Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J3/00—Working-up of proteins for foodstuffs
  • A23J3/14—Vegetable proteins
  • A23J3/16—Vegetable proteins from soybean
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J3/00—Working-up of proteins for foodstuffs
  • A23J3/22—Working-up of proteins for foodstuffs by texturising
  • A23J3/26—Working-up of proteins for foodstuffs by texturising using extrusion or expansion
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L11/00—Pulses, i.e. fruits of leguminous plants, for production of food; Products from legumes; Preparation or treatment thereof

Definitions

• the present invention relates to a textured soy protein material for instant dry foods.
• Instant dried foods are dried foods that can be made edible in about 3 to 5 minutes by cooking them by adding hot water to soften them, adding water and hot water to simmer, or adding water and heating in a microwave.
• Instant noodles and instant miso soup that use these as ingredients can be stored for a long time, and from the perspective of sustainability in recent years, they are thought to be important food ingredients in the future as well.
• the importance of instant foods is increasing. Under these trends, instant dried foods not only add color to products, but are also one of the important elements that are deeply involved in the deliciousness of products.
• instant dried foods include vegetables, meat, and processed meat products.
• instant dried vegetable foods include cabbage, green onions, and wakame seaweed, which are dried to a final moisture content of about 2 to 3% by mass using freeze-drying (FD) or hot air drying (AD), either as is or after pretreatment such as seasoning and boiling.
• instant dried meat foods include beef, pork, and chicken, which are dried as is or after pretreatment such as seasoning and boiling, using FD or AD.
• instant dried foods have also been used that have a firmer texture and improved resilience by mixing with textured protein that has a meat-like texture.
• instant dried processed meat foods include sausages, roasted pork, diced meat, kamaboko, fish sausages, and other processed meat products made from meat and fish, which are dried using FD or AD.
• Textured protein materials are obtained by expanding the texture of a mixture of plant-derived protein materials such as soybeans and wheat in an extruder, and have traditionally been produced to have a quality that is close to the elasticity of livestock meat, and are widely used as an ingredient in the manufacture of processed foods that use livestock meat, such as hamburgers, meatballs, gyoza dumplings, meat buns, shumai, minced meat cutlets, croquettes, and minced meat.
• livestock meat such as hamburgers, meatballs, gyoza dumplings, meat buns, shumai, minced meat cutlets, croquettes, and minced meat.
• These textured protein materials expand when discharged from the extruder, and because they have internal voids, some have good restoration properties when hot water is added, and they are often used as a substitute for meat in instant foods.
• Patent Document 1 discloses a technology that adds oat fiber as a secondary ingredient to create a textured protein material with a meat-like texture that has a more appropriate hardness and a meat-like flaking texture.
• Patent Document 2 a textured protein material extruded from an extruder is rehydrated with water, dehydrated, seasoned, and then dried, thereby maintaining the voids in the textured protein material in an expanded state and improving the reconstitution properties when hot water is added.
• Patent Document 3 discloses that the above object can be achieved by increasing the amount of water fed to an extruder, and freeze-drying the unexpanded tissue obtained using a cooling die.
• Patent No. 5794373 JP 2017-175942 A International Publication No. 2022/202884 Brochure
• a textured soy protein material for instant dried food applications has many voids inside, and therefore has excellent restorability when hot water is added. However, it has the problem that pre-applied flavors are lost when reconstituted with hot water.
• the textured soy protein materials exemplified in Patent Documents 1 and 2 as prior art still have room for improvement in terms of off-flavoring. Since Patent Document 3 uses a special extruder that can handle high moisture in the production, it is expected that a more versatile technology will be developed.
• the present invention aims to provide a textured soy protein material for instant dried foods that has good reconstitution when reconstituted in hot water and has little loss of flavor.
• a textured soy protein material made from non-defatted soybeans is flavored and dried into instant dried foods that have good restorability when reconstituted in hot water and have little loss of flavor, thus completing the present invention.
• the present invention relates to (1) a textured soy protein material for instant dried foods derived from non-defatted soybeans, which contains 6% by mass or more of fats and oils and 30% by mass or more and 60% by mass or less of crude protein in the dried matter.
