd. FIG. 1 is a partially sectional front view showing a biaxial extruder, and FIG. 2 is a longitudinal sectional front view showing the arrangement of screw elements inside the barrel.

The present invention involves a process of mixing and kneading the supplied raw material flour and water, and preheating the mixed raw material in a barrel heated to about 100°C while uniformly hydrating and mixing it with a kneading disk. The preheated raw materials are kneaded under pressure while being heated to about 150°C, and in the middle of the kneading and transfer, a reverse screw element is combined and subjected to strong shear stress under high pressure conditions. A high heat treatment process consisting of a series of shoeing processes, which consists of gelatinizing the raw materials and sterilizing general living bacteria and heat-resistant bacteria in the dough, and the dough obtained by the sewing process is supplied with cooling water. There is a cooling process in which the dough is cooled by passing it through several barrels equipped with two transporting screw elements inside, and the dough is cooled to a predetermined temperature and is continuously extruded by a die attached to the tip of the barrel. It is composed of a combination of molding and extrusion processes. In addition,
The type of raw material flour used in the present invention is not particularly limited, and various grain flours such as coarsely crushed rice grains, Doudou flour, Doudou coarse grain flour, and rolled flour may be used alone or in a mixture at an appropriate ratio. It is possible to do so.

Hereinafter, one embodiment of the manufacturing method according to the present invention will be specifically described in conjunction with its manufacturing apparatus.

The high heat treatment process consists of a feed barrel B into which raw materials and water are input, and a preheating barrel B2 in which the input raw materials and water are heated and kneaded at a relatively low temperature of about 100°C until they become semi-raw. and a packing barrel B3 for completely gelatinizing the hydrated raw material while heating and kneading the preliminarily heated and kneaded raw materials at a temperature of about 150°C under pressure. Each barrel is mechanically connected in series to allow free movement of the raw material in sequence. The cooling process involves several cooling barrels B4 to B6.
The cooling barrel B at the rear end is equipped with a die D for feeding out the manufactured dough raw material. The above-mentioned cooling treatment barrels 84 to B6
is mechanically continuous with the high heat treatment zone. The foot barrel B1 has an input port for raw materials, a chute 1 is attached to the input port, and a water addition pipe 1) for supplying absorbed water is attached to an appropriate position.
Inside the foot barrel B, two sets of mutually meshed transfer screw elements 12, 12 for transferring the input raw material are rotatably fitted. The preheating barrel B2 heats the transferred raw materials while hydrating and mixing them with a kneading disk. On the inside of the rebarrel, multi-stage kneading disks 21 21 are attached so as to mesh with each other and rotate. The preheating barrel B2 is equipped with a heater 3 and a cold water jacket (not shown) for the purpose of heating and cooling the raw materials. A barrel with a constant temperature control is used. Barrel B for shoeking.

This uses a barrel having the same structure as the preheating barrel B2, and inside it there is a screw element 1-31 with a transfer function, and this transfer screw element 31 is used to send out the dough with an appropriate pressure. A reverse screw element 32 is installed in combination with a reverse screw element 32 which generates high pressure by interfering with the material and causes the raw material to remain there for a predetermined period of time. In this shoeking barrel B, the semi-raw raw material fed from the preheating barrel B2 is passed through two screw elements 3.
By retaining the material for a predetermined period of time while applying pressure due to the effects of steps 1 and 32, it is possible to completely gelatinize the material under high heat. Further, in this shoeing barrel B3, the shearing action of the two screw elements 31 and 32, especially the shearing stress of the reverse screw element 32, makes it possible to fully exhibit the sterilization effect on the stuffed fabric. The cooling barrels B, ~B6 have the same construction as the preheating barrel B2 and the shoeking barrel B3 described above, and there are internally engaged transfer screw elements 41, . . . 41 for rotation. It is arranged as follows. The die D is attached to the end of the last cooling barrel B, and has an orifice 5 through which dough of a desired size is formed and extruded.

〔Example〕

Example 1 (Manufacturing example of dough for rice crackers) Screw rotation speed: 160-200 rpm Fresh flour: 40-42 kg/h Amount of water added (amount of water added)
・10～l 21/h Barrel temperature・・Barrel B2 empty B
6, the order is 100-150-40-40-40°C.

Die temperature: 40°C Fresh powder is continuously supplied from the feeder 2 to the chute 1 of the raw material input barrel B1, and then water is supplied from the water pipe 1). F1. While being kneaded, the raw material is transferred to the preheating barrel B2.If the raw material is sufficiently mixed and kneaded in the preheating barrel B2 heated to 100°C, the raw material absorbs water uniformly and the raw material temperature is raised to nearly 100°C. When the raw materials are raised and then transferred into the shoe-king barrel B□, the partially gelatinized raw materials in the preheating barrel B2 are further sufficiently stirred and kneaded, and are completely gelatinized by high-temperature heating and kneaded well. The temperature of the fabric obtained in this shoe-king barrel B3 is 1.
The temperature was 44 to 147°C, but as it passed through the cooling barrels B4 to B, it was gradually cooled down, and the final product temperature immediately after extrusion from die D was 89 to 94°C. The time required for the raw material input into the raw material input barrel B to turn into edible dough and be extruded from the die D was about 1.5 minutes.

