JP7782964B2 - Dry sausage-like food and its manufacturing method - Google Patents

Description

The present invention relates to a dry sausage-like food product and a method for producing the same.

The use of plant-based meat alternatives is considered one solution to achieving the Sustainable Development Goals (SDGs) adopted by the United Nations in 2015. Using plant-based meat alternatives instead of animal meat is expected to eliminate hunger from the world, reduce environmental impact, and lead to the realization of sustainable food production.

However, when attempting to prepare dry sausage-like foods using plant-based meat substitutes, for example, the common method of using commercially available granular vegetable protein has the problem of a dry texture compared to dry sausages prepared using animal meat.

As an attempt to solve this problem, for example, Patent Document 1 discloses dry sausages that are less oily and easier to chew.

However, there is still a demand for dry sausage-like foods with improved texture and methods for producing them.

JP 2011-160666 A

The present invention provides a dry sausage-like food product with improved texture and a method for producing the same.

The inventors have discovered that a better texture can be achieved in dry sausage-like foods that use soybeans or processed soybean products as ingredients by adjusting the breaking stress to 45,000 to 600,000 Pa. The inventors have also discovered a method for producing dry sausage-like foods with a good texture, the method comprising the steps of: (a) preparing a soybean emulsion; (b) mixing the soybean emulsion obtained in step (a) with granular soy protein to prepare a food ingredient mixture; (c) filling a casing with the food ingredient mixture obtained in step (b); and (d) heat-treating the food ingredient mixture filled in the casing in step (c). The present invention is based on these findings.

The present invention includes the following inventions.
(1) A dry sausage-like food product using soybeans or processed soybeans as a raw material, having a breaking stress of 45,000 to 600,000 Pa.
(2) The dry sausage-like food according to (1), which does not contain animal meat.
(3) A dry sausage-like food according to (1) or (2), wherein the raw materials are soybean emulsion and granular soybean protein.
(4) A dry sausage-like food according to (3), wherein the blending ratio of the soybean emulsion and the granular soybean protein is 80-95:20-5 relative to the total amount of the soybean emulsion and the granular soybean protein.
(5) The dry sausage-like food according to (3) or (4), wherein the major axis of the granular soy protein is 3 to 13 mm.
(6) The dry sausage-like food according to any one of (3) to (5), wherein the soybean emulsion comprises powdered soybean protein, water, and vegetable oil.
(7) A dry sausage-like food according to any one of (1) to (6), having a breaking stress of 100,000 to 550,000 Pa.
(8) A dry sausage-like food according to any one of (1) to (7), having a water activity value of 0.750 to 0.880.
(9) The dry sausage-like food according to any one of (1) to (8), further comprising a sugar.
(10) The dry sausage-like food according to (9), wherein the sugar is sucrose and/or trehalose.
(11) The dry sausage-like food according to (9) or (10), wherein the sugar content is 3.0 to 18.0% by mass relative to the total amount of the dry sausage-like food.
(12) A method for producing a dry sausage-like food product, comprising:
(a) preparing a soybean emulsion;
(b) mixing the soybean emulsion obtained in step (a) and the granular soybean protein to prepare a food raw material mixture;
(c) stuffing the food material mixture obtained in step (b) into a casing; and (d) heat-treating the food material mixture stuffed into the casing in step (c).
A method for producing a dry sausage-like food product comprising:
(13) The method according to (12), wherein step (a) comprises mixing powdered soy protein, water, and vegetable oil to prepare a soybean emulsion.
(14) A manufacturing method according to (12) or (13), wherein the blending ratio of the soybean emulsion obtained in step (a) and the granular soy protein in step (b) is 80 to 95:20 to 5 relative to the total amount of the soybean emulsion and the granular soy protein obtained in step (a).
(15) The method according to any one of (12) to (14), wherein in step (b), the major axis of the granular soy protein before mixing is 3 to 13 mm.
(16) The method according to any one of (12) to (15), wherein in step (b), a sugar is further mixed to prepare a food raw material mixture.
(17) The method according to (16), wherein the sugar is sucrose and/or trehalose.
(18) The dry sausage-like food according to (16) or (17), wherein the blending amount of the sugars is 1.5 to 10.0% by mass relative to the total amount of the food raw material mixture obtained in step (b).
(19) The method according to any one of (12) to (18), wherein the step of heat-treating the food raw material mixture in step (d) comprises a step of drying the mixture.

