WO2007117123A1

WO2007117123A1 - Apparatus and method for manufacturing long term preserving bioactive packed whole bean curd

Info

Publication number: WO2007117123A1
Application number: PCT/KR2007/001766
Authority: WO
Inventors: Dong-Kwon Lee; Chang-Youl Lee; Jin-Woo Lee
Original assignee: Dong-Kwon Lee; Chang-Youl Lee; Jin-Woo Lee
Priority date: 2006-04-12
Filing date: 2007-04-11
Publication date: 2007-10-18
Also published as: KR200421592Y1

Abstract

Provided is an apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time. The apparatus includes: a first mixing basin (10); a far-infrared ray steaming basin (11); a once-through type boiler (9); a plate type cooler (12); a second high-speed homo-mixer blending basin (13); a filling-packing machine (14); a hand truck (15); a steam multi-level pressure-type molding, sterilizing, and cooling apparatus (16); a conveyer belt (21); and a refrigeration reservoir (17) for storing and preserving the whole bean curd transferred through the conveyer belt (21).

Description

APPARATUS AND METHOD FOR MANUFACTURING LONG TERM PRESERVING BIOACTIVE PACKED WHOLE BEAN

CURD

Technical Field

[1] The present invention relates to an apparatus and method for manufacturing packed whole bean curd which contains all bioactive substances of soybean and can be preserved for a long time in a fresh and hygienic condition. Background Art

[2] Bean curd (or tofu) is conventionally manufactured according to a method comprising the steps of: selecting and cleaning soybean and then immersing it into water; pulverizing the water-soaked soybean to obtain soybean juice; steaming the soybean juice and filtering it from bean curd refuse; adding a coagulating agent to the filtered soybean juice to obtain uncurdled bean curd; and pressing the uncurdled bean curd to obtain desired bean curd.

[3] However, in such a conventional method, there has been a problem in that the bean curd refuse corresponding to about 120% of total soybean weight is produced in the step of filtering the soybean juice. Further, wastewater about BOD 10,000ppm is produced in the step of pressing the uncurdled bean curd.

[4] In addition, considering the amount of soybean used as a raw material, a total production of bean curd is not sufficient.

[5] Therefore, the inventor has previously developed an apparatus and method for manufacturing functional whole bean curd that can be preserved for a long time (disclosed in Korean Patent No. 10-0451483).

[6] In this apparatus and method, the apparatus includes a high-speed multi-level pump, a mixing basin, a steaming basin, a cooler, a blending basin, a high pressure equalizer, a filling-packing machine, a once-through type boiler, a steam molder, and a cooling system. Further, the method is performed as follows: Minutely pulverized full fat- activated raw soybean flours are mixed with soft water in the mixing basin in the ratio of lkg : 5.5f so as to obtain raw soybean milk; The mixture is steamed in the steaming basin at 102⁰C to obtain steamed soybean milk and is then transferred to the cooler to obtain cooled soybean; The cooled soybean is mixed with the coagulating agent in the blending basin, and the mixture of the cooled soybean and the coagulating agent is equalized in the high pressure equalizer; The equalized mixture is packed by the filling-packing machine and is then curdled according to a natural coagulation scheme for 15 minutes at 95⁰C in the steam molder; Thus obtained soybean is sterilized for 10 minutes at 121°C, thereby obtaining whole bean curd. As a result, by addressing a problem of the conventional bean curd manufacturing method, 100% increase in the production of whole bean curd has been achieved as compared with the amount of soybean used as a raw material. In addition, since bean-curd refuse and wastewater are not produced during the manufacture of the whole bean curd, there is an advantage in that manufacturing time is reduced.

[7] However, the invention has disadvantages as follows:

[8] First, excessive energy is consumed by the high-speed multi-level pump and the high pressure equalizer which perform processes in which full fat-activated raw soybean flour, soft water, and raw soybean are produced in the high-speed multi-level pump, the raw soybean milk is then homogeneously mixed in the mixing basin, the mixture of cooled soybean milk and the coagulating agent is produced in the blending basin and is subject to a second equalization by the high pressure equalizer at 150 to 400 bar. Therefore, according to the conventional apparatus and method, a manufacturing cost of whole bean curd is expensive.

[9] Second, since the mixture of the cooled soybean milk and the coagulating agent is filled in a specific container and is then firstly curdled for 15 minutes at 95°C in the steam molder according to the natural coagulation scheme, protein molecules are clustered during the manufacture of whole bean curd, which leads to decrease in a binding capacity. Therefore, a protein texture and shape of manufactured functional whole bean curd are damaged and thus easily broken, resulting in quality deterioration. Accordingly, the conventional apparatus and method have a problem in terms of product quality.

[10] Third, pectin, anthocyanin, organic germanium, and so on are lost in bioactive substances since full fat-activated raw soybean flour used as a raw material is obtained by peeling off soybean. Therefore, according to the conventional apparatus and method, there is a problem in that some nutrients of bioactive substances of soybean are lost.

[11] Fourth, when the conventional apparatus is installed in a place where clean room equipment is not provided, there is a problem in terms of hygiene and freshness.

[12] Meanwhile, an invention disclosed in Korea Patent No. 10-2003-0010418, titled as freeze-dried whole-tofu with improved storage stability and manufacture thereof, is developed. The method of the invention includes the steps of: 1) producing raw soybean milk by mixing full fat-activated raw soybean flour and water with five to six times the amount of full fat- activated raw soybean flour; 2) producing steamed soybean milk by heating the raw soybean at 95 to 100⁰C for 5 to 10 minutes; 3) cooling the steamed soybean milk so that the product temperature of 95 to 100⁰C is cooled down to 80 to 85°C; and 4) producing whole bean curd in which a natural food additive is added by injecting a 0.5% coagulating agent (or GDL) together with a 5% natural food additive into soybean milk. Therefore, by adding the natural food additive to whole bean curd manufactured according to the natural coagulation scheme, there is a merit in terms of taste and functionality.

[13] However, the invention has problems as follows.

[14] First, the whole bean curd is molded according to the natural coagulation scheme without being pressed, and full fat-activated raw soybean flour and water are mixed in the ratio of 1:5.5 exactly so that the saccharinity of soybean milk is 12° when measured by a saccharometer. This is a very important process since binding capacity and resilience are excellent when the saccharinity of soybean milk is 12°. However, when the full fat-activated raw soybean flour is added with water five to six times the amount of full fat-activated raw soybean flour, the binding capacity and the resilience deteriorate during the manufacture of whole bean curd since the saccharinity of raw soybean milk is not uniform. Therefore, when whole bean curd is manufactured by adding a freeze-dried food additive according to the conventional method, the whole bean curd may be damaged, causing a quality problem.

[15] Second, when the saccharinity of raw soybean milk is 12° (measured by a saccharometer), it is preferable that steamed soybean milk is produced in a pressure-type steaming basin within five minutes at 102⁰C. However, while the process is performed for 5 to 10 minutes at 95 to 100⁰C, there has been a problem in that binding capacity and resilience deteriorate when whole bean curd is manufactured by adding the freeze- dried food additive according to the conventional method.