The confectionery dough obtained in this example was extruded in a uniform, unexpanded state. When this extruded dough was observed under a scanning electron microscope, the powder particles were completely crushed and the starch particles were also almost disintegrated. The air bubbles were fine (dispersed).The resulting dough had an extremely low moisture content of about 25%, and could be easily dried in a short period of time.

Furthermore, slice the obtained dough into 2 to 3 thick slices.
The findings of the product, which was dried under ventilation for 48 hours at ℃ and then subjected to secondary processing by baking or frying, were found to be a puffed product with an extremely dense popcorn-like structure and a relatively light texture that melts well in the mouth. We were able to demonstrate that it was possible to obtain a new texture that had never existed before. Furthermore, the presence of general viable bacteria was not observed in the dough extruded from Die D, confirming a strong sterilization effect, and producing an excellent edible dough that can solve various problems caused by bacteria derived from raw materials. I was able to get it.

Example 2 (manufacturing example of dumpling dough) Screw rotation speed...160~z4orpm Joshin powder...
...24kg/h Sugar (sucrose 7; maltose 3)...12kg/h water addition amount.
・・・・・・181/h Barrel temperature... From barrel B2 to B,
The order is 100-150-40-40-40°C.

Die temperature: 40°C Inside the raw material input barrel B1, fresh flour and sugar are stably supplied to the chute l from separate feeders, and then water is supplied from the water supply pipe 1). be supplied with. When the Joshin flour and sugar were uniformly mixed and stirred in the preheating barrel B2 heated to 100℃, the Joshin flour uniformly absorbed water, the sugar was dissolved, and the product temperature rose to nearly 80℃. After being uniformly kneaded into the dough, it is fed into the next shoe-making barrel B3. The partially gelatinized dough in the preheating barrel B2 is kneaded again under high temperature and pressure in the shoemaking barrel B heated to 150°C to obtain a completely gelatinized dough. The temperature of the dough in the shoering barrel B was 1) 6°C. The gelatinized fabric is 4
The dough was gradually cooled by passing through cooling barrels B4 to B6 whose temperature was set at 0°C and extruded from die D at a temperature of 57°C. Note that the time required for production in this example was also about 1.5 minutes, similar to Example 1. The dumpling dough obtained in this example had a moisture content of 138.6%, in which the rice flour particles were uniformly and finely ground, and had a strong "firmness". In addition, the secondary processed product had a smooth texture and an extremely excellent texture. Further, as in Example 1, no common viable bacteria were observed in the dough, indicating an extremely excellent sterilizing effect and an excellent effect of solving problems caused by bacteria originating from raw materials.

Example 3 (Production example of mochi dough) Screw rotation speed: 160-240 rpm Mochi flour...
...32-38kg/h water addition amount (water injection amount)...14
~201/h Barrel temperature...100-150-40-40-40"c from barrel B2 to B in CD order.

Die temperature: 40'C Mochi powder is continuously supplied from the feeder 2 to the chute 1 of the raw material input barrel B1, and then water is supplied from the water addition pipe 1), which undergoes some kneading. The raw material is then transferred to the preheating barrel B2 while being heated to 100°C. When the raw material is sufficiently kneaded in the preheating barrel B2 heated to 100°C, the raw material absorbs water uniformly and the raw material temperature is raised to nearly 100°C. When transferred into the barrel B3, the preheating barrel B
The partially gelatinized raw materials in 2 are further sufficiently stirred and kneaded, and are completely gelatinized by high-temperature heating, resulting in a well-kneaded dough. The temperature was 144 to 147°C in the high-temperature and high-pressure section, but it gradually cooled as it passed through the cooling barrels B4 to B6, and the final product temperature immediately after extrusion from die D was 61°C. The time required for the raw material input into the raw material input barrel B to turn into edible dough and be extruded from the die D was approximately 1.5 minutes, as in Examples 1 and 2.
It was a minute. The mochi dough obtained in this example had a more uniform texture and was smoother than commercially available mochi dough (cut mochi). In addition, the elongation was extremely good in secondary processing by firing, but it was found that it melted more easily in heating by steaming than commercially available products. Furthermore, as in Example 1, no common viable bacteria were observed in the dough, indicating an extremely excellent sterilizing effect and an excellent effect in solving problems caused by bacteria originating from raw materials.

Confirmation of sterilization effect on heat-resistant bacteria It was confirmed that all of Examples 1 to 3 had an excellent sterilization effect on bacteria, but in order to particularly confirm these facts, the following experiment was conducted.

Bacillus 5ubti1is (
IFO-3134) spores were added at the same time as the raw material.
' and confirmed whether or not it remained in the extruded dough.