The present invention provides a dry sausage-like food product with improved texture and a method for producing the same.

Specific Description of the Invention

The dry sausage-like food of the present invention uses soybeans or processed soybeans as an ingredient and is characterized by a breaking stress of 45,000 to 600,000 Pa. According to the present invention, it is also possible to obtain a dry sausage-like food with a pleasant taste in which the bitterness characteristic of soybeans is masked.

The manufacturing method of the present invention is characterized by comprising the steps of: (a) preparing a soybean emulsion; (b) mixing the soybean emulsion obtained in step (a) with granular soy protein to prepare a food ingredient mixture; (c) filling a casing with the food ingredient mixture obtained in step (b); and (d) heat-treating the food ingredient mixture filled in the casing in step (c). Using the manufacturing method of the present invention, it is also possible to produce dry sausage-like foods with a pleasant taste in which the bitterness characteristic of soybeans is masked.

Generally, sausage refers to a product made primarily from animal meat such as meat or fish, which is seasoned, kneaded, shaped, and then usually cooked. Among sausages, dry sausages such as dry sausage, semi-dry sausage, salami sausage, and soft salami sausage are manufactured to withstand relatively long storage periods, and are specified by the Japanese Agricultural Standards for their moisture content. For example, dry sausage and salami sausage are specified as having a moisture content of 35% or less, while semi-dry sausage and soft salami sausage are specified as having a moisture content of 55% or less.

The dry sausage-like food of the present invention is a food that uses soybeans or processed soybeans as the main ingredient and has a texture, taste, etc. similar to dry sausages prepared using animal meat as the main ingredient.

The dry sausage-like food product of the present invention may contain a certain amount of animal meat, or may be free of animal meat. The animal meat may be any edible meat suitable for human consumption, and may be non-fat extracted, non-dried, fresh meat, fresh meat products, fresh meat by-products, and mixtures thereof. According to a preferred embodiment of the present invention, the dry sausage-like food product of the present invention does not contain animal meat.

In this invention, the term "breaking stress (Pa)" refers to the force (stress) with which a sample pushes back against a load when it breaks due to compression. Specifically, this breaking stress (Pa) is the average value of the breaking stress measured at approximately the center of the top surface of a dry sausage-like food product with a product temperature of 25±1°C and dimensions of 10 mm in diameter and 10 mm in height, placed on the measurement table as the measurement sample, using a creep meter (RE2-33005S, manufactured by Yamaden Co., Ltd.) with a wedge-shaped plunger 30 mm wide x 25 mm long and 30° angle, a load cell of 200 N, and a compression (measurement) speed of 1 mm/sec.

The breaking stress of the dry sausage-like food product of the present invention is 45,000 to 600,000 Pa, preferably 100,000 to 550,000 Pa, more preferably 120,000 to 400,000 Pa, and even more preferably 200,000 to 350,000 Pa.

Soybeans used in the present invention may be of various types and shapes, for example, small, medium, or large shapes, and various colors (yellow, white, black, green). Soybeans used in the present invention include, but are not limited to, Tsurumusume, Yuzuru, Toyomusume, Toyokomachi, Kariyutaka, Toyomare, Yukihomare, Miyagishirome, Tachinagaha, Ootsuru, Tamahomare, Chuseihiguro, Suzuhime, Suzumaru, Yukishizuka, Suzunooto, Elstar, Kosuzu, Suzukomachi, Suzuotome, Osuzu, Okushirome, Suzukari, Tanrei, Osodenomai, Fukuibuki, Ryuho, and others. Some examples include Cormorant, Suzuyutaka, Tomoyutaka, Tachiyutaka, Tamaurara, Hatayutaka, Ayakogane, Otofuke Osode, Aomarukun, Hoen, Nakasennari, Suzukogane, Enrei, Ginrei, Nishimusume, Akishirome, Fukuyutaka, Murayutaka, Sachiyutaka, Kitamusume, Sayanami, Tamamasari, Tokachikuro, Iwaikuro, Tamadaikoku, Yumeminori, Tanbaguro, Akitamidori, Kiyomidori, Hayahikari, and Ichihime.