[16] Third, it is preferable that a coagulating agent is injected after the mixture of the steamed soybean milk and the natural food additive are added and equalized. However, coagulation reaction between soybean milk and coagulating agent (GDL) starts when a 0.5% coagulating agent (GDL) and a 5% natural food additive are simultaneously injected into soybean milk at 80 to 85⁰C. As a result, the natural food additive cannot be homogeneously mixed. Therefore, there has been a problem in terms of productivity due to quality deterioration when whole bean curd is manufactured by adding the freeze-dried food additive according to the conventional method. Disclosure of Invention Technical Problem

[17] The present invention provides an apparatus and method for manufacturing packed whole bean curd having bioactive substances and preserved for a long time. The apparatus is an effective energy saving system and includes a clean room, bioactive whole raw soybean particles, a water softener, a first mixing basin, a once-through type boiler, a far-infrared steaming basin, a plate type cooler, a second high-speed homo- mixer blending basin for mixing an enzyme and a coagulating agent, a filling-pacing machine, a hand truck, a steam multi-level pressure-type molding, sterilizing, and cooling apparatus, a conveyer belt, and a refrigeration reservoir. In this system, a reaction between soybean protein and enzyme is activated. Accordingly, whole bean curd can be produced in a hygienic condition in a cost effective manner regardless of skills of operators. The produced whole bean curd contains all bioactive substances without loss of nutrients and has an excellent binding capacity, resilience, and tasty flavor.

[18] The present invention also provides an apparatus and method for manufacturing packed whole bean curd having bioactive substances and preserved for a long time, wherein the whole bean curd can be homogeneously produced to have improved functionality and taste by adding a variety of natural food additives. Technical Solution

[19] According to an aspect of the present invention, there is provided an apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time, the apparatus comprising: a first mixing basin 10 that is provided with a soft water supply pipe, which is connected to a water supply source, and an ingredient injection hopper and that includes an agitator for producing raw soybean milk by mixing ingredient and soft water; a far-infrared ray steaming basin 11 that includes a steam injecting pipe 1 Ia for steaming the raw soybean milk supplied from a raw soybean milk supply pipe connected to the first mixing basin 10; a once-through type boiler 9 that is connected to a steam supply pipe 20 for supplying steam to the steam injecting pipe 11a and supplies steam to the far-infrared steaming basin 11 and that is connected to the first mixing basin 10 through a steam generating soft water supply pipe 6; a plate type cooler 12 that is connected to the far-infrared steaming basin 11 through a steamed soybean milk supply pipe 24, is connected to a groundwater supply pipe 25, and includes a cooling pipe 12a so as to cool off steamed soybean milk; a second high-speed homo-mixer blending basin 13 that includes a cooled soybean milk supply pipe 23, which provides the steamed soybean milk cooled in the plate type cooler 12, a cooled soybean milk supply extension 13b, a cooled soybean milk mixture outlet pipe, a coagulating agent injection hopper 13c, and a second high-speed homogeneous agitator 13a which homogeneously mixes a mixture of the cooled soybean milk; a filling-packing machine 14 that fills the cooled soybean milk mixture, which is mixed in the second high-speed homo-mixer blending basin 13, in a packing container; a hand truck 15 that includes a moving wheel 15b and a stainless tray plate 15a for loading the packing container filled by the filling-packing machine 14; a steam multilevel pressure-type molding, sterilizing, and cooling apparatus 16 that is connected to the hand truck 15 and produces the packed whole bean curd by sterilizing, molding, and cooling by the aid of pressure; a conveyer belt 21 that is connected to the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 and transfers the cooled packed whole bean curd; and a refrigeration reservoir 17 for storing and preserving the whole bean curd transferred through the conveyer belt 21.

[20] The first mixing basin includes a soft water supply extension, a first agitator, a soft water level indicating window, and an injection hopper.

[21] The far- infrared steaming basin includes a pressure-type lid, a ceramic radiator, a steam jet drain pipe, a steamed soybean milk outlet pipe, and a pressure safety valve.

[22] The steaming basin includes a digital steam temperature sensor. A steam temperature indicator is installed on a control panel disposed to the front side of the steaming basin.

[23] The once-through type boiler generates steam by using heavy oil as a heat source.

[24] The plate type cooler is constructed such that groundwater is provided through a pump and steamed soybean milk is passed through a cooling pipe, thereby obtaining cooled soybean milk having a temperature of 10 to 12 ⁰C.

[25] The second high-speed homo-mixer blending basin includes a screw-type impeller rotating at the speed of 10,000 RPM as an agitating means, a cooled soybean milk extension, and a mixture outlet pipe through which a mixture of a cooled soybean milk, a natural food additive, an enzyme, and a coagulating agent are discharged

[26] The filling-packing machine includes a refrigeration reservoir for storing the mixture of the cooled soybean milk, the natural food additive, the enzyme, and the coagulating agent and a continuous automatic filling-packing system.

[27] The hand truck is constructed such that a multi-layered stainless tray plate can be inserted in a multi-level rack structure.

[28] The steam multi-level pressure-type molding, sterilizing, and cooling apparatus includes an opening/closing door through which the hand cart is introduced, and a steam jet supply pipe which is vertically disposed on three lateral inner walls of a molding, sterilizing, and cooling chamber operating by the use of pressure and a far- infrared ray. Steam jet nozzles are disposed along the steam jet supply pipe with a specific interval. A cooled water jet supply pipe is disposed through an upper inner wall and three lateral inner walls so as to be connected with a groundwater source. Cooled water jet nozzles are disposed along the cooled water jet supply pipe with a specific interval.

[29] Ceramic plates are disposed to the inner upper portion and three lateral inner walls of the molding, sterilizing, and cooling chamber.

[30] A steam pressure reducing valve is disposed in the middle of the steam jet supply pipe. [31] The steam multi- level pressure-type molding, sterilizing, and cooling apparatus includes a digital temperature indicator. The control panel includes a digital temperature indicator for indicating a temperature sensed by the temperature sensor.

[32] The control panel of the steam multi-level pressure-type molding, sterilizing, and cooling apparatus includes a power switch, a steam supply switch, a steam temperature setting switch, a steam temperature setting indicator, a steam supply timer switch, and a molding, sterilizing, and cooling chamber pressure gauge.

[33] A pressure safety valve is disposed an outer upper portion of the steam multi-level pressure-type molding, sterilizing, and cooling apparatus.

[34] A cooling compressor, a cooler/air handling unit, and an air curtain are installed in the refrigeration reservoir.

[35] An air shower room, the cooling compressor, and a clean air handling unit are disposed to an entrance or exit of the clean room so that an environment inside the clean room remains at a temperature of 20 to 22⁰C and a Class 100,000 to 200,000 EA/ FT3.

[36] The filling-packing machine includes a refrigeration reservoir for storing the mixture of the cooled soybean milk, the natural food additive, the enzyme, and the coagulating agent. Further, the filling-packing machine includes a continuous automatic filling-packing unit.

[37] The hand truck is constructed such that a multi-layered stainless tray plate can be inserted in a multi-level rack structure.

[38] The steam multi-level pressure-type molding, sterilizing, and cooling apparatus includes an opening/closing door through which the hand cart is introduced, and a steam jet supply pipe which is vertically disposed on three lateral inner walls of a molding, sterilizing, and cooling chamber. Steam jet nozzles are disposed along the steam jet supply pipe with a specific interval. A cooled water jet supply pipe is disposed through an upper inner wall and three lateral inner walls so as to be connected with a groundwater source. Cooled water jet nozzles are disposed along the cooled water jet supply pipe with a specific interval.

[39] Ceramic plates are disposed to the inner upper portion and three lateral inner walls of the molding, sterilizing, and cooling chamber.

[40] A steam pressure reducing valve is disposed in the middle of the steam jet supply pipe.

[41] The steam multi- level pressure-type molding, sterilizing, and cooling apparatus includes a digital temperature indicator. The control panel includes a digital temperature indicator for indicating a temperature sensed by the temperature sensor.

[42] The control panel of the steam multi-level pressure-type molding, sterilizing, and cooling apparatus includes a power switch, a steam supply switch, a steam temperature setting switch, a steam temperature setting indicator, a steam supply timer switch, and a molding, sterilizing, and cooling chamber pressure gauge.