• a method for producing a textured soy protein material for instant dried foods characterized in that a raw material containing 50% by mass or more of non-defatted soybeans in the dry matter is treated with an extruder, the method comprising the steps of: treating a raw material containing 50% by mass or more of non-defatted soybeans in the dry matter; and the textured soy protein material contains 6% by mass or more and 25% by mass or less of oil and fat and 30% by mass or more and 60% by mass or less of crude protein.
• (6) A method for producing a textured soy protein material for instant dried foods according to (5), wherein an extruder having three or more screws is used.
• the present invention also relates to (1) A textured soy protein ingredient for instant dried foods derived from non-defatted soybeans, containing 6% by mass or more of fats and oils and 30% by mass or more and 60% by mass or less of crude protein in the dried matter.
• a method for producing a textured soy protein material for instant dried foods characterized in that a raw material containing 50% by mass or more of non-defatted soybeans in the dry matter is treated with an extruder, the method comprising the steps of: processing a raw material containing 50% by mass or more of non-defatted soybeans in the dry matter; and the textured soy protein material contains 6% by mass or more and 25% by mass or less of oil and fat and 30% by mass or more and 60% by mass or less of crude protein.
• the present invention makes it possible to obtain a textured soy protein material for instant dried foods that is easy to produce, has good reconstitution when rehydrated in hot water, and has little loss of flavor.
• the textured soy protein material used in the present invention is a material having a water-insoluble texture with a directional property.
• a specific example of the method for producing the material is a method for extruding soybeans as the main raw material, water and other suitable raw materials in an extruder.
• the raw materials are kneaded in the apparatus under conditions where the inside of the apparatus is pressurized and heated, and the resulting kneaded product is extruded under normal pressure, and the extruded product is cut and dried as necessary.
• the kneaded material is extruded under high temperature and pressure or under normal pressure, it changes into an extrudate with an expanded structure.
• the textured soybean protein material may be in the form of granules, flakes, sliced meat, or the like.
• non-defatted soybeans The textured soy protein material used in the present invention is derived from non-defatted soybeans, or non-defatted soybeans are used as a raw material.
• Defatting is a process of extracting fats and oils from soybeans using organic solvents such as hexane, isopropanol, ethanol, etc.
• organic solvents such as hexane, isopropanol, ethanol, etc.
• non-defatted soybeans do not go through this process, and non-defatted soybeans refer to soybeans that have not been immersed in the above organic solvents.
• non-defatted soybeans of the present invention examples include unextracted full-fat soybeans, pressed soybeans whose oil has been extracted by pressing, or crushed products thereof, as well as concentrated soy protein and isolated soy protein extracted with water from these soybeans.
• defatted soybeans that are usually used as a raw material for soy protein ingredients are not included because they are subjected to solvent extraction. It is preferable to use an expeller press or the like to squeeze soybeans.
• the raw material for the textured soy protein material used in the present invention is mainly non-defatted soybeans, which preferably account for 50% by mass or more of the total raw material in terms of dry matter, more preferably 60% by mass or more, 70% by mass or more, 80% by mass or more, 90% by mass or more, or 95% by mass or more, and most preferably non-defatted soybeans are the only raw material.
• the amount of protein ingredients that make up the textured soy protein ingredient varies depending on the protein ingredient used, but it is preferable that soy protein accounts for 50% by mass or more, 65% by mass or more, 80% by mass or more, or 95% by mass or more of the total protein, and it is most preferable that the total protein consists solely of soy protein.
• the textured soy protein material used in the present invention is derived from non-defatted soybeans. "Derived from” means that most of the substances constituting the textured soy protein material originate from non-defatted soybeans, and is preferably 50% by mass or more of the textured soy protein material in dry matter equivalent, more preferably 60% by mass or more, 70% by mass or more, 80% by mass or more, 90% by mass or more, 95% by mass or more, and most preferably composed only of substances originating from non-defatted soybeans.
• the crude protein content in the final dry matter of the textured soy protein material is 30% by mass or more and 60% by mass or less. Preferably, it is 35% by mass or more, and more preferably 38% by mass or more. Also, it is preferably 55% by mass or less, and more preferably 50% by mass or less. Alternatively, it is preferably 35 to 55% by mass, and more preferably 38 to 50% by mass.
• a textured soy protein material By not having a crude protein content that is too low, a textured soy protein material can be constituted that maintains the texture, retains the flavor, and is less likely to lose its flavor.
• Crude protein content is measured by the Kjeldahl method. Specifically, the mass of nitrogen measured by the Kjeldahl method is expressed as the crude protein content in the dry matter in "mass %" relative to the mass of protein material.