The soybean processed product of the present invention refers to soybeans that have been subjected to processes such as soaking, heating, defatting, and crushing, or to mixing with various ingredients such as seasonings. The soybean processed product of the present invention can be used in a variety of dishes as a meat substitute.

Generally, soy protein is a general term for defatted soybeans or soy protein products processed using defatted soybeans as a starting material. The granular soy protein of the present invention is a soy protein product processed from defatted soybeans as a starting material, which is granulated using defatted soybean flour as a starting material by extrusion molding or steam granulation. Granular soy protein may be produced by known methods or may be purchased commercially.

In the present invention, soybean emulsion refers to an emulsion containing soybean protein. The soybean protein contained in the soybean emulsion may be powdered soybean protein, which may be produced by a known method or may be commercially available.

The soybean emulsion of the present invention preferably contains, but is not limited to, powdered soybean protein, water, and vegetable oil, with the vegetable oil preferably being salad oil.

The blending ratio of soybean emulsion and granular soy protein contained in the raw material mixture for the dry sausage-like food product of the present invention is not limited, but is preferably 80-95:20-5, and more preferably 90-95:10-5, where the total amount of soybean emulsion and granular soy protein is taken as 100.

The size of the granular soy protein particles in the present invention is not limited, but preferably the major axis is 3 to 13 mm, more preferably 3.5 to 12.5 mm. The minor axis is preferably 2 to 7 mm, more preferably 2.5 to 6 mm. The major axis refers to the maximum length of the granular soy protein particles observed with the naked eye. The minor axis refers to the smallest value perpendicular to the major axis of the granular soy protein particles observed with the naked eye.

Moisture is one of the most fundamental components that determines the properties of food, and its content varies from less than 1% to over 99% depending on the food. Furthermore, the moisture contained in food can be broadly divided into free water and bound water. The former exhibits vapor pressure as a normal aqueous solution and evaporates relatively easily. In contrast, the latter exists as crystal water or in a hydrogen-bonded state with polymers such as proteins and polysaccharides, and is relatively resistant to evaporation. Therefore, when analyzing the moisture content of food, it is necessary to select and apply a method appropriate for the food. Meat and meat products, including dry sausage and semi-dry sausage, are measured using the atmospheric pressure heating method. Specifically, the measurement is performed by heating at atmospheric pressure under a specified temperature and time (135°C, 2 hours). The difference in weight before and after heating is measured to determine the moisture content.

In this invention, water activity refers to the amount of water required for microbial growth and enzyme activity, and indicates the relationship between microbial growth and enzyme activity and water. Water is essential for microbial growth, but microorganisms cannot utilize bound water, and the only water available for microbial growth is free water. If the amount of free water is low, microorganisms cannot grow, and if there is an increase in free water, microorganisms grow more easily. In the 1950s, W.J. Scott introduced the unit of water activity (Aw) to the field of food science. In this invention, water activity (Aw) can be calculated by dividing the water vapor pressure (P) inside a sealed container containing food by the vapor pressure of pure water (P0) at that temperature.

The water activity value of the dry sausage-like food product of the present invention is not limited, but is preferably 0.750 to 0.880, and more preferably 0.800 to 0.860.

Sugars in the present invention include, but are not limited to, sugar (including sucrose), glucose, high fructose liquid sugar, trehalose, palatinose, etc., with sucrose and/or trehalose being preferred, and sucrose and trehalose being more preferred. The dry sausage-like food of the present invention may also contain carbohydrates other than sugars, and examples of carbohydrates other than sugars include, but are not limited to, starch syrup, sorbitol, reduced palatinose, etc.

The sugar content in the dry sausage-like food product of the present invention is not limited, but is preferably 3.0 to 18.0% by mass, and more preferably 4.5 to 13.5% by mass, based on the total amount of the dry sausage-like food product.

Specifically, the sugar content contained in the dry sausage-like food product of the present invention is the average value obtained by the following measurement method.