[43] A cooling compressor, a cooler/air handling unit, and an air curtain are installed in the refrigeration reservoir.

[44] The soft water supply pipe and the steam generating soft water supply pipe are branched from the water supply pipe connected to the water supply source. A water softener, a residual chlorine remover, and an ultraviolet sterilizer are disposed along the water supply pipe.

[45] Hereinafter, a method of manufacturing packed whole bean curd having bioactive substances will be described, wherein the method is performed by an apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time according to the present invention.

[46] The method includes the steps of: producing raw soybean milk by injecting and agitating soft water and bioactive whole raw soybean particles into a first mixing basin 10 of the apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time, and supplying the produced raw soybean milk to a far-infrared steaming basin 11 ; steaming the raw soybean milk by supplying steam generated in a once-through type boiler 9 to the steaming basin 11 ; cooling the steamed soybean milk by transferring it to a plate type cooler 12, and transferring the cooled soybean milk to a second high-speed homo-mixer blending basin 13; producing a mixture of soybean milk, an enzyme, and a coagulating agent by agitating the transferred cooled steamed soybean milk by the use of a second high-speed homogeneous agitator 13a while injecting the enzyme, followed by the injection of the coagulating agent; transferring the mixture to a filling-packing machine 14 so as to be packed in an oxygen barrier packing container in a filling-packing manner and then transferring it to a hand truck 15; producing packed whole bean curd by placing the hand truck 15 loaded with the filling-packed mixture to a steam multi-level pressure- type molding, sterilizing, and cooling apparatus 16; and preserving the packed whole bean curd by transferring it to a refrigeration reservoir 17.

[47] Preferably, the soft water and the bioactive whole raw soybean particles are mixed in the first mixing basin in the ratio of 5.5: 1.

[48] In a molding, sterilizing, and cooling chamber 16c operating by the use of pressure and a far- infrared ray, multi-level pressure-type sterilizing are performed so that packed whole bean curd having bioactive substances and preserved for a long time together with packed whole bean curd having bioactive substances and added with a natural food additive are subject to a first pressure-sterilization process at 85 to 9O⁰C, followed by a second pressure-sterilization process at 100 to 121⁰C.

[49] In the second high-speed homo-mixer blending basin, an enzyme is firstly injected to the cooled soybean milk through an ingredient injection hopper and is then agitated with the cooled soybean milk for equalization. Secondly, a coagulating agent is injected to homogeneously produce a mixture of the cooled soybean milk, the enzyme, and the coagulating agent.

[50] The mixture is transferred to the filling-packing machine 14 so as to be filling- packed in the oxygen barrier packing container. Then, the packed mixture is contained in the hand truck 15 and then transferred to the steam multi- level pressure-type molding, sterilizing, and cooling apparatus 16. In this case, the supply of steam heat is regulated in consideration of a characteristic in which the enzyme is inactive at a specific temperature and time. Since the enzyme is activated for 40 to 60 minutes at 55 to 65⁰C, this condition is used to activate a reaction between soybean protein and enzyme, thereby promoting a crosslinking polymerization reaction between soybean protein molecules. Thus, with being bonded to a coagulating agent, packed whole bean curd having bioactive substances is formed to have an excellent binding capacity, resilience, soft shape, and tasty flavor. Thereafter, the whole bean curd is pressure- sterilized at 85 to 21⁰C, and is then subject to a pressure-cooling process at 10 to 12⁰C, and then stored and aged in the refrigeration reservoir 17 for maintaining a temperature of 10 to 12 ⁰C. As a result, packed whole bean curd having bioactive substances and preserved for a long time is obtained which has an excellent sanitation and freshness.

Advantageous Effects

[51] According to an apparatus and method for manufacturing packed whole bean curd having bioactive substances and preserved for a long time, 100% productivity improvement can be expected since energy is saved by decreasing the number of steps of manufacturing (in a high-speed multi-level pump and a high pressure equalizer), such that raw soybean milk and steamed soybean milk are produced by the use of full fat- bioactivated raw soybean flour and soft water, and thereafter are cooled off. Then, in the second homo-mixer blending basin, a mixture of the cooled soybean milk, the enzyme, and the coagulating agent is properly produced. As a result, a manufacturing cost of the packed whole bean curd having bioactive substances and preserved for a long time is reduced, which is significantly important factor for attracting customers.

[52] In addition, the use of enzyme promotes a crosslinking polymerization reaction between protein molecules containing all protein components of soybean by utilizing steam heat. The result is then boned with a coagulating agent according to a natural coagulation scheme. Therefore, there is an advantage in that packed whole bean curd having bioactive substance and preserved for a long time can be manufactured to have a good resilience and tasty favor as well as high marketability.

[53] In addition, since whole bean curd needs to maintain its freshness, and its quality is highly affected by manufacturing environments, the apparatus for manufacturing the packed whole bean curd preserved for a long time according to the present invention is installed in a clean room. Therefore, it is possible to maintain whole bean curd in a hygienic and fresh condition.

[54] In addition, water significantly affects in the preservation and quality of bean curd, considering that 86% whole bean curd is composed of water. Therefore, water used in the present invention is softened by a water softener, and its residual chlorine is removed by a residual chlorine remover. Then, the result is sterilized by an ultraviolet sterilizer to obtain water having a hardness of 0. As a result, it is possible to increase quality of the packed whole bean curd preserved for a long time.

[55] In addition, whole bean curd is composed of protein, and thus it is very important to preserve the whole bean curd regardless of protein variation in order to improve quality of the whole bean curd. Therefore, an oxygen barrier packing container and an oxygen barrier wrapping sheet are used as a packing container in the method of the present invention. Further, since the whole bean curd is sterilized and disinfected using steam to facilitate long term preservation, it is possible to increase quality of the packed whole bean curd having bioactive substances and preserved for a long time.

[56] In addition, since a temperature indicator and a timer indicator of a steam multilevel pressing, molding, sterilizing and cooling apparatus operate in a digital manner, an enzyme reaction time and a sterilization/disinfection time can be precisely recognized. Therefore, it is possible to manufacture the packed whole bean curd having bioactive substances and preserved for a long time with a good and uniform quality.

[57] In addition, there is an advantage in that the whole bean curd manufactured according to the present invention can be effective in preventing lifestyle habit illnesses (e.g., obesity, hypertension, diabetes, heart disease, etc.) since all bioactive substances of soybean are included without loss.

[58] In addition, the packed whole bean curd having bioactive substances, preserved for a long time, and added with a natural food additive (i.e., spinach powder, carrot powder, and green tea powder) has a clear natural color and a high vitamin C component as well as a large amount of mineral and fiber components. Therefore, the packed whole bean curd is effective as a functional food, that is, a health food with low calorie. Moreover, when eggs or cheese powders are used as the natural food additive, the packed whole bean curd is effective as a health food for children in a growth period or for aged people. Furthermore, when Korean red ginseng powder and safflower seed powder are used as the natural food additive, the packed whole bean curd is effective as a food for preventing lifestyle habit illnesses. Brief Description of the Drawings [59] FIG. 1 is a view for illustrating a configuration of an apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time according to the present invention. [60] FIG. 2 is a perspective view of a steam multi-level pressure-type molding, sterilizing, and cooling apparatus.

[61] FIG. 3 is a vertical cross-sectional front view of a clean room.