• the nitrogen conversion coefficient is 6.25. Basically, it is calculated by rounding off the value to the second decimal place.
• the fats and oils are mostly derived from the raw material non-defatted soybeans, but various fats and oils can be added.Specific examples include soybean oil, rapeseed oil, rice oil, corn oil, sunflower oil, palm oil, beef tallow, lard, and their fractionated oils, hardened oils, and interesterified oils, and these can be appropriately selected and used.Of these, it is preferable to use fats and oils such as soybean oil, sunflower oil, and palm oil.
• the fat/oil content is 6% by mass or more and 25% by mass or less, preferably 12% by mass or more, preferably 19% by mass or less, and more preferably 14% by mass or more in the dry matter of the final textured soy protein material. Also, it is preferably 6 to 25% by mass, and more preferably 12 to 19% by mass. If the fat/oil content is not too low, the effect of preventing flavor loss is maintained, and if the fat/oil content is not too high, sufficient texturization is achieved. Note that these fat/oil contents also include those originally contained in the raw material non-defatted soybeans, etc.
• various raw materials can be used for the textured soy protein material of the present invention, so long as the physical properties are not affected.
• specific examples include vegetable protein materials including legume proteins isolated from peas, mung beans, chickpeas, etc., cereal proteins isolated from wheat, barley, rice, etc., proteins isolated from sunflower, sesame, corn, etc., and animal protein materials such as egg white and casein. Vegetable protein materials are preferred, and those derived from peas, mung beans, and wheat are preferred.
• alkali metal salts such as salt, divalent metal salts such as calcium chloride, carbohydrates such as starch and polysaccharides, dietary fiber, emulsifiers, flavorings, and other known additives.
• the production of the textured soy protein material involves introducing the above-mentioned raw materials, water and other suitable raw materials into an extruder, kneading the raw materials with a screw in the device under conditions where the inside of the device is pressurized and heated, and extruding the resulting kneaded material under normal pressure from a hole in a part called a "die" at the outlet of the device, and cutting and drying the extrudate as necessary.
• the kneaded material is extruded from high temperature and high pressure through the die under normal pressure, it changes into an extrudate with an expanded texture.
• the ratio of the powdered raw material to water in this case varies depending on conditions such as temperature, but can be, for example, 100:60 to 100:10, preferably 100:50 to 100:15, and more preferably 100:45 to 100:20.
• the textured soy protein material of the present invention is produced using an extruder as an apparatus, and it is preferable to use an extruder having three or more screws arranged in a barrel, i.e., an extruder with three or more screws. This makes it easier to adjust the texture such as swelling.
• the cross sections of the screws are meshed so as to be in a straight line in the vertical or horizontal direction.
• the operating conditions for supplying the raw material for producing the textured soy protein material to the extruder and extruding it from the die under pressurized and heated conditions to normal pressure can be appropriately selected and adjusted based on known conditions.
• the temperature at the tip of the barrel is preferably 120 to 220°C, more preferably 140 to 200°C, as a heating condition.
• the pressure at the die at the tip of the barrel is preferably 2 to 100 kg/cm ⁇ 2, more preferably 5 to 40 kg/cm ⁇ 2, as a pressurizing condition.
• the obtained textured soy protein material can be cut into pieces of suitable size with a cutter or the like, if necessary, and dried.
• An example of a drying method is to expose the textured soy protein material to hot air at 60°C to 100°C for about 10 to 30 minutes using a fluidized bed dryer.
• the moisture content of the textured soy protein material obtained after drying is preferably 15% by weight or less, more preferably 1 to 12% by weight, and even more preferably 1 to 10% by weight.
• the present invention relates to a textured soy protein material for instant dried foods.
• Instant dried foods are foods that can be reconstituted and eaten by immersing in hot or cold water.
• the instant dried foods of the present invention are prepared by drying a textured soy protein material that has been pre-seasoned.
• the present invention is particularly suitable for instant dried ingredients used as ingredients in instant noodles, instant miso soup, etc.
• the textured soybean protein material can be flavored, for example, by preliminarily preparing a seasoning liquid containing water, fruit juice, sugars, organic acids, salts, other seasonings, colorings, oils and fats, and then impregnating the material with the seasoning liquid.
