JP7680855B2 - Method for producing food containing non-expanded extrudate of vegetable protein - Google Patents

Description

The present invention relates to a food product comprising a non-expanded extrusion product of vegetable protein. In particular, the present invention relates to a technology for producing a food product having a juicy texture and mouthfeel similar to meat from a non-expanded extrusion product of vegetable protein.

Soybean and other vegetable proteins are widely used in the field of processed foods, and in recent years, there has been a trend towards more active use of them due to health concerns, such as the prevention of lifestyle-related diseases. Vegetable proteins are regulated by the JAS standard as the "Japanese Agricultural Standard for Vegetable Proteins," and the raw materials for vegetable proteins are to be selected from soybean flour, defatted soybean flour, wheat flour, wheat gluten, etc.

Based on their properties, vegetable proteins are classified into powdered vegetable proteins, paste-like vegetable proteins, granular vegetable proteins, fibrous vegetable proteins, etc., and granular soybean protein has been used in processed meat foods such as minced meat to give them a granular texture, prevent the loss of meat juices, and improve cooking yields.

For example, Patent Document 1 describes the use of textured protein obtained by expanding soy protein to impart a juicy texture to processed foods. Patent Document 2 describes the use of granular soy protein to impart a meat-like texture to processed foods.

JP 2003-235461 A JP 2018-126094 A

Processed foods obtained by blending conventional granular soy protein ingredients have a texture similar to that of meat when eaten, but there are some aspects that differ from the texture of meat, and there is a demand for a texture that is even closer to that of meat. Furthermore, when using vegetable proteins as meat substitutes, it is important that the texture is good and that the food is juicy.

In light of this situation, the objective of the present invention is to develop a technology for producing foods that have the juiciness and texture of meat using plant-derived protein materials.

Non-expanded extrusions of vegetable protein are often distributed or stored frozen due to their high moisture content, and it is recommended that they be thawed naturally before cooking. However, if they are thawed naturally before cooking, they will lack juiciness, be difficult to separate, and have a hard texture.

As a result of thorough research into the above-mentioned problems, the inventors discovered that by immersing a non-expanded extruded product of vegetable protein in a liquid and thawing it, a food product that has a texture similar to meat but is juicy, easy to separate, and has excellent flavor can be obtained, which led to the completion of the present invention.

The present invention includes, but is not limited to, the following inventions.
[1] A method for producing a food product, comprising the step of thawing a frozen unexpanded vegetable protein extrudate by immersion in a liquid.
[2] The method according to [1], wherein the vegetable protein comprises a vegetable protein derived from soybean.
[3] The method according to [1] or [2], wherein the moisture content of the non-expanded extrusion product of vegetable protein in a frozen state is 50 to 70% by mass.
[4] The method according to any one of [1] to [3], wherein the temperature of the liquid for immersion is 5 to 100° C.
[5] The method according to any one of [1] to [4], wherein the food has a meat-like texture.
[6] The method according to any one of [1] to [5], further comprising the step of cooking the thawed non-expanded vegetable protein extrusion product.
[7] The method according to any one of [1] to [6], further comprising a step of pressure dehydrating the thawed non-expanded vegetable protein extrusion product prior to cooking.
[8] A method for improving the texture of a food, comprising the step of thawing a frozen non-expanded extrudate of vegetable protein by immersing it in a liquid.

According to the present invention, it is possible to produce a food product from a non-expanded extrusion product of vegetable protein that has a texture similar to meat, but is juicy and easy to break apart. Furthermore, since the food product produced according to the present invention does not have a flavor derived from the vegetable raw material, it can be said to have an excellent flavor as a meat substitute.

FIG. 1 is a photograph showing the appearance of the food cooked in Experiment 1. FIG. 2 is a photograph showing the appearance of the food cooked in Experiment 2. FIG. 3 is a photograph showing the appearance of the food cooked in Experiment 3.

