MXPA00005971A - Pelletisation process - Google Patents

Abstract

A process for the production of a fermenting material which comprises forming a dough by adding water to a dried gluten in an amount of from 19 to 60%by weight based on the weight of the dough, pelletising the dough and, if necessary, adding water to adjust the moisture content to from 35 to 60%by weight based on the weight of the pellets before sterilising the pellets by steam treatment. A koji product produced by koji making using one or more fermenting materials obtained as well as a seasoning produced therefrom.

Description

EMPASTILLADO PROCESS FIELD OF THE INVENTION The present invention relates to a process of pasting, and more particularly to a process for the pasting of a dried gluten material which can be used as a fermentation material for the production of fermented products such as soy sauce and toppings. , etc.

BACKGROUND OF THE INVENTION EP-A-0 711 510 claims a process for the production of a fermentation material which comprises using 5-1-00% by weight of a dry gluten product and 95-0% by weight of wheat or material Prime, add steam to the material so that the moisture content is adjusted when granulating, within a range of 12-18%, and granulation followed by steam treatment. It is claimed that steam treatment denatulates wheat gluten. Adjustment of moisture content to the required range is said to facilitate granulation, which, upon vaporization, obtains satisfactory denaturation of the protein. The dry gluten product is claimed to include dry wheat gluten product, dried corn gluten product and the like. The fermentation material can be used in the preparation of fermented products such as soy sauce, millet, dressings and the like. However, when steam is added directly to gluten, in the case of saturated steam and wheat gluten and talcum, there are problems not only with the formation of undesirable hard lumps, which tend to be eliminated by sieving causing losses, but that it is also very difficult to obtain a moisture content of 12-18%, especially for larger scale production. Vitality causes elasticity of the wheat gluten paste when water is added. PI AN 87-189049 describes a method for preparing a brewing material for Koji, by heating flour to denature its protein, hydrating it to a moisture content of 30-50%, granulating and treating with steam.

BRIEF DESCRIPTION OF THE INVENTION We have found that these problems can be solved by devitalizing wheat gluten before tabletting. Devitalization is part of the denaturation and can be obtained by heat treatment. Before the devitalization, water can be added in an amount of 19 to 60%, depending on the degree of devitalization, to form a paste and to facilitate the tabletting. Additional water can be introduced into the granules, if necessary, to adjust the moisture content from 35 to 60% based on the weight of the granules, so that they are suitable for Koji fermentation, before sterilization and additional steam denaturation . There are no lumps or losses are generated. The process of devitalization is necessary only when gluten is vital, for example, in the case of vital wheat gluten. Accordingly, the present invention provides a process for the production of a fermentation material which comprises forming a paste by adding water to dry gluten in an amount of 19 to 60% by weight based on the weight of the paste, filling the paste and add water to adjust the moisture content to 35-60% by weight, based on the weight of the granules before sterilizing the granules by steam treatment.