60-70 mL of purified water was added to 5 g of the prepared dry sausage-like food product, and the mixture was homogenized at 10,000 rpm for 1 minute to extract the sugars with water. Further purified water was added to make 100 mL of the solution, and 50 mL of the solution was centrifuged at 3,000 rpm, 5°C, and 10 minutes to obtain the supernatant. 2 mL of acetonitrile was added to 2 mL of the supernatant, and the mixture was vigorously stirred. After centrifugation at 3,000 rpm, 5°C, and 10 minutes, the supernatant was obtained. 1 mL of the supernatant was filtered through a 0.20 μm membrane filter (Advantec), and this was used as the measurement sample solution. If the concentration of the measurement sample solution is too high to perform the measurement properly, the measurement sample solution can be further diluted with 50% acetonitrile solution.

Separately, a standard solution prepared using 10 standards (lactose monohydrate, trehalose dihydrate, maltose monohydrate, sucrose, fructose, glucose, galactose, xylose, and ribose) was analyzed by HPLC. Measurements were performed on samples with concentrations of 25 μg/mL, 100 μg/mL, and 250 μg/mL to obtain a calibration curve. The above measurement sample solution was then analyzed by HPLC, and the sugar content was calculated from the obtained calibration curve. The HPLC conditions were as shown in Table 1 below.

The amount of sugar used in the manufacturing method of the present invention is not limited, but is preferably 1.5 to 10.0% by mass, and more preferably 2.5 to 7.5% by mass, of the total amount of the food ingredient mixture.

In the manufacturing method of the present invention, other additives may be mixed with the soybean emulsion and granular soy protein as needed and then packed. Mixing may be carried out using a conventional mixer. Specific examples of additives are preferably those that comply with the Food Sanitation Act, and include, but are not limited to, seasonings (salt, soy sauce, etc.), spices, colorants, flavorings, emulsifiers, preservatives, antioxidants, binders, etc.

In the manufacturing method of the present invention, filling refers to covering or packaging the mixture using the following filler (casing). Examples of filler materials include, but are not limited to, 1. bovine intestine, porcine intestine, ovine intestine, stomach, or esophagus; 2. collagen film or cellulose film; and 3. synthetic films with heat resistance, water resistance, oil resistance, etc. Filling can be carried out using a stuffer. The mixture is fed into the inlet of the stuffer, filled into a filler (casing) placed in the nozzle of the discharge section of the stuffer, and then knotted to an appropriate length before being discharged. Any filling method can be used in the stuffer, including, for example, a double-gear rotary method or a blade rotor method.

In the manufacturing method of the present invention, the mixture filled into the filler (casing) is heat-treated. This heat treatment allows the mixture to have the desired water activity value. The water activity value is not limited, but is preferably 0.750 to 0.880, and more preferably 0.800 to 0.860.

In the manufacturing method of the present invention, the heat treatment may include a drying step, and the drying step may be carried out once or multiple times. The drying step may be carried out appropriately taking into consideration the type, quality, quantity, size, etc. of the ingredients contained in the food ingredient mixture packed into the filler (casing). Drying may be carried out using commonly used drying methods such as heat, hot air, or electromagnetic heating. Drying may also be carried out under pressurized or reduced pressure, but is preferably carried out under atmospheric pressure.

The manufacturing method of the present invention may further include a smoking treatment. Smoking not only imparts antiseptic and antibacterial properties, but also imparts a smoky aroma and color, making it possible to provide a dry sausage-like food that meets consumer preferences. Smoking can be carried out in a smokehouse (smoke generator) by burning or smoking sawdust, sawdust, chips, etc. of cherry, oak, beech, silver, pine, cypress, larch, etc. to generate smoke.

The manufacturing method of the present invention may further include a drying process as a final step. This final drying is carried out primarily for the purpose of adjusting the desired water activity value. The final drying may be the same as or a different process from the previous drying. The manufacturing method of the present invention may also use a drying method that does not involve heating (e.g., cold air drying). The temperature and time of this final drying are adjusted to achieve the desired water activity value.

The present invention will be described in detail below, but the present invention is not limited to these examples. Unless otherwise specified, units and measurement methods follow the provisions of the Japanese Industrial Standards (JIS).

Test 1: Evaluation of physical properties of dry sausage-like food products Dry sausage-like foods of the present invention were prepared according to the formulations shown in Table 2 below.