[62] FIG. 4 is a flowchart of a manufacturing process of packed whole bean curd having bioactive substances and preserved for a long time. [63] FIG. 5 is a flowchart of a manufacturing process of packed whole bean curd having bioactive substance, preserved for a long time, and added with a natural food additive. [54] *** Reference Numbers in the Drawings ***

[65] 1 : water supply source 2 : water supply pipe

[66] 3 : water softener 4 : residual chlorine removing machine

[67] 5 : ultraviolet sterilizer 6 : steam generating soft water supply pipe

[68] 7 : soft water supply pipe 8 : ingredient injection hopper

[69] 9 : once-through type boiler 10 : first mixing basin

[70] 10a : soft water supply extension 10b : first agitator

[71] 10c : soft water level indicating window 1 l:far-infrared steaming basin

[72] l la : steam jet drain pipe 1 Ib : pressure-type lid

[73] 1 Ic : ceramic plate 1 Id: raw soybean milk supply extension

[74] l ie : pressure safety valve 12 : plate type cooler

[75] 12a : cooling pipe 13 : second high-speed homo-mixer blending basin

[76] 13a : second high-speed homo-mixer blending basin 13b:cooled soybean supply extension

[77] 13c : coagulating agent injection hopper

[78] 14 : filling-packing machine 14a : refrigeration reservoir

[79] 14b : conveyer belt 15 : hand truck

[80] 15a : stainless tray plate 15b : moving wheel 15c : plastic box 16 : cooling apparatus

[81] 16a : opening/closing door 16b : control panel

[82] 16c : molding, sterilizing, and cooling chamber

[83] 16d : steam jet supply pipe 16e : steam jet nozzle

[84] 16f : cooled water jet supply pipe 16g : cooled water jet nozzle

[85] 16h : pressure safety valve 16i : groundwater supply pipe

[86] 16j : moving wheel 16k : ceramic plate

[87] 161 : steam pressure reducing valve 17 : refrigeration reservoir

[88] 17a : door 17b : air curtain

[89] 17c : cooling compressor 17d : cooler/air handling unit [90] 18 : clean room 18a : clean air handling unit

[91] 18b : cooling compressor 18c : air shower room

[92] 18d : packed whole bean curd input part 19 : control pannel

[93] 20 : steam supply pipe 21 : conveyer belt

[94] 22 : raw soybean milk supply pipe 23 : cooled soybean milk supply pipe

[95] 24 : steamed soybean milk supply pipe 25 : groundwater supply pipe

[96] 26 : groundwater outlet pipe 27 : steam supply pipe

[97] Vl : soft water supply valve V2 : soft water supply valve

[98] V3 : raw soybean milk supply valve V4 : steam supply valve

[99] V5 : steamed soybean milk supply valve V6: coagulating agent mixture outlet valve

[100] V7 : cooled soybean milk supply valve V8 : drain valve

[101] V9 : drain valve VlO : drain valve

[102] VI l: manual type groundwater supply valve V 12: manual type groundwater outlet valve

[103] V13 : manual type T-valve V14 : steam supply valve

[104] P : groundwater pump Sl : power switch

[105] P : groundwater pump S2 : steam supply switch

[106] S3 : temperature setup switch S4 : cooled water supply switch

[107] S5 : timer switch S6 : molding, sterilizing, and cooling chamber pressure gauge

[108] TS2 : temperature sensor T2 : temperature indicator

[109] T3 : timer indicator SWl : power switch

[110] SW2 : steam generating water supply switch

[111] SW3 : soft water supply switch SW4 : first agitation switch

[112] SW5 : steam supply switch SW6 : second high-speed homo-mixer switch

[113] SW7 : raw soybean milk supply switch SW8 : steamed soybean milk supply switch

[114] SW9 : cooled soybean milk supply switch Tl : digital type steam temperature indicator

[115] TSl : steamed soybean milk temperature sensor

Mode for the Invention

[116] Hereinafter, an apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time according to the present invention will be described with reference to the accompanying drawings.

[117] FIG. 1 is a view for illustrating a configuration of an apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time according to the present invention. FIG. 2 is a perspective view of a steam multi-level pressure-type molding, sterilizing, and cooling apparatus. FIG. 3 is a vertical cross- sectional front view of a clean room. [118] FIG. 4 is a flowchart of a manufacturing process of packed whole bean curd having bioactive substances and preserved for a long time. FIG. 5 is a flowchart of a manufacturing process of packed whole bean curd having bioactive substance, preserved for a long time, and added with a natural food additive.

[119] Referring to FIG. 1, the apparatus for manufacturing the packed whole bean curd having bioactive substances and preserved for a long time according to the present invention includes a clean room 18, wherein the clean room 18c is provided with an air shower room 18c installed at an entrance of the clean room 18, a cooling compressor 18b, and a clean air handling unit 18a. A first mixing basin 10 for producing raw soybean milk by mixing full fat-bioactivated raw soybean flour and soft water, a far- infrared steaming basin 11 for steaming the firstly mixed raw soybean milk, a once- through type boiler 9 for supplying steam to the far-infrared steaming basin 11, a plate type cooler 12 disposed at an upper portion to cool off steamed soybean milk, a second high-speed homo-mixer blending basin 13 for homogeneously mixing the cooled soybean milk with a natural food additive, an enzyme, and a coagulating agent, a filling-packing machine 14 for filling-packing the mixture of the cooled soybean milk, the natural food additive, the enzyme, and the coagulating agent in a specific container, a hand truck 15 for loading the filled packing container, a steam multi-level pressure- type molding, sterilizing, and cooling apparatus 16 for producing packed bean curd by introducing the hand truck 15 loaded with the packing container and then by molding, sterilizing, and cooling it by the aid of pressure, and a refrigeration reservoir 17 for preserving the produced packed whole bean curd.

[120] A control panel 19 is disposed between the first mixing basin 10 and the second high-speed homo-mixer blending basin 13. The control panel 19 includes a power switch SWl, a steam generating water supply switch SW2, a soft water supply switch SW3, a first agitation switch SW4, a steam supply switch SW5, a second high-speed homo-mixer switch SW6, a raw soybean milk supply switch SW7, a steamed soybean milk supply switch SW8, and a cooled soybean milk supply switch SW9. In addition, a digital type steam temperature indicator Tl is provided in the control panel 19.

[121] The first mixing basin 10 includes a soft water supply extension 10a, a first agitator

10b, an injection hopper 8, a soft water level indicating window 10c, and a manual type T- valve V 13.

[122] The first mixing basin 10 is connected with a soft water supply pipe 7 to provide soft water. The soft water supply pipe 7 is connected to a water supply source 1 through a water supply pipe 2.

[123] A water softener 3, a residual chlorine remover 4, and an ultraviolet sterilizer 5 are disposed along the water supply pipe 2.

[124] A soft water supply valve V2 is disposed along the soft water supply pipe 7. [125] The soft water level indicating window 10c is provided to accurately measure the amount of soft water supplied to the first mixing basin 10. The first mixing basin 10 includes the first agitator 10b whereby soft water having a hardness of 0 is supplied through the soft water supply pipe 7, and the soft water is mixed with the bioactive whole raw soybean particles to produce raw soybean milk. The first agitator 10b is attached with a screw-type impeller and rotates at the speed of 3,500 RPM.

[126] The far- infrared steaming basin 11 has a pressure-type structure and includes a pressure-type lid 1 Ib and a pressure safety valve 1 Ie disposed on the pressure-type lid 1 Ib. A steam jet pipe 1 Ia, a ceramic plate 1 Ic, and a raw soybean milk supply extension 1 Id are disposed inside the steaming basin 11.

[127] The far- infrared steaming basin 11 includes a steam temperature sensor TSl to sense the temperature of steamed soybean milk. The temperature of steamed soybean milk sensed by the steam temperature sensor TS 1 is indicated by the steam temperature indicator Tl disposed to the control panel 19. A steamed soybean milk supply pipe 24 is disposed to the left side of the steaming basin 11 and is connected to a lower portion of the plate type cooler 12. A steamed soybean milk supply valve V5 is disposed to a steamed soybean milk supply pipe 24. A drain valve V8 is disposed to a lower central portion of the steaming basin 11 so that residuals can be completely removed when cleaning the steaming basin 11.