In the present invention, vegetable protein that has been extruded without swelling is used. In the past, vegetable protein such as granular soy protein that has been expanded has been used as a meat substitute, and although it has a texture similar to that of meat, there are some parts that are different from the texture of meat, and a texture closer to that of meat has been desired. The non-expanded vegetable protein extrusion product used in the present invention is vegetable protein that has been extruded without swelling, and has a meat-like texture.

Non-expanded vegetable protein extrusions are distributed or stored frozen due to their high moisture content, but if they are thawed naturally and then cooked, they lack juiciness, are difficult to separate, and have a hard texture. In the present invention, frozen non-expanded vegetable protein extrusions are thawed by immersing them in liquid rather than allowing them to thaw naturally, making it possible to produce foods that are juicy, easy to separate, and have a meat-like texture. In addition, thawing by immersing in liquid reduces the odor caused by soybeans, the raw material for the vegetable protein, so foods produced by the present invention also have an excellent flavor.

In the present invention, the liquid used when thawing the frozen non-expanded vegetable protein extrusion product is not particularly limited, but is preferably an aqueous liquid, and more preferably water or a seasoning liquid. The temperature of the liquid in which the non-expanded vegetable protein extrusion product is immersed when thawing is not particularly limited, but is preferably 1°C or higher, and can be 5°C or higher or 10°C or higher. It is also preferably 100°C or lower, and can be 90°C or lower or 80°C or lower. The thawing time is not particularly limited, but can be, for example, 1 minute to 3 days (72 hours), more preferably 2 minutes to 24 hours, and may be 3 minutes to 10 hours or 4 minutes to 5 hours. More specifically, it is preferable to immerse the product in the liquid at 60°C or lower for 30 minutes to 72 hours, and it is preferable to immerse the product in the liquid at 60°C or lower for 1 to 30 minutes.

In the present invention, after thawing in liquid, the non-expanded extruded vegetable protein product may be washed with water or pressure-dehydrated. There are no particular limitations on the method of pressure-dehydration, and it may be squeezed by hand, using a weight, or using a device such as a centrifugal dehydrator or a pressurized dehydrator.

In the present invention, when a seasoning liquid is used as the liquid used for thawing the frozen non-swollen extrusion product of vegetable protein, the composition thereof is not particularly limited. The seasoning liquid may contain various seasonings and additives, such as alcoholic beverages such as cooking sake, wine, sake, and plum wine, vinegars such as grain vinegar, fruit vinegar, and synthetic vinegar, soy sauce, miso, mirin, koji, fermented milk sauces, gochujang, fish sauce, salt, protein hydrolysates, carbohydrates, starches, sweeteners, acidulants, umami seasonings (amino acids, nucleic acids, etc.), colorants, flavors, minerals, vitamins, thickeners, emulsifiers, antioxidants, and bacteriostatic agents.

The seasoning liquid may contain various ingredients, and spices, aromatic vegetables, herbs, etc. can be used as appropriate. Examples include herbs and spices such as pepper, paprika, basil, Japanese pepper, wasabi, and chili pepper; nuts and seeds such as walnuts, sesame, pine nuts, and almonds; seafood such as tuna, scallops, and dried bonito; processed meat products such as bacon, corned beef, and ham; eggs; aromatic vegetables such as shiso, ginger, celery, onion, tomato, carrot, garlic, green onion, parsley, green pepper, pickles, myoga, and shiso fruit; plum, olive, grapefruit, sudachi, apple, lemon, and mandarin orange fruit and their juice; mushrooms such as shiitake, mushroom, and wood ear mushroom; algae such as kombu and wakame; and extracts such as natural extracts, yeast extracts, meat extracts, seafood extracts, and vegetable extracts.