Test Example 1
Water and edible vegetable oil were added to a silent cutter and cut until dispersed. After the water and edible vegetable oil were homogenized, powdered soy protein was added and cut until a paste was formed. Additives (salt, antioxidants, carbohydrates, sugars, starch, seasonings, spices, emulsifiers, and coloring agents) were added to the emulsion and mixed until homogenous. Next, 7 kg of granular soy protein was added and mixed until homogenous, obtaining a food ingredient mixture.

The resulting food ingredient mixture was mixed in a mixer for 2 minutes while being subjected to a vacuum. The food ingredient mixture was then stuffed into a casing, dried at 70°C for 50 minutes, smoked at 70°C for 10 minutes, heated with steam at 74°C for 30 minutes, and dried at 50°C for 15 hours. The resulting dry sausage-like food product was designated Test Example 1 and its physical properties were evaluated.

Test Example 2
Water and edible vegetable oil were added to a silent cutter and cut until dispersed. After the water and edible vegetable oil were homogenized, powdered soy protein was added and cut until a paste was formed. Additives (salt, antioxidants, carbohydrates, sugars, starch, seasonings, spices, emulsifiers, and colorings) were added to the emulsion and mixed until homogenous. Next, 21 kg of granular soy protein was added and mixed until homogenous, obtaining a food ingredient mixture.

The resulting food ingredient mixture was mixed in a mixer for 2 minutes while being subjected to a vacuum. The food ingredient mixture was then stuffed into a casing, dried at 70°C for 50 minutes, smoked at 70°C for 10 minutes, heated with steam at 74°C for 30 minutes, and dried at 50°C for 15 hours. The physical properties of the resulting dry sausage-like food product were evaluated as Test Example 2.

Test Example 3
Water and edible vegetable oil were placed in a silent cutter and cut until dispersed. After the water and edible vegetable oil were homogenized, powdered soy protein was added and cut until a paste was formed. Additives (salt, antioxidants, carbohydrates, sugars, starch, seasonings, spices, emulsifiers, and colorings) were added to the emulsion and mixed until homogenous. A food ingredient mixture was obtained without adding granular soy protein.

The resulting food ingredient mixture was mixed in a mixer for 2 minutes while being subjected to a vacuum. The food ingredient mixture was then stuffed into a casing, dried at 70°C for 50 minutes, smoked at 70°C for 10 minutes, heated with steam at 74°C for 30 minutes, and dried at 50°C for 15 hours. The resulting dry sausage-like food product was designated Test Example 3 and its physical properties were evaluated.

Test Example 4
Water and edible vegetable oil were added to a silent cutter and cut until dispersed. After the water and edible vegetable oil were homogenized, powdered soy protein was added and cut until a paste was formed. Additives (salt, antioxidants, carbohydrates, sugars, starch, seasonings, spices, emulsifiers, and coloring agents) were added to the emulsion and mixed until homogenous. Next, 7 kg of granular soy protein was added and mixed until homogenous, obtaining a food ingredient mixture.

The resulting food ingredient mixture was mixed in a mixer for 2 minutes while being subjected to a vacuum. The food ingredient mixture was then stuffed into a casing, dried at 70°C for 50 minutes, smoked at 70°C for 10 minutes, steam-heated at 74°C for 30 minutes, and dried at 50°C for 18 hours. The resulting dry sausage-like food product was designated Test Example 4 and its physical properties were evaluated.

As a positive control, a commercially available dry sausage containing animal meat (product name: Tokuyo Calpas (manufactured by Natori Co., Ltd.)) was used as Comparative Example 1, and its physical properties were evaluated.

Physical Property Evaluation Test Test Examples 1 to 4 and Comparative Example 1 were used as test specimens measuring 10 mm in diameter x 10 mm (height) and were measured for breaking stress (Pa) using a creep meter (RE2-33005S, manufactured by Yamaden Co., Ltd.). The breaking stress was expressed as an average value of n = 10, and the standard deviation was also calculated. The measurement results are shown in Table 3.

The results in Table 3 show that Test Example 1 exhibited a breaking stress closest to that of the commercially available dry sausage used as the positive control. Therefore, it was demonstrated that the dry sausage-like food product of the present invention has a texture equivalent to that of commercially available dry sausages that use animal meat as the main ingredient.

Test 2: Sensory evaluation of dry sausage-like food
A dry sausage-like food product of the present invention was prepared according to the formulation shown in Table 4 below.