DETAILED DESCRIPTION OF THE INVENTION In this description "tabletting" is used as a synonym for "granulate". The dried gluten can be wheat gluten, corn gluten or rice gluten, and one or more glutens can be used to produce the granule. When the dried gluten used is wheat gluten, it is advantageous to devitalize wheat gluten before adding water, although devitalization is not necessary. Devitalization can be carried out by heating to a temperature above 60 ° C, for example by means of hot air or contact with a hot surface, in a dryer, an oven or by using a steam-coated container. The duration of devitalization can be from 5 seconds to 3 hours and depends on the temperature used, generally longer periods of time are required at lower temperatures. For example, devitalization can be carried out at a temperature of 60 ° C to 200 ° C for a period of 3 hours to 5 seconds, preferably 100 ° C to 120 ° C for a period of 30 to 5 minutes. Before adding water to dried gluten, it is advantageous to add wheat such as wheat flour or wheat bran as the source of carbohydrates to dry gluten. The amount of wheat added can be up to 90%, preferably from 5 to 50% and especially from 10 to 30% by weight based on the weight of the dried raw material. The amount of water added to the dried gluten is preferably 30 to 45% by weight based on the weight of the pasta. The amount of water added depends on the vitality of the gluten as well as the composition of the raw materials. The dough can be compacted by conventional means such as a screw press, a meat grinder or a granule mill. The granules can be cylindrical in shape with an average diameter of 1 to 10 mm, preferably 2 to 8 mm, and especially of 4 to 6 mm, or can have a spherical shape with a diameter of 1 to 10 mm, preferably 2 mm. to 8 mm and especially from 4 to 6 mm. The water that is added to the granules before sterilization by steam treatment preferably increases the moisture content from 40 to 50% by weight based on the weight of the granules. After cooling, the granules can be turned into Koji by mixing them with carbohydrates, inoculating them with Aspergilli and fermenting the Koji substrate for approximately 2 days. The Koji can then be converted into a dressing by conventional methods or by a method as described in EP 0640294 or in our co-pending patent applications EP-A-96114850.9, (EP 0829205), EP-A-96202309.9 (EP 0824873), all of which is incorporated herein by reference. The use of the granules of the present invention in Koji fermentation provides a good hydrolysis yield due to the ease of disintegration during hydrolysis. Advantageously, the process can be carried out continuously, for example using a filament line concept but with a lower precision with respect to the thickness of the pulp and the diameter of the filaments. The continuous process includes mixing the ingredients (gluten dry devitalization, wheat flour, wheat bran), tabletting, addition of water, steam treatment, cooling and inoculation of spore suspension. The substrate is then loaded into the Koji machine for fermentation and subsequent hydrolysis.

EXAMPLES The following examples further illustrate the invention.

Example 1 kg of vital wheat gluten are devitalized by heating it to 100 ° C in a ribbon mixer with a steam jacket for 30 minutes. The wheat gluten devitalized in this way is mixed with 2.5 kg of wheat bran and 12.5 kg of wheat flour. Water is added to the mixture to obtain a moisture content of 33%, w / w. The paste that is formed is then fed to a chopper to produce cylindrical granules, each with a diameter of 5 mm. Additional water is introduced to the granules so that the moisture content of the granules is 47% w / w. The granules are then subjected to steam at 100 ° C for 10 minutes and then cooled to a temperature below 40 ° C. The cooled granules are mixed with a liquid suspension of 25 g of spore inoculum of Aspergillus oryzae. The Koji fermentation is carried out for 42 hours at 27-33 ° C. The matured Koji is hydrolyzed by adding water to obtain a hydrolyzate with a total solids content of 20.2% m / m. The hydrolysis is carried out at 4 ° C for 2 weeks, before 2 weeks of moromi fermentation, where salt is added at a level of 12% m / m. Moromi is pressed and the transparent sauce is treated with heat at 90 ° C for 20 minutes. The product prepared in this way has a light color, a good aroma and an excellent flavor.

Example 2 Water is added directly to a mixture of 35 kg of rice gluten, 2.5 kg of wheat bran and 12.5 kg of wheat flour, to obtain a moisture content of 45% w / w. The paste that is formed is then fed into a chopper to produce cylindrical granules, each with a diameter of 5 mm. A similar procedure is followed for steam treatment, Koji processing and sauce preparation, as in example 1. The product prepared in this way has a light color, good aroma and excellent flavor.

Example 3 A procedure similar to that of Example 2 is carried out, except that corn gluten powder is used instead of rice gluten powder and the moisture content of the pasta before the tabletting is 35% w / w. Additional water is introduced to the granules before the steam treatment so that the moisture content of the granules is 47% w / w. The product prepared in this way has a light color, a good aroma and excellent flavor.

Example 4 A procedure similar to that of Example 1 is carried out, except that 35 kg of devitalized wheat gluten is mixed with 2 kg of wheat bran and 4 kg of wheat flour, and water is added to provide a moisture content of 40%. % p / p before tabletting.

Example 5 A procedure similar to that of Example 1 is carried out, except that 35 kg of devitalized wheat gluten are mixed with 5 kg of vital wheat gluten, 2.4 kg of wheat bran and 4.7 kg of wheat flour, and water is added to provide a moisture content of 33% w / w before tabletting.