Experimental area 1 Appeal'FA 32-38kg/h Amount of water added 14-20 ffi/h Experimental area 2 Mochiko 32kg/h Amount of water added 201/h Experimental area 3 Joshinko 22kg/h Sugar 12kg/h Amount of water added 18 f/h h Screw rotation speed 16Q~24Orpm Barrel temperature
100-150-40-40-40”c Details of the experimental method can be found in J.A. [1overesse, 0.
CerfS, Gilbert and J, CChe
ftel″Influence of Extrusion
on -Cooking on Lbe Therma
l D'estruction of Bacillus
stearothermophilus 5por
es in a 5tarch-Protein-Su
crose Mix' Lebensm, -Wiss
,u,-Technol,, 15.3.135.19
83 was followed.

As shown in the table below, the B.5ubtilis spores introduced into the experiment were not detected in any dough, such as dumpling dough, mochi dough, or any other dough. It was revealed that

Sterilization effect against heat-resistant bacteria note *... Indicates the number of bacteria in 1g of dough.

Unit of water: 1/h Neither coliform bacteria nor Staphylococcus aureus were detected.

〔Effect of the invention〕

The effects of the present invention are as follows.

■ It is possible to continuously produce edible dough having moisture similar to that of dumplings or rice cakes using any type of flour or a mixture of these flours.

■ According to the conventional manufacturing method and equipment, it took an extremely long time of 2 to 3 days to manufacture edible dough, but with the method and equipment of the present invention, the process from inputting raw materials to extrusion of edible dough can be completed. It becomes possible to manufacture the product in an extremely short time of about 1.5 minutes.

- As the manufacturing time is shortened, manufacturing costs can be reduced, contributing to lower product prices.

■ A twin-screw extruder handles everything from inputting raw materials to extruding edible dough, making it extremely hygienic as it does not come into contact with human hands.

■ Since it is manufactured using a twin-screw extruder, even if there is a large amount of water in the raw material, there will be no forward extrusion failure due to backflow, and stable manufacturing can be performed.

■ In the manufacturing process, there is no energy loss due to friction, so power consumption is low, contributing to cost reduction.

■ Extrusion using a twin-screw extruder, in particular extrusion is performed while applying shear stress in a high heat treatment block, making it possible to completely sterilize not only general bacteria derived from raw materials but also heat-resistant bacteria, making it extremely hygienic. Edible dough can be obtained.

[Brief explanation of drawings]

The figures show an apparatus for carrying out the present invention; FIG. 1 is a partially cutaway front view, and FIG. 2 is a longitudinal sectional front view showing the arrangement of screw elements. B-warming/feeding barrel, B2...preheating barrel,
B3... Barrel for shoe king, 84-B6... Barrel for cooling, D... Gui, L... Shooter, 1)... Pipe for adding water, 12.31.41... Screw element for transfer, 21... Knee ding disk, 32...reverse screen, knee element, 5...orifice, 2...feeder, 3...heater Patent applicant Akini Umemura, patent attorney representing the Food Industry Extrusion Shoes Technology Research Association]゛( ]゛(2 others 1., J'm Figure 1 Figure 2

Claims (8)

[Claims] (1) In the twin-screw extruder, raw flour is
A preheating step of heating and kneading the raw materials until they become semi-raw while adding water, and heating and kneading the preliminarily heated and kneaded raw materials at a relatively high temperature under pressure to completely gelatinize the hydrated raw materials. Edible food using a twin-screw extruder that combines a cooking process, a cooling process in which the gelatinized raw material is gradually cooled, and a process in which it is extruded into the desired shape using a die at the rear end of this cooling process. Fabric manufacturing method. (2) A method for producing edible dough using a twin-screw extruder according to claim 1, wherein the preheating step is performed at a temperature of about 100°C. (3) A method for producing edible dough using a twin-screw extruder according to claim 1 or 2, wherein the cooking step is performed at a temperature of about 150°C. (4) The cooking process involves the action of sterilizing bacteria in the dough by shearing stress generated by a transfer screw element and a reverse screw element that performs a transfer action in the opposite direction to this transfer screw element. A method for producing edible dough using the twin-screw extruder according to any one of claims 1 to 3. (5) A raw material input zone equipped with a feeder for raw material supply and a water supply mechanism, a preheating zone where the input raw materials are heated and kneaded at a relatively low temperature, and a comparison of preheated raw materials in a semi-raw state under pressure. A cooking zone that aims to gelatinize the hydrated raw material while heating and kneading at a high temperature, a cooling zone that gradually cools the gelatinized raw material dough, and a biaxial die that extrudes and molds the cooled dough. Edible dough manufacturing equipment using a mold extruder. (6) Preheating zone is located inside the barrel for shearing, crushing,
An edible dough manufacturing apparatus using a twin-screw extruder according to claim 5, which is a rotatable combination of one or more stages of kneading disks for kneading. (7) The cooking zone is designed to generate high pressure inside a barrel that can be heated from the outside using a screw element that has a transfer function and a reverse screw element that prevents the transfer of raw materials by this screw element with an appropriate pressure. An edible dough manufacturing apparatus using a twin-screw extruder according to claim 5 or 6, which utilizes a structure configured as follows. (8) The cooling processing zone utilizes a structure in which a screw element for transfer is fitted inside a barrel having a cooling function.
An apparatus for producing edible dough using the twin-screw extruder described in any of the above.