[128] The ceramic plate 1 Ic is included in the steaming basin 11. A steam generating soft water supply pipe 6 is disposed to a lower portion of the once-through type boiler 9. A steam generating supply valve Vl is disposed to the steam generating soft water supply pipe 6. A steam supply pipe 27 is disposed to an upper portion of the once-through type boiler 9 and is connected to the steam injecting pipe 1 Ia of the steaming basin 11.

[129] A steam supply valve V4 is disposed along the steam supply pipe 27 and is open by manipulating the steam supply switch SW5.

[130] A drain valve V9 is disposed to a lower portion of the once-through type boiler 9 so that residuals can be completely removed when cleaning the once-through type boiler 9.

[131] The drain valve V9 is a manually open and closed. A steam supply pipe 22 is connected to the left side of the once-through type boiler 9. Also, the steam supply pipe 22 is connected to a steam jet supply pipe 16d of the steam multi-level pressure- type molding, sterilizing, and cooling apparatus 16. A steam supply valve V14 is disposed along the steam supply pipe 22 and is open by manipulating the supply switch SW7.

[132] A groundwater supply pipe 25 is connected to a lower portion of the plate type cooler 12. Groundwater is supplied to the plate type cooler 12 by the use of an automatic pump P disposed to a lower portion of the groundwater supply pipe 25. [133] A manual- type groundwater supply valve Vl 1 is disposed to the groundwater supply pipe 25. A groundwater outlet pipe 26 is connected to a lower portion of the plate type cooler 12. A manual-type groundwater outlet valve V 12 is disposed to the groundwater outlet pipe 26.

[134] A cooled soybean milk supply pipe 23 is disposed to the left side of the plate type cooler 12 and is connected to a cooled soybean milk supply extension 13b of the second high-speed homo-mixer blending basin 13. A cooled soybean milk supply valve V7 is disposed to the cooled soybean milk supply pipe 23.

[135] The second high-speed homo-mixer blending basin 13 includes a second high-speed homogeneous agitator 13 a, the cooled soybean milk supply extension 13b, and a mixture outlet pipe 24 through which a mixture of a cooled soybean milk, a natural food additive, an enzyme, and a coagulating agent are discharged. An outlet valve V6 is disposed to the mixture outlet pipe 24. The second high-speed homogeneous agitator 13a uses a motor having a screw-type impeller rotating at the speed of 10,000 RPM.

[136] The mixture outlet pipe 24 is disposed to a lower portion of the second high-speed homo-mixer blending basin 13 and is connected to a refrigeration reservoir 14a of the filling-packing machine 14. The outlet valve V6 is disposed to the mixture outlet pipe 24.

[137] The filling-packing machine 14 includes the refrigeration reservoir 14a disposed at an upper portion thereof and an automatic packing and transferring conveyer belt 14b. A plurality of hand trucks 15 are disposed to the left side of the filling-packing machine 14. Each hand truck 15 includes a multi-layered stainless tray plate 15a and a moving wheel 15b. The steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 is disposed to the right side of the hand truck 15.

[138] The steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 includes an opening/closing door 16a through which the hand truck 15 is introduced, a control panel 16b, a molding, sterilizing, and a cooling chamber 16c operating by the use of pressure and a far- infrared ray, a ceramic plate 16k, the steam jet supply pipe 16d, a steam pressure reducing valve 161, a steam jet nozzle 16e, a cooled water jet supply pipe 16f, a cooled water jet nozzle 16g, a pressure safety valve 16h, a groundwater supply pipe 16i, the automatic groundwater pump P, a drain pipe VlO, and a moving wheel 16j.

[139] The steam pressure reducing valve 161 is disposed in the middle portion of the steam spreading supply pipe 16d.

[140] The control panel 16b is disposed to the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16. Further, the control panel 16b includes a power switch Sl, a steam supply switch S2, a temperature setting switch S3, a cooled water supply switch S4, a timer setting switch S5, and a molding, sterilizing, and cooling chamber pressure gauge S6.

[141] A temperature sensor TS2 is disposed to the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 to sense the temperature of the molding, sterilizing, and cooling chamber 16c. The temperature sensed by the temperature sensor TS2 is displayed by a temperature indicator T2 included in the control panel 16b. A plurality of ceramic plates 16k are disposed to the upper inner surface and three lateral inner surfaces of the molding, sterilizing, and cooling chamber 16c.

[142] The refrigeration reservoir 17 is disposed to the right side of the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16. The refrigeration reservoir 17 includes a door 17a, a cooling compressor 17c, a cooler/air handling unit 17d, and an air curtain 17b.

[143] Hereinafter, a method of manufacturing packed whole bean curd having bioactive substances and preserved for a long time will be described in detail wherein the method is performed by an apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time.

[144] <Initial State>

[145] The air shower room 18c is installed at an entrance of the clean room 18. The cooling compressor 18b and the clean air handling unit 18a are installed so that an environment inside the clean room 18 remains at a dry temperature of 22 to 2O⁰C and a Class 100,000 EA/FT3. An apparatus for manufacturing packet whole bean curd having bioactive substances and preserved for a long time using an energy saving type enzyme is installed in the clean room 18. The apparatus is not yet operating in this state.

[ 146] <Water Treatment Process>

[147] Water is supplied from the water supply source 1 to the water supply pipe 2 and is processed to obtain soft water (hardness 0) through the water softener 3. Residual chlorine is removed by the residual chlorine remover 4. Finally, the water is sterilized by the ultraviolet sterilizer 5.

[148] The processed soft water (hardness 0) is supplied to the soft water supply pipe 7 of the first mixing basin 10 and to the steam generating soft water supply pipe 6 of the once-through type steam boiler 9.

[149] <Steam Generating Process>

[150] In the initial state, the power switch SWl of the control panel 19 is turned on, and the steam generating soft water supply switch SW2 is turned on. Then, soft water is supplied through the steam generating soft water supply valve Vl and thus the once- through type steam boiler 9 operates. As a result, steam is generated.

[151] <Step 1: Producing And Supplying Raw Soybean Milk>

[152] Upon turning on the soft water supply switch SW3, the soft water supply valve V2 is open, and thus soft water is supplied to the first mixing basin 10.

[153] When a proper amount of soft water is completely supplied by using the soft water level indicating window 10c, the bioactive whole raw soybean particles are injected into the injection hopper 8. The ratio between bioactive whole raw soybean particles and soft water is lkg:5.5f .

[154] Upon completing the supply of soft water (hardness 0) and the injection of the bioactive whole raw soybean particles, the first agitation switch SW4 is turned on and thus the first agitator 10b operates. As a result, raw soybean milk is produced which has a saccharinity of 12° when measured by a saccharometer. In this case, it is preferable that the first agitator 10b rotates at the speed of 3,000 to 3,500 RPM for 10 to 15 minutes.

[155] The raw soybean milk supply switch SW7 is turned on to open the raw soybean milk supply valve V3. Thus, raw soybean milk produced in the first mixing basin 10 is supplied to the far- infrared steaming basin 11 through the raw soybean milk supply pipe 2 and the raw soybean milk supply extension 11a.