The seasoning liquid may contain edible oils and fats, which may be any of vegetable oils and fats, animal oils and fats, processed oils and fats, powdered oils and fats, etc. For example, soybean oil, rapeseed oil, canola oil, corn oil, sunflower oil, safflower oil, corn oil, cottonseed oil, sesame oil, perilla oil, linseed oil, peanut oil, olive oil, grape seed oil, macadamia nut oil, hazelnut oil, pumpkin seed oil, walnut oil, camellia oil, tea seed oil, perilla oil, borage oil, rice bran oil, wheat germ oil, palm oil, palm kernel oil, coconut oil, cacao butter, beef tallow, lard, chicken fat, milk fat, fish fat, seal fat, algae fat, etc. may be used alone or in combination. In addition, oils and fats that have been reduced in saturation by quality improvement, hydrogenated oils and fats, esterified oils of glycerin and fatty acids, interesterified oils, fractionated oils and fats, etc. may be used as appropriate. Furthermore, it may be extracted from a plant that has been bred using recombinant gene technology.

In the present invention, by adding a non-puffed extrusion product of vegetable protein thawed as described above to a food, it is possible to impart a juicy feel and texture like meat to the food. According to the present invention, it is possible to further improve the juiciness and texture of the food, and for example, by adding the product to a processed meat food, it is possible to impart a texture closer to the specific texture of meat to the food. Thus, in one aspect, the present invention is a method for improving the texture of food.

The foods to which the present invention can be applied are not particularly limited, but examples include processed foods such as processed meat foods and processed seafood foods.
The food according to the present invention may or may not contain meat such as livestock meat or fish meat. By applying the present invention to a food that does not contain meat and imparting a meat-like texture to the food, the food can be made suitable for vegans, vegetarians, etc.

The non-swollen extrusions of vegetable protein thawed according to the present invention can be cooked as appropriate and eaten. The cooking method is not particularly limited, but examples include baking, frying, steaming, stewing, smoking, deep-frying, microwave cooking, and retort cooking. When cooking, the non-swollen extrusions of vegetable protein may be cooked alone, or may be cooked together with any ingredients such as vegetables, fruits, seaweed, mushrooms, meat, seafood, noodles, cooked rice, seasonings, spices, dairy products, eggs, starch, and grain flour. For example, they can be fried with vegetables, seasonings, and spices to make stir-fried vegetables, boiled to make stew, baked with sauce to make teriyaki, baked in an oven and dried to make foods such as squid, scallops, and jerky, or fried with bread crumbs or batter to make tempura, fried chicken, cutlet, etc. In addition, by mixing the unexpanded extrusion product of vegetable protein thawed according to the present invention with any material, forming it into any shape, coating it with breadcrumbs or batter, wrapping it in food wrappers or bakery dough, or filling it into a casing, it is possible to produce processed foods such as hamburger steaks, meatballs, minced meat cutlets, fish balls, meatballs, nuggets, ham, sausages, fish paste (kamaboko, chikuwa, etc.), gyoza, shumai, spring rolls, Chinese buns, curry bread, and the like.

Food products containing non-puffed extrusions of vegetable protein thawed according to the present invention may be cooked to an edible state and then frozen for storage, or may be frozen midway through cooking to form semi-cooked products. Food products obtained according to the present invention have a good meat-like texture when eaten.

Non-swollen extrusions of vegetable protein The non-swollen extrusions of vegetable protein according to the present invention are produced by extruding vegetable protein, and have a texture similar to meat. Granular soy protein materials that have been used as minced meat substitutes in the past have a sponge-like internal structure due to swelling, whereas the vegetable protein extrusions of the present invention have a layered structure oriented in one direction due to extrusion, and this oriented structure provides a texture similar to meat muscle fibers. In addition, the vegetable protein extrusions of the present invention are not swollen, and therefore provide a firm chewiness similar to meat.

In a preferred embodiment, the non-expanded extrusion product according to the present invention has a moisture content of 30 to 80% by mass, and may also be 40 to 75% by mass or 50 to 70% by mass. With such a moisture content, it is easier to achieve a meat-like hardness and chewiness, and it is easier to feel a more meat-like fibrous texture. The moisture content of the non-expanded extrusion product can be adjusted by adding water during extrusion, and the moisture content can also be adjusted by using an aqueous solution containing seasonings such as soy sauce, colorings, etc.

