JPS6240975B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for continuously mass producing a water-in-oil emulsion that has been sterilized, has a high shelf life, and is foamed if necessary, from an oil phase and an aqueous phase. Aqueous phases having a viscosity within a range are mixed and emulsified to form an oil-in-water emulsion. After the emulsion is sterilized, it is cooled and stirred in a closed cooling stirrer, and if necessary, an appropriate amount of gas is mixed in to form an oil-in-water emulsion. By inverting it to a water-in-water emulsion,
To provide a method for consistently producing a low-fat water-in-oil emulsion suitable as a filling material for confectionery, bread, etc., which has good flavor and has a long shelf life, from raw materials. Buttercream is generally used as a finishing material for Western sweets or as a filling material for bread and the like. This consists of butter, margarine or toning, sugar, and coloring if necessary.
It is made by mixing spices, eggs, starch syrup, Western liquor, etc. (called creaming or whipping) to make a smooth and uniform cream. Conventionally, such buttercream is made by putting margarine etc. in an open vertical mixer (such as a Kanto mixer) and stirring vigorously with a hopper or beater to disperse and incorporate air into the composition, and then adding sugar solution or powder. Manufactured by adding sugar, etc. Sometimes it is manufactured by gradually adding sugar solution or powdered sugar to margarine or the like while stirring. However, such conventional methods have various drawbacks as described below. In other words, as food hygiene awareness has increased in recent years, there is a demand for filling materials that are hygienic with less bacterial contamination and contain fewer synthetic preservatives. Not only is it easy for foreign matter to get mixed in, but it is also extremely difficult to prevent the contamination of germs, and the current situation is that it is impossible to sterilize the product. Also, the optimum temperature range for whipping margarine etc. is narrow; whipping at a relatively high temperature will result in a sticky buttercream, while whipping at a low temperature will result in a dry buttercream.
In workplaces where temperature control is not possible, several types of products (5 to 8 types) are required depending on each temperature as the temperature changes not only in winter and summer, but also throughout the four seasons. This product uses oils and fats that make it difficult to melt in the mouth. Furthermore, it is difficult to adjust the air content (overrun), making it difficult to obtain quality with a constant specific gravity.In particular, filling materials traditionally used for confectionery, bread, etc., have a heavy texture such as flower paste and candy. However, since a certain amount of agitation is required to mix the various materials sufficiently, overrun becomes high, making it difficult to produce products with high specific gravity (low overrun). Furthermore, various drawbacks have been pointed out, such as the need for manpower to handle solid materials such as margarine and shortening, which makes it difficult to save labor. To address the above-mentioned drawbacks, margarine for butter cream has appeared in which some ingredients such as sugar, sugar solution, and milk are added in advance during margarine production, and margarine for butter cream is also produced using a pressurized mixer and nitrogen gas during whipping. Methods have also been proposed in which a press-fitting method has been adopted, contributing to faster work, more uniform quality, and improved oxidation stability, but these are only partial solutions and do not provide a fundamental solution. has not arrived yet. Furthermore, in recent years, from a nutritional standpoint, low-calorie margarine with a low fat content has been developed and put into practical use. However, the stable emulsification type of emulsions with low fat content is oil-in-water type, and it is difficult to create a water-in-oil type state, and requires complicated emulsification operations or means, and furthermore, it is difficult to create a water-in-oil type emulsion. Even if it is successful, it has the disadvantage that syneresis tends to occur during storage, especially when it is stored in the state of butter cream. As a result of intensive research in view of the above points, the present inventors found that a low-fat oil-in-water emulsion that can be easily produced by using an aqueous phase having a viscosity within a specific range can be produced by cooling and stirring. We obtained the knowledge that it can be easily converted into a stable water-in-oil emulsion. The present invention was completed based on this knowledge. That is, in the present invention, an oil phase and an aqueous phase having the following viscosity are mixed and emulsified using an emulsifier to form an oil-in-water emulsion, and after heat sterilization, the emulsion is cooled and stirred in a closed cooling stirrer. This is a method for producing a water-in-oil emulsion, which is characterized by inverting the emulsion into a water-in-oil emulsion while mixing an appropriate amount of gas. Viscosity of the aqueous phase (measured using a B-type viscometer manufactured by Tokyo Keiki Co., Ltd.; unit: poise) 20°C 30-300 40°C 5-50 According to the present invention, a low-fat water-in-oil emulsion When manufacturing a product, the emulsion is first made into an oil-in-water emulsion, which is the most stable, and then it is easily converted into a water-in-oil emulsion by simply cooling and stirring. It can be produced extremely easily without using complicated operations or means such as carefully and gradually adding a large amount of an aqueous phase. In addition, when trying to produce butter cream, instead of whipping the main raw materials such as margarine or snow toning that have been tempered (ripened) as in the conventional method, the starting material including the oil phase and aqueous components can be used instead. Since everything from raw materials to the final target product is manufactured in an integrated manner,