[156] <Step 2: Producing Steamed Soybean Milk>

[157] After raw soybean milk is supplied to the far-infrared steaming basin 11, the steam supply switch SW5 is turned on to open the steam supply valve V4. Then, steam generated in the once-through type steam boiler 9 is supplied to the far- infrared steaming basin 11 through the steam supply pipe 27. When the steam is supplied to the steam injecting pipe 11a, the raw soybean milk is steamed by heat and moisture of the steam and by permeation force of a far-infrared radiator of a ceramic plate, thereby producing steamed soybean milk. The temperature of the steamed soybean milk is 102⁰C at a time when steaming is completed. This temperature is sensed by the temperature indicator Tl of the steamed soybean milk temperature sensor TSl.

[158] When the pressure inside the far-infrared steaming basin 11 increases in the steaming process and thus this pressure becomes greater than the pressure measured at the installation time, the pressure safety valve 1 Ie is open so that steam can be discharged. Thus, the steaming process can be accomplished in a safe manner.

[159] <Step 3: Cooling And Transferring Steamed Soybean Milk>

[160] Upon completing the steaming process, the groundwater pump P of the plate type cooler 12 operates, and thus the manual-type groundwater supply valve Vl 1 is manually open. Then, groundwater of 1O⁰C is supplied to the plate type cooler 12 through the groundwater supply pipe 25 and circulates inside the plate type cooler 12. The manual-type groundwater outlet valve V 12 is manually open, and the circulated groundwater is discharged through the groundwater outlet pipe 26.

[161] The steamed soybean milk supply valve V5 is open when the steamed soybean milk supply switch SW8 is turned on. Thus, the steamed soybean milk is supplied through the cooling pipe 12a of the plate type cooler 12 by the aid of pressure within the far- infrared steaming basin 11, thereby producing cooled soybean milk having a product temperature of 10 to 12⁰C. Thereafter, the cooled soybean milk supply switch SW9 is turned on, and the cooled soybean milk is transferred to the second high-speed homo- mixer blending basin 13 through the cooled soybean milk supply extension 13b.

[162] <Step 4: Producing Mixture Of Cooled Soybean Milk, Enzyme, And Coagulating

Agent>

[163] Cooled soybean milk having a saccharinity of 12° (when measured by a sac- charometer) and a product temperature of 10 to 12⁰C is transferred to the second highspeed homo-mixer blending basin 13. Then, a 0.2 to 0.5% enzyme is firstly mixed to the cooled soybean milk through the coagulating agent injection hopper 13c. The resulting mixture is agitated by the second high-speed homogeneous agitator 13a. The cooled soybean milk is secondly mixed with a 0.06 to 0.3% coagulating agent through the coagulating agent injection hopper 13c and is then agitated by the second highspeed homogeneous agitator 13 a. As a result, a mixture of the cooled soybean milk, the enzyme, and the coagulating agent is produced.

[164] In this process, the second high-speed homogeneous agitator 13a may run at the speed of 10,000 RPM. The screw-type impeller may run for 10 to 15 minutes. Preferably, the enzyme is firstly introduced.

[165] <Step 5: Filling-Packing and Transferring Mixture to Hand Truck>

[166] When the mixture produced in step 4 is supplied to the refrigeration reservoir 14a of the filling-packing machine 14, the mixture of the cooled soybean milk, the enzyme, and the coagulating agent is filling-packed in an oxygen barrier packing container having a specific volume and is then transferred to the conveyer belt 14b. The transferred mixture is contained in the stainless tray plate 15a manually, and is then loaded in the hand truck 15.

[167] <Step 6: Placing Hand Truck In Steam Multi-Level Pressure-Type Molding,

Sterilizing, And Cooling Apparatus And Producing Packed Whole Bean Curd>

[168] The mixture produced in Step 4 is filling-packed in the container, which has a specific volume and is made of an oxygen barrier film, and is then contained in the stainless tray plate 15a of the hand truck 15. The opening/closing door 16a of the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 is open, and the hand truck 15 is introduced to the molding, sterilizing, and cooling chamber 16c installed in the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16. The manual type T-valve V13 is open, and the steam supply switch SW5 of the control panel 19 is turned on. Then steam supply valve V 14 is open, and steam of the once-through type steam boiler 9 is supplied to the steam jet supply pipe 16d and the steam pressure reducing valve 16c through the steam supply pipe 22. In this process, for example, it will be assumed that the power switch Sl of the control panel 16b of the steam multi-level pressure-molding, sterilizing, and cooling apparatus 16 is turned on, the temperature is set to 55 to 65⁰C, which is suitable for enzyme activation, by the temperature setting switch S3, the time is set to 40 to 60 minutes (i.e., an enzyme reaction time) by the timer switch S5, and the steam supply switch S2 is turned on. In this case, steam is ejected from the steam jet nozzle 16e into the molding, sterilizing, and cooling chamber 16c through the steam jet supply pipe 16d and the steam pressure reducing valve 16c. Then, the temperature of the molding, sterilizing, and cooling chamber 16c maintains at 55 to 65⁰C. The enzyme reaction of the mixture produced in Step 4 is activated only for 40 to 60 minutes by the use of steam heat in th e range of 55 to 65⁰C at which enzyme is activated. The enzyme promotes a crosslinking polymerization reaction between soybean protein molecules included in the cooled soybean milk, which leads to the formation of a covalent bond. As a result, with being boded with the coagulating agent according to the natural coagulation scheme, packed whole bean curd having bioactive substances and preserved for a long time is molded to have an excellent binding capacity, resilience, soft shape, and tasty flavor. To sterilize the molded packed whole bean curd, the temperature setting switch S3 is turned on. Then, the temperature is set to 85 to 9O⁰C, and the timer switch S5 is set to 15 to 20 minutes. If steam is provided in this state, low-temperature and pressurized sterilization is performed. After sterilization, the temperature setting switch S3 is set to 121⁰C, and the timer switch S5 is set to 5 minutes. Steam is provided in this state in order to pressure-sterilize the packed whole bean curd at a high temperature, thereby obtaining desired packed whole bean curd having bioactive substances and preserved for a long time.

[169] Upon supplying steam heat to the molding, sterilizing, and cooling chamber 16c, far-infrared electromagnetic wave energy is generated in the ceramic plate 16k disposed inside the molding, sterilizing, and cooling chamber 16c. The permeation force of a far-infrared ray promotes molding and sterilization, thereby saving energy.

[170] After the packed whole bean curd is sterilized at a high temperature of 121⁰C, groundwater is transferred to the cooled water supply pipe 16f through the groundwater supply pipe 16i by the operation of the pump P upon turning on the cooled water supply switch S4. Then, cooled water is ejected from the cooled water jet nozzle 16g for a pressure-cooling operation. As a result, the packed whole bean curd having bioactive substances and preserved for a long time is produced while being cooled down to have a product temperature of 10 to 12⁰C.

[171] Herein, to improve quality of the packed whole bean curd, it is important to maintain the enzyme activation temperature of 55 to 65⁰C and the enzyme reaction time of 40 to 60 minutes with respect to the mixture of the cooled soybean milk, the enzyme, and the coagulating agent. Since the temperature sensor TS2, the temperature indicator T2, and the timer indicator T3 operate in a digital manner, they can sense and check exact temperature and reaction time at which the enzyme undergoes a crosslinking polymerization reaction with the soybean protein of the mixture of the cooled soybean milk, the enzyme, and the coagulating agent filling-packed in the oxygen barrier packing container. In addition, they also can accurately sense and check a temperature of low-temperature sterilization, a temperature of high-temperature sterilization, and a temperature of a cooling process. A pressure condition of the molding, sterilizing, and cooling chamber 16c is displayed on the molding, sterilizing, and cooling chamber pressure gauge S6. As a result, it is possible to produce the packed whole bean curd having bioactive substance and preserved for a long time with high and uniform quality in a safe and easy manner, thereby enhancing marketability.