The non-expanded extrusion product of the present invention can be produced by adding starches, polysaccharides, etc. to vegetable protein as necessary, and extruding the mixture using a twin-screw extruder or the like so as not to expand the mixture.

The protein content of the entire raw material of the non-expanded extrusion product is preferably 50% by mass or more of the solid content, and can be 60% by mass or more or 70% by mass or more. If the protein content is too low, it may be difficult to realize a layered structure oriented in one direction by extrusion molding. The vegetable protein used in the present invention can be preferably a protein derived from a plant such as soybean, wheat, rapeseed, pea, broad bean, chickpea, etc., and the vegetable protein may be treated with an enzyme or the like. In addition, one type of vegetable protein may be used, or multiple types of vegetable proteins may be used. As the protein derived from soybean, for example, defatted soybean flour, fat-containing soybean flour, isolated soybean protein, concentrated soybean protein, soy milk powder, etc. can be used as a raw material, and isolated soybean protein, concentrated soybean protein, and defatted soybean flour are particularly preferred.

The non-expanded extrusion product may contain secondary materials such as starches, polysaccharides, edible oils and fats, dietary fiber, colorants, seasonings, fragrances, emulsifiers, organic acids, salts, and vitamins. These secondary materials may be used alone or in combination of two or more. Examples of starches include wheat starch, potato starch, tapioca starch, sago starch, corn starch, and modified starches thereof. Examples of polysaccharides include pullulan, gum arabic, guar gum, xanthan gum, gellan gum, and hemicellulose.

In the present invention, any known extruder can be used without limitation as long as it can extrude vegetable protein without expanding it. In a preferred embodiment, the non-expanded extrusion product according to the present invention can be molded using an extruder having a die capable of cooling. For example, when a twin-screw extruder is used, the heating temperature of the barrel can be adjusted so that the temperature in the front half of the barrel is 40 to 120°C and the temperature in the rear half of the barrel is 140 to 180°C, and it is preferable to increase the temperature stepwise. In addition, the pressure can be adjusted so that the pressure immediately before the cooling die is 0 to 50 kg/ ^cm2 , and is preferably 35 kg/cm2 or ^less or 20 kg/cm2 or ^less . The screw can be used in appropriate combination with a kneading disk, a reverse element, etc. In a preferred embodiment, the extruder has a raw material supply port, a mechanism for feeding raw materials through a screw in the barrel, mixing, compressing, and temperature adjustment mechanisms, and further has a die attached to the tip of the barrel.

The cooling conditions may be appropriately set so that the extrusion does not cause swelling, but it is preferable to cool the extrudate so that the temperature immediately after it is extruded from the cooling die is 90°C or less, and it can also be cooled to 70°C or less or 50°C or less. The cooling die can be cooled by water cooling, and the temperature and flow rate of the cooling water can be appropriately adjusted depending on the size and type of extruder, the amount of raw material processed, etc. There is no particular limit to the size of the cooling die used, and the flow path length and inner diameter can be appropriately adjusted depending on the size and type of extruder, the amount of raw material processed, etc. By extruding the vegetable protein so as not to cause swelling, a layered structure oriented in one direction is formed, resulting in a fibrous texture similar to that of meat.

The method for freezing the non-expanded extrusion moldings is not particularly limited, and may be appropriately selected from an air blast method, a liquid method, a contact method, a liquefied gas method, etc., and may be quick freezing or slow freezing. The apparatus used is not particularly limited, and may be a continuous type or a batch type. For example, a conveyor type or rack type tunnel freezer or a spiral freezer may be used. Before freezing, the non-expanded extrusion moldings may be subjected to a heat treatment such as retort sterilization for sterilization or the like, or may be refrigerated for storage or the like.
The non-expanded vegetable protein extrusion product may be stored in a packaging container, and may be vacuum-packaged or gas-substituted. Examples of packaging containers include trays, packs, cups, bags, and the like, and may be made of an appropriate material such as paper, resin, or metal. The extrusion product may also be canned or bottled.