After the intermediate sterilization process, the buttercream is whipped in a closed-type device that has been thoroughly washed and sterilized, so that low-fat buttercream products that are extremely hygienic and have a high shelf life are continuously produced in large quantities. The solid fat content index (SFI) of the fat used in the present invention is preferably 15 to 60 at 10°C, 10 to 50 at 20°C, 5 to 45 at 25°C, and 0 to 35 at 30°C. These oils and fats are generally edible animal and vegetable oils alone or in combination, or hydrogenated or
It can be obtained by appropriately combining methods such as fractionation and transesterification, and raw material oils include soybean oil, rapeseed oil, peanut oil, corn oil,
Coconut oil, palm kernel oil, palm oil, beef tallow, fish oil, and various other edible animal and vegetable fats and oils can be used. Next, the aqueous phase, which is an important requirement in the present invention, has a viscosity of 30 to 300 poise at 20°C and 5 to 50 poise at 40°C (however, the viscosity is 30 to 300 poise at 20°C and 5 to 50 poise at 40°C (provided that The viscosity is preferably within the range (measured using a rotor); outside these viscosity ranges, it is difficult to obtain stable and good products. The above viscosity can be easily obtained by using various sugars, powdered candy, and other substances that increase the viscosity to a desired viscosity in the aqueous phase. The emulsifier is not particularly limited, and one or more of glycerin fatty acid esters, propylene glycol fatty acid esters, polyglycerin fatty acid esters, sucrose fatty acid esters, sorbitan fatty acid esters, and lecithin may be used in combination as appropriate. Bye. These emulsifiers may be added to either the aqueous phase or the oil phase, or may be added to a mixture of both phases, but in either case, they should be selected appropriately so that a stable emulsified state can be obtained, and therefore, they should be added. Although the amount is not particularly limited, it seems generally preferable to be about 0.2 to 2%. Furthermore, the closed-type cooling stirring device may be of any type as long as it is a closed-type device equipped with a foaming stirring device and cooling equipment.
For example, it may be a continuous ice cream freezer. The gas mixed into such a device as needed may be air, nitrogen, etc., but it goes without saying that a sterile gas is preferable. In addition, in the present invention, various coloring agents such as coloring agents and spices,
This does not prevent the addition of flavor components as appropriate. Next, to explain the manufacturing process of the present invention, an aqueous phase and an oil phase having a predetermined viscosity are mixed and emulsified using a means such as a homomixer together with an emulsifier to form an oil-in-water emulsion, and then heated at 70 to 80°C. half an hour~
Heat sterilize for 60 minutes. Next, the sterilized oil-in-water emulsion was fed into the device from one end of the closed-type cooling stirring device, which had been previously sterilized by an appropriate means such as hot water or heated steam, and was rapidly cooled and stirred, followed by sterilization if necessary. While mixing gas,
Phase conversion is caused to continuously obtain a water-in-oil emulsion from the other end of the device. The manufacturing process of the present invention is not limited to the above process steps, and may be a method with appropriate changes. Examples and comparative examples will be shown below to explain the effects of the present invention in more detail. Note that all parts and percentages are based on weight. Examples 1 to 8 and Comparative Examples 1 to 9 [] Preparation of oil phase

[Table] A~
Four types of oil phases of D were prepared. [] Preparation of aqueous phase Marustar (trade name, Hayashibara Shoji Co., Ltd., sugar content 75%)
A maltose-based aqueous solution), powdered starch syrup, and water were used as appropriate to prepare aqueous phases having the respective viscosities shown below. However, since 75 parts of the water phase was used for the 25 parts of the oil phase prepared in [] above, the blending ratio of each water phase was indicated so that the total amount was 75 parts.

[Table] [] Manufacturing process: Heat 75 parts of the aqueous phase prepared in [] to about 60°C and add it to [] while stirring with a homomixer.
25 parts of the heated oil phase prepared above was added to about 65°C, mixed and emulsified for 10 minutes, and further stirred and sterilized at about 75°C for 60 minutes to obtain an oil-in-water emulsion. Next, this emulsion is introduced into a closed-type whipper equipped with a stirring device capable of foaming and cooling equipment, and is cooled and stirred while mixing a small amount of air, and the residence time in the device is about 4 to 5 minutes. Cool to 10-