[172] Furthermore, in the molding, sterilizing, and cooling chamber 16c, high heat can be provided to the packed whole bean curd by the use of an assistant means for pressing, thereby facilitating a sterilization effect. In addition, due to internal pressure produced in the process of steam heating process, package disruption can be avoided. Moreover, a cooling speed can be increased in the cooling process of the packed whole bean curd.

[173] <Step 7: Transferring And Storing Cooled Packed Whole Bean Curd Having

Bioactive Substances And Preserved For Long Time In Refrigeration Reservoir And Completing Desired Packed Whole Bean Curd>

[174] The opening/closing door 16a of the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 is open, and the hand truck 15 is moved to outside. Then, 50 pieces of the cooled packed whole bean curd having bioactive substances and preserved for a long time are put into a plastic box placed on the stainless tray plate 15a and is then transferred to the refrigeration reservoir 17, in which the cooling compressor 17c, the cooler/air handling unit 17d, and the air curtain 17b are installed, through the door 17a of the refrigeration reservoir 17 by the use of a conveyer belt. The cooled whole bean curd is stored and aged in the refrigeration reservoir 17 for a long-term preservation. Accordingly, packed whole bean curd is achieved which has good resilience, binding capacity, hygienic conditions, tasty flavor, marketability, and quality.

[175] In this step, the temperature of the refrigeration reservoir 17 may maintain at 10 to

12⁰C.

[176] FIG. 5 is a flowchart of a manufacturing process of packed whole bean curd having bioactive substances, preserved for a long time, and added with a natural food additive, wherein the process is performed by an apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time according to the present invention. [177] The step of filling-packing the produced mixture and the step of loading the filling- packed container on a hand truck and transferring it to the steam multi-level pressure- type molding, sterilizing, and cooling apparatus are the same as described above. The supply of steam heat is regulated so that an enzyme reaction is activated at a specific temperature and time, thereby promoting a crosslinking polymerization reaction between soybean protein molecules. Thus, with being bonded to a coagulating agent, packed whole bean curd having bioactive substances, preserved for a long time, and added with a natural food additive is formed to have an excellent binding capacity, resilience, tasty flavor, and functionality.

[178] In the packed whole bean curd having bioactive substances, preserved for a long time, and added with a natural food additive according to the present invention, bioactive whole raw soybean particles are produced according to the natural coagulation scheme. Thus, all of bioactive substances of soybean can be contained such as soybean protein, isoflavon, lecithin, linoleic acid, soybean oligosaccharide, saponin, mineral, vitamins B and D, anthocyanin, and dietary fiber.

[179] In addition, the packed whole bean curd is produced by using the bioactive whole raw soybean particles according to the natural coagulation scheme while skipping a pressing process. Since a natural food additive (e.g., spinach powder, green tea powder, carrot powder, cheese powder, Korean red ginseng powder, cocoa powder, coffee powder, sprout powder, shrimp powder, oriental medical herb powder, etc.) can be easily added, the packed whole bean having bioactive substances, preserved for a long time, and added with a bioactive natural food additive can be produced to have excellent quality in terms of nutrition, exterior appearance, physical property, and functionality.

[180] Hereinafter, a process of manufacturing packed whole bean curd having bioactive substances, preserved for a long time, and added with a natural food additive will be described wherein the process is performed by an apparatus for manufacturing packed whole bean curd having bioactive substances, preserved for a long time, and added with a natural food additive by using an energy saving enzyme according to the present invention.

[181] Steps 1, 2, and 3 are carried out in the same manner as the method of manufacturing packed whole bean curd having bioactive substances and preserved for a long time wherein the method is performed by the apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time by using an energy saving enzyme according to the present invention.

[182] In Step 4, a natural food additive is firstly added into cooled soybean milk. The natural food additive may be added in a certain amount which does not deteriorate a textural property of the whole bean curd. Preferably, the amount of added natural food additive is about 5 to 10% of the amount of cooled soybean milk.

[183] While cooled soybean milk is combined with the mixture of a natural food additive, an enzyme, and a coagulating agent in Step 4, the cooled soybean milk having a sac- charinity of 12° (when measured by a saccharometer) and a product temperature of 10 to 12⁰C is transferred and supplied to the second high-speed homo-mixer blending basin 13. Then, the cooled soybean milk, the natural food additive, the enzyme, and the coagulating agent are homogeneously mixed in the following three processes: 1) the natural food additive whose amount is equal to 5 to 10% of the amount of cooled soybean milk is injected through the coagulating agent injection hopper 13c and thus the cooled soybean milk and the natural food additive are mixed by the second highspeed homogeneous agitator 13a; 2) an enzyme whose amount is equal to 0.2 to 0.5% of the amount of cooled soybean milk is injected and mixed; and 3) the coagulating agent whose amount is equal to 0.06 to 0.3% of the amount of cooled soybean milk is injected and mixed. Herein, the second high-speed homogeneous agitator 13a may operate at the speed of 10,000 RPM. The screw-type impeller may operate for 15 to 20 minutes.

[184] Steps 5 and 6 are carried out in the same manner as the aforementioned process of manufacturing packed whole bean curd having bioactive substances and preserved for a long time according to the present invention.

[185] In Step 7, the opening/closing door 16a of the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 is open, and the hand truck 15 is moved to outside. Then, 50 pieces of the cooled packed whole bean curd having bioactive substances, preserved for a long time, and added with a natural food additive are put into a plastic box placed on the stainless tray plate 15a and is then transferred to the refrigeration reservoir 17, in which the cooling compressor 17c, the cooler/air handling unit 17d, and the air curtain 17b are installed, through the door 17a of the refrigeration reservoir 17 by the use of a conveyer belt. The cooled whole bean curd is stored and aged in the refrigeration reservoir 17 for a long-term preservation. Accordingly, packed whole bean curd having bioactive substances, preserved for a long time, and added with a natural food additive is produced to have good resilience, binding capacity, hygienic conditions, tasty flavor, marketability, and quality. In this step, the temperature of the refrigeration reservoir 17 may maintain at 10 to 12⁰C. Industrial Applicability

[186] According to an apparatus and method for manufacturing packed whole bean curd having bioactive substances and preserved for a long time, 100% productivity improvement can be expected since energy is saved by decreasing the number of steps of manufacturing (in a high-speed multi-level pump and a high pressure equalizer), such that raw soybean milk and steamed soybean milk are produced by the use of full fat- bioactivated raw soybean flour and soft water, and thereafter are cooled off. Then, in the second homo-mixer blending basin, a mixture of the cooled soybean milk, the enzyme, and the coagulating agent is properly produced. As a result, a manufacturing cost of the packed whole bean curd having bioactive substances and preserved for a long time is reduced, which is significantly important factor for attracting customers. While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims.