In the present invention, by immersing a frozen non-expanded extrusion of vegetable protein in a liquid and thawing it, the meat-like fibrous texture can be enhanced and a juicy and flaky texture can be imparted to the food. According to the present invention, it is possible to further improve the texture of processed foods, and to impart to the processed foods a texture that is closer to the texture specific to meat. Thus, in one aspect, the present invention is a texture improver for processed foods. The texture improver of the present invention can be used in processed foods that contain meat to enhance the meat-like texture, and can also be used in processed foods that do not contain meat to impart a meat-like texture to the processed foods.

The present invention will be described in more detail based on specific examples, but the present invention is not limited to the following examples. In this specification, concentrations and the like are based on mass, and numerical ranges are described as including their endpoints, unless otherwise specified.

Experiment 1: Chicken sauce-like food No chicken chunks (moisture content: about 68%) from Vegetarian Butcher Japan Co., Ltd. were used as a non-swollen extrusion product of soy protein. 200 g of frozen non-swollen extrusion product was immersed in an immersion liquid (water or seasoning liquid) and thawed under the conditions shown in the table below. However, for sample 1-1, the frozen non-swollen extrusion product was not immersed in an immersion liquid but was naturally thawed in a refrigerator (5°C) (Comparative Example). In addition, for sample 1-7, after thawing, it was washed with water and then squeezed out water by hand until the weight was approximately the same as before immersion. The seasoning liquid (sauce) used in this experiment was prepared by mixing 50 parts by mass each of soy sauce, mirin, and sugar.

150 g of the thawed non-puffed extrusions were mixed with 150 g of seasoning liquid and then pan-fried for 5 minutes (Figure 1). However, for sample 1-10, which was thawed by immersing in seasoning liquid, no seasoning liquid was used when pan-fried.

The cooked chicken-like foods were subjected to a sensory evaluation of the texture, the ability to break apart, the juiciness, and the penetration of flavor. The sensory evaluation was conducted by a panel of five trained members in consultation with each other, based on the following criteria.
■ Texture (meat-like fibrous texture)
5 (very good): Texture very similar to foods made from meat, with a strong fibrous feel. 4 (good): Texture very similar to foods made from meat, with a fibrous feel. 3 (fairly good): Texture somewhat similar to foods made from meat, with some fibrous feel. 2 (fairly bad): Texture somewhat different from foods made from meat, with a weak fibrous feel. 1 (very bad): Texture different from foods made from meat, with no fibrous feel. ■Fragility 5 (very good): Texture very similar to foods made from meat. 4 (good): Texture similar to foods made from meat. 3 (fairly good): Texture somewhat similar to foods made from meat. 2 (fairly bad): Texture somewhat different from foods made from meat, does not fall apart very easily. 1 (very bad): Unlike foods made from meat, difficult to fall apart. ■Juicy 5 (very good): Feels very juicy when chewing. 4 (good): ): Has a strong juicy texture when chewed3 (fairly good): Has a juicy texture when chewed2 (fairly bad): Does not have much juicy texture when chewed1 (very bad): Does not have any juicy texture when chewed■Flavor penetration5 (very good): Has very good juicing throughout4 (good): Has good juicing throughout3 (fairly good): Has juicing throughout2 (fairly bad): Has not fully penetrated1 (very bad): Has not penetrated throughout

When frozen non-expanded extrusions were thawed by immersing them in an immersion liquid, the texture, crumbliness, juiciness, and flavor penetration were better than when the extrusions were thawed naturally (Sample 1-1).