• the impregnation method may be any method that allows the textured soy protein material to be uniformly impregnated with water or flavoring liquid. Heating during or after the soaking is also effective.
• the textured soy protein material to be made into a dried food may have any size suitable for use as an ingredient in instant foods.
• the size can be adjusted before or after the above-mentioned flavoring treatment step.
• the flavored textured soy protein material is then dried.
• Methods for drying include freeze-drying (FD), hot air drying (AD), microwave drying (MD), and the like. Freeze-drying is preferred because it causes little change in state before and after drying. Freeze-drying, hot air drying, and microwave drying can be performed using known means.
• the moisture content of the dried food of the present invention is suitably 1 to 15% by mass, preferably 1 to 10% by mass. There are no particular limitations on the moisture content as long as the moisture activity is low and spoilage does not occur.
• the textured soy protein material of the present invention has the characteristics of having a good meat-like fibrous texture, a fast water absorption rate, and being less likely to lose flavor when reconstituted with water. Due to these characteristics, the textured soy protein material can be used as an ingredient for instant foods that reconstitute well with hot water.
• the textured protein material can also be used as a meat substitute for livestock meat such as beef, pork, and chicken, and fish meat.
• the textured soy protein material of the present invention has a good meat-like texture even after reconstitution with hot water.
• the extruder used was a four-screw extruder "WDR40 QD" (manufactured by Technobel Co., Ltd.)
• the extruder had four screws arranged in parallel inside the barrel, and when viewed from the tip side (cross section) of the screws, they were arranged in a horizontal line.
• 100 parts by mass of full fat soy flour and 32 parts by mass of water were fed to the extruder as raw materials, and heated and pressurized while mixing, and the raw material mixture was extruded from the die at the end of the barrel under normal pressure.
• the extruded material was cut with a cutter immediately after the outlet from the die to a length of about 20 mm, and then dried with hot air in a dryer at 80 ° C for about 4 hours to a moisture content of 5 mass%, to obtain a textured soy protein material having a shape of ⁇ 5.0 ⁇ 0.8 mm ⁇ 16.0 ⁇ 2.4 mm. This was used as soy protein material A in the following study after measuring the amount of fat and oil and the amount of crude protein.
• the extruder was operated under the following conditions: ⁇ Die: circular opening (diameter 3.5 mm x 5 holes) ⁇ Powder raw material flow rate: 85 kg/hour ⁇ Screw diameter: 40 mm - Barrel temperature: Inlet side: 80°C, center: 120°C, outlet side: 165°C
• Production Example 2 (Preparation of textured soy protein materials B and F) Coarsely crushed whole soybeans were pressed and further pressed with an expeller press (manufactured by Suehiro Co., Ltd.) to separate pressed soybean oil and pressed oil cake. The pressed oil cake was used as a raw material and subjected to an extruder treatment in the same manner as in Production Example 1 to prepare textured soy protein material B. Furthermore, textured soy protein materials C to E were each commercially available products. Textured soy protein material C: Vegtex SHF, textured soy protein material D: New Fujinic BSN, textured soy protein material E: New Fujinic 58. All were manufactured by Fuji Oil Co., Ltd.
• textured soy protein material E 80g of textured soy protein material E and 20g of soybean oil were placed in a pot and heated while stirring until the oil had spread throughout and was gone, producing textured soy protein material F, which had oil added after textured soy protein material E.
• Microwave drying 50 g of the frozen sample was spread on a plate and dried by heating at 200 W for 10 minutes in a microwave oven (model ER-N6, Toshiba Corporation).
• a score of 3 or more in each of the three items was considered to be acceptable.
• 1 point for rehydration Almost no rehydration. Has a firm texture.
• Table 2 shows the analytical values of the freeze-dried samples before flavoring and the sensory evaluation after drying and rehydration.
• Material A which used whole soybeans, received very good ratings in all three sensory evaluation categories.
• Material B which used compressed soybeans, also received high ratings and passed, although it had some off flavor and a soybean smell.
• material C had a hard texture and low water absorption rate, so it received a low rehydration rating, while materials D and E, which had good rehydration, had a lot of off flavor.
• Material F to which oil was added later, behaved in the same way as material E, and all of C to F failed.
• the present invention it is possible to prepare instant dried foods that have good physical properties, such as being easily rehydrated with hot water and not losing their flavor.
• the quality of ingredients in instant foods can be improved, making these foods more versatile.

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