Claims

[1] An apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time, the apparatus comprising: a first mixing basin 10 that is provided with a soft water supply pipe, which is connected to a water supply source, and an ingredient injection hopper and that includes an agitator for producing raw soybean milk by mixing ingredient and soft water; a far-infrared ray steaming basin 11 that includes a steam injecting pipe 11a for steaming the raw soybean milk supplied from a raw soybean milk supply pipe connected to the first mixing basin 10; a once-through type boiler 9 that is connected to a steam supply pipe 20 for supplying steam to the steam injecting pipe 11a and supplies steam to the far- infrared steaming basin 11 and that is connected to the first mixing basin 10 through a steam generating soft water supply pipe 6; a plate type cooler 12 that is connected to the far- infrared steaming basin 11 through a steamed soybean milk supply pipe 24, is connected to a groundwater supply pipe 25, and includes a cooling pipe 12a so as to cool off steamed soybean milk; a second high-speed homo-mixer blending basin 13 that includes a cooled soybean milk supply pipe 23, which provides the steamed soybean milk cooled in the plate type cooler 12, a cooled soybean milk supply extension 13b, a cooled soybean milk mixture outlet pipe, a coagulating agent injection hopper 13c, and a second high-speed homogeneous agitator 13a which homogeneously mixes a mixture of the cooled soybean milk; a filling-packing machine 14 that fills the cooled soybean milk mixture, which is mixed in the second high-speed homo-mixer blending basin 13, in a packing container; a hand truck 15 that includes a moving wheel 15b and a stainless tray plate 15a for loading the packing container filled by the filling-packing machine 14; a steam multi- level pressure-type molding, sterilizing, and cooling apparatus 16 that is connected to the hand truck 15 and produces the packed whole bean curd by sterilizing, molding, and cooling by the aid of pressure; a conveyer belt 21 that is connected to the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 and transfers the cooled packed whole bean curd; and a refrigeration reservoir 17 for storing and preserving the whole bean curd transferred through the conveyer belt 21.

[2] The apparatus according to claim 1, wherein, in the first mixing basin 10, an ingredient injection hopper is disposed to an upper portion thereof, a first agitator is disposed therein, and a soft water supply extension is vertically disposed in a longitudinal direction on an inner main wall thereof.

[3] The apparatus according to claim 1, wherein, in the once-through type boiler 9, the steam generating soft water supply pipe is connected to a lower portion thereof, the steam supply pipe, the steam jet pipe of the steaming basin, and a steam pressure reducing valve are connected to an upper portion thereof, the steam supply pipe and the steam jet supply pipe of the steam multi-level pressure-type molding, sterilizing, and cooling apparatus are connected to the upper portion thereof, and a drain valve is disposed to the lower portion thereof to remove foreign materials when cleaning inside the once-through type steam boiler.

[4] The apparatus according to claim 1, wherein the far-infrared steaming basin 11 is constructed of a main body and a pressure-type lid for opening and closing the main body by the aid of pressure, includes an far- infrared ray ceramic plate therein, and is provided with the steam jet pipe.

[5] The apparatus of according to claim 1, wherein, in the plate type cooler 12, a cooling pipe is disposed therein, a groundwater supply pipe and a groundwater outlet pipe are connected to a lower portion thereof, the steamed soybean milk supply pipe and the cooling pipe are connected to a lower left portion of the plate type cooler, the cooled soybean milk supply pipe and the cooled soybean milk supply extension inside the second high-speed homo-mixer blending basin are connected to a upper right portion thereof.

[6] The apparatus according to claim 1, wherein, in the second high-speed homo- mixer blending basin 13, a coagulating agent injection hopper through which a coagulating agent is injected together with a natural food additive and an enzyme is disposed to an upper portion thereof, the second high-speed homogeneous agitator and a screw type impeller are disposed therein, and the cooled soybean milk supply extension, which is connected to the cooled soybean milk supply pipe, is disposed to an upper portion of an main wall thereof.

[7] The apparatus according to claim 1, wherein the steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16 is constructed of a opening/closing door, a control panel, and a molding, sterilizing, and cooling chamber operating by the use of pressure and a far-infrared ray, wherein the cooled water jet supply pipe and the cooled water jet nozzle are disposed to an upper inner portion and three lateral inner surfaces of the molding, sterilizing, and cooling chamber, and wherein the three lateral inner surfaces of the molding, sterilizing, and cooling chamber are provided with the steam jet supply pipe and the steam jet nozzle.

[8] The apparatus according to claim 7, wherein a ceramic plate is disposed to the inner upper surface and three lateral inner surfaces of the molding, sterilizing, and cooling chamber.

[9] The apparatus according to claim 7, wherein a digital type temperature sensor is disposed in the molding, sterilizing, and cooling chamber, and a temperature indicator is disposed to the control panel so as to indicate a temperature sensed by the temperature sensor in a digital manner.

[10] The apparatus according to claim 1, wherein the apparatus is disposed in a clean room which is constructed of an air shower room and a packed whole bean curd injection hole and in which a clean air handling unit is connected to the cooling compressor to maintain a specific temperature and a specific fresh air.

[11] The apparatus according to claim 1, wherein the soft water supply pipe and the steam generating soft water supply pipe are branched from the water supply pipe connected to the water supply source, and wherein a water softener, a residual chlorine remover, and an ultraviolet sterilizer are disposed along the water supply pipe.

[12] A method of manufacturing a packed whole bean curd having bioactive substances and preserved for a long time, the method comprising the steps of: producing raw soybean milk by injecting and agitating soft water and bioactive whole raw soybean particles into a first mixing basin 10 of the apparatus for manufacturing packed whole bean curd having bioactive substances and preserved for a long time, and supplying the produced raw soybean milk to a far- infrared steaming basin 11 ; streaming the raw soybean milk by supplying steam generated in a once-through type boiler 9 to the steaming basin 11 ; cooling the steamed soybean milk by transferring it to a plate type cooler 12, and transferring the cooled soybean milk to a second high-speed homo-mixer blending basin 13; producing a mixture of soybean milk, an enzyme, and a coagulating agent by agitating the transferred cooled steamed soybean milk by the use of a second high-speed homogeneous agitator 13a while injecting an enzyme, followed by the injection of the coagulating agent; transferring the mixture to a filling-packing machine 14 so as to be packed in an oxygen barrier packing container in a filling-packing manner and then transferring it to a hand truck 15; producing packed whole bean curd by placing the hand truck 15 loaded with the filling-packed mixture to a steam multi-level pressure-type molding, sterilizing, and cooling apparatus 16; and preserving the packed whole bean curd by transferring it to a refrigeration reservoir.

[13] The method according to claim 12, wherein the soft water and the bioactive whole raw soybean particles are mixed in the first mixing basin in the ratio of 5.5:1.

[14] The method according to claim 12, wherein, in a molding, sterilizing, and cooling chamber operating by the use of pressure and a far-infrared ray, multilevel pressure-type satirizing are performed so that packed whole bean curd having bioactive substances and preserved for a long time is subject to a first pressure-sterilization process at 85 to 9O⁰C, followed by a second pressure- sterilization process at 100 to 121⁰C.

[15] The method according to claim 12, wherein, in the second high-speed homo- mixer blending basin, an enzyme is firstly injected to the cooled soybean milk through an ingredient injection hopper and is then agitated with the cooled soybean milk for equalization, and a coagulating agent is then secondly injected to homogeneously produce a mixture of the cooled soybean milk, the enzyme, and the coagulating agent.

[16] The method according to claim 12, wherein, in the second high-speed homo- mixer blending basin, a natural food additive whose amount is about 5 to 10% of the amount of cooled soybean milk is firstly injected to cooled soybean milk through an ingredient injection hopper.

[17] The method according to claim 16, wherein the natural food additive is selected from a group consisting of spinach powder, green tea powder, carrot powder, cheese powder, Korean red ginseng powder, safflower seed powder, sprout powder, cocoa powder, coffee powder, and chitosan powder each of which having a granularity of 200 to 300 meshes when freeze-dried.

[18] The method according to claim 12, wherein the amount of enzyme injected into the second high-speed homo-mixer blending basin is 0.2 to 0.3% of the amount of the cooled soybean milk.

[19] The method according to claim 12, wherein the amount of a coagulating agent injected into the second high-speed homo-mixer blending basin is 0.06 to 0.3% of the amount of the cooled soybean milk.

[20] The method according to claim 12, wherein the mixture of the enzyme and the coagulating agent is injected into the molding, sterilizing, and a cooling chamber and then an enzyme reaction is activated for 40 to 50 minutes while maintaining a steam temperature of 55 to 65⁰C.