Example 6 A procedure similar to that of Example 1 is carried out, except that the devitalization of wheat gluten is carried out by directly adding superheated steam to 1 bar and 150 ° C to wheat gluten before mixing it with carbohydrates and forming the granules.

Example 7 A procedure similar to that of Example 1 is carried out, except that the devitalization of the wheat gluten is carried out in a fluidized bed dryer with an inlet air temperature adjusted to 110 ° C.

Example 8 A procedure similar to that of Example 1 is carried out, except that the diameter of the granules is 3 mm.

Example 9 A procedure similar to that of Example 1 is carried out, except that the tabletting is carried out using a screw press.

Example 10 A procedure similar to that of Example 1 is carried out, except that the granulator or splicer used produces spherical granules with a diameter of 3-8 mm.

Example 11 A procedure similar to that of Example 1 is carried out, except that 25 kg of corn gluten granules prepared as described in Example 3 are fermented together with the wheat gluten granules.

Example 12 A procedure similar to that of Example 3 is carried out, except that 35 kg of devitalized wheat gluten are mixed as in example 1, together with 35 kg of rice gluten, 5 kg of wheat bran and 25 kg of wheat flour. wheat, before the tabletting.

Example 13 A procedure similar to that of Example 11 is carried out, except that 40 kg of milled soybean defatted and steam-treated are used instead of corn gluten.

Example 14 A procedure similar to that of Example 1 is carried out, except that wheat flour and wheat bran are mixed with vital wheat gluten, before devitalization.

Example 15 A procedure similar to that of Example 1 is carried out, except that an inoculum of lactic acid bacteria is added at 7 x 105 cfu / g to the steam-treated granules before Koji fermentation and the hydrolysis is carried out at 35 ° C during 2 days. The pressing is carried out after the hydrolysis and salt is added to a level of 12% m / m.

Example 16 A procedure similar to that of Example 1 is carried out, except that the devitalization step is omitted and water is added to the mixture of wheat gluten, wheat bran and wheat flour to obtain a moisture content of 20%. / p.

Claims (15)

1. A process for the production of a fermentation material which comprises forming a paste by adding water to dry gluten, in an amount of 19 to 60% by weight, based on the weight of the pasta, pasting the pasta, and if it is necessary, add water to adjust the moisture content from 35 to 60% by weight based on the weight of the granules, before sterilizing the granules by steam treatment.

2. The process as described in claim 1, wherein one or more glutens are used to produce the granulate.

3, The process as described in claim 1, wherein the dried gluten is wheat gluten, corn gluten or rice gluten.

4. The process as described in claim 1, wherein the dried gluten used is vital wheat gluten, the wheat gluten is devitalized before adding the water.

5. The process as described in claim 4, wherein the devitalization is carried out at a temperature of 60 ° to 200 ° C for a period of 3 hours to 5 seconds.

6. The process as described in claim 4, wherein the devitalization is carried out by means of superheated steam, hot air and a dryer, an oven or a steam-lined container.

7. The process as described in claim 1, wherein wheat is added to the dried gluten before adding water to the dried gluten and pasting.

8. The process as described in claim 4, wherein wheat is added to the dried gluten before the devitalization of the wheat gluten.

9. The process as described in claim 7 or claim 8, wherein the wheat is wheat flour or wheat bran.

10. The process as described in claim 1, wherein the dough is stuffed by a screw press, a meat grinder or a granule mill.

11. The process as described in claim 1, wherein the granules have a cylindrical shape or a spherical shape and with an average diameter of 1 to 10 mm.

12. A Koji product, produced by making Koji using one or more fermentation materials obtained by a process according to any of the preceding claims.

13. A Koji product, produced as described in claim 12, and together with other protein substrates.

14. A process for preparing Koji product, which comprises mixing granules obtained by a process according to any of the preceding claims, with carbohydrates, inoculating with Aspergilli and fermenting the Koji substrate for a period of time to elaborate fermented Koji so that Enzymes are produced which are capable of hydrolyzing protein and carbohydrates.

15. A dressing made from a Koji product, as described in either of claim 12 or claim 13.