In addition, when comparing Sample 1-6 and Sample 1-7, by dehydrating the soaking liquid once after soaking, the seasoning liquid was able to penetrate more easily to the inside, resulting in better flaking, juiciness, and flavor penetration.

Experiment 2: Chicken cutlet-like food Vegetarian Butcher Japan's No chicken chunks (moisture content: about 68%) were used as a non-swollen extrusion product of soy protein. 200 g of frozen non-swollen extrusion product was immersed in an immersion liquid (water or seasoning liquid) and thawed in the same manner as in Experiment 1. However, for sample 2-1, the frozen non-swollen extrusion product was not immersed in an immersion liquid but was naturally thawed in a refrigerator (5°C) (Comparative Example). The seasoning liquid was prepared by boiling the raw materials shown in the table below.

150 g of thawed non-puffed extrusions were immersed in 150 g of seasoning liquid at 5°C for 4 hours, the seasoning liquid was drained off, and the extrusions were coated with flour, egg liquid, and breadcrumbs in that order, and deep-fried at 170°C for 4 minutes (Figure 2). However, for sample 2-9, which was immersed in seasoning liquid and then thawed, the thawed non-puffed extrusions were not immersed in seasoning liquid again, but were coated with flour, egg liquid, and breadcrumbs, and deep-fried.

After cooking, the chicken cutlet-like foods were evaluated in terms of texture, juiciness, and flavor penetration in the same manner as in Experiment 1.

When frozen non-expanded extrusions were immersed in an immersion liquid and thawed, the texture, crumbliness, juiciness, and flavor penetration were better than when the extrusions were thawed naturally (sample 2-1).

Experiment 3: Jerky-like food Vegetarian Butcher Japan's No chicken chunks (moisture content: about 68%) were used as a non-puffed extrusion product of soy protein. 200 g of the frozen non-puffed extrusion product was immersed in an immersion liquid (water or seasoning liquid) and thawed in the same manner as in Experiment 1. However, for Sample 3-1, the frozen non-puffed extrusion product was not immersed in an immersion liquid but was naturally thawed in a refrigerator (5°C) (Comparative Example). The seasoning liquid was prepared in the same manner as in Experiment 2.

150 g of the thawed non-puffed extrusion molded product was immersed in 150 g of seasoning liquid at 5°C for 4 hours, the seasoning liquid was drained off, and the product was baked for 60 minutes at 120°C using a steam convection oven (SSC-C06DC, Maruzen) (Figure 3). However, for sample 3-9, which was immersed in seasoning liquid and then thawed, the thawed non-puffed extrusion molded product was baked in an oven without being immersed in seasoning liquid again.

After cooking, the jerky-like food was evaluated in terms of texture, ease of detachment, juiciness, and flavor penetration in the same manner as in Experiment 1.

When frozen non-expanded extrusions were immersed in an immersion liquid and thawed, the texture, crumbliness, juiciness, and flavor penetration were better than when the extrusions were thawed naturally (sample 3-1).

Claims (8)

A method for producing a food product comprising the step of thawing a frozen unexpanded vegetable protein extrudate by immersion in an aqueous liquid . The method of claim 1, wherein the vegetable protein comprises a vegetable protein derived from soybeans. The method according to claim 1 or 2, wherein the moisture content of the unexpanded extruded vegetable protein in a frozen state is 50 to 70% by mass. The method according to any one of claims 1 to 3, wherein the temperature of the aqueous liquid for immersion is 5 to 100°C. The method according to any one of claims 1 to 4, wherein the food has a meat-like texture. The method according to any one of claims 1 to 5, further comprising the step of cooking the thawed non-puffed vegetable protein extrusion. The method according to any one of claims 1 to 6, further comprising a step of pressure dehydrating the thawed non-puffed vegetable protein extrusion before cooking it. A method for improving the texture of a food product, comprising the step of thawing a frozen unexpanded extrudate of vegetable protein by immersing it in an aqueous liquid .