Test Example 5
Water and edible vegetable oil were added to a silent cutter and cut until dispersed. After the water and edible vegetable oil were homogenized, powdered soy protein was added and cut until a paste was formed. Additives (salt, antioxidants, carbohydrates, sugars, starch, seasonings, spices, emulsifiers, and coloring agents) were added to the emulsion and mixed until homogenous. Next, 7 kg of powdered soy protein was added and mixed until homogenous, obtaining a food raw material mixture.

The resulting food ingredient mixture was mixed in a mixer for 2 minutes while being subjected to a vacuum. The food ingredient mixture was then stuffed into a casing, dried at 70°C for 50 minutes, smoked at 70°C for 10 minutes, heated with steam at 74°C for 30 minutes, and dried at 50°C for 15 hours. A sensory evaluation was conducted on the resulting dry sausage-like food product, designated Test Example 5.

Test Examples 6 to 8 were prepared in the same manner as Test Example 5, and a sensory evaluation was conducted. Test Example 1 was prepared in the same manner as Test 1, and a sensory evaluation was conducted.

Sensory Evaluation Test: For Test Examples 1 and 5 to 8, a sensory evaluation was conducted by 10 panelists (7 men and 3 women) in accordance with the following three evaluation items and evaluation criteria. All scores were given in increments of 1 point. The sensory evaluation results are shown as the average scores given by the 10 panelists. The average scores and standard deviations are shown in Table 5. As a positive control for the soybean masking effect, a commercially available dry sausage (product name: Tokuyou Calpas (manufactured by Natori Co., Ltd.)) was given an evaluation result of 4 points for the soybean masking effect.

Soy masking effectiveness : 4 points: Very effective.
3 points: Effective.
2 points: Somewhat effective.
1 point: No effect.

Sweetness level : 4 points: Very sweet.
3 points: Sweet.
2 points: Slightly sweet.
1 point: Not sweet.

Taste preference : 4 points: Very pleasant.
3 points: Good.
2 points: Somewhat favorable.
1 point: Not desirable.

These results show that the more sugar added, the greater the soybean-masking effect and sweetness, but adding too much sugar impairs the taste of the dry sausage-like food.

Claims (6)

A dry sausage-like food product using soybeans or processed soybeans as a raw material, having a breaking stress of 45,000 to 600,000 Pa,
Further comprising sugars,
the sugar content is 1.6 to 18.0% by mass relative to the total amount of the dry sausage-like food;
The dry sausage-like food has a blending ratio of the soybean emulsion and the granular soybean protein of 80-95:20-5 relative to the total amount of the soybean emulsion and the granular soybean protein . 2. The dry sausage-like food according to claim 1 , wherein the sugar is sucrose and/or trehalose. A method for producing a dry sausage-like food product, comprising:
(a) preparing a soybean emulsion;
(b) mixing the soybean emulsion obtained in step (a) and the granular soybean protein to prepare a food raw material mixture;
(c) stuffing the food material mixture obtained in step (b) into a casing; and (d) heat-treating the food material mixture stuffed into the casing in step (c).
comprising
The dry sausage-like food contains sugars,
the sugar content is 1.6 to 18.0% by mass relative to the total amount of the dry sausage-like food;
A production method in which the blending ratio of the soybean emulsion obtained in step (a) and the granular soy protein in step (b) is 80-95:20-5 relative to the total amount of the soybean emulsion and granular soy protein obtained in step (a) . The method according to claim 3 , wherein the sugar is sucrose and/or trehalose. A method for producing a dry sausage-like food product, comprising:
(a) preparing a soybean emulsion;
(b) mixing the soybean emulsion obtained in step (a) and the granular soybean protein to prepare a food raw material mixture;
(c) stuffing the food material mixture obtained in step (b) into a casing; and (d) heat-treating the food material mixture stuffed into the casing in step (c).
comprising
A production method in which the blending ratio of the soybean emulsion obtained in step (a) and the granular soy protein in step (b) is 80-95:20-5 relative to the total amount of the soybean emulsion and granular soy protein obtained in step (a). The method according to claim 5 , wherein the dry sausage-like food contains sugars, and the sugars are sucrose and/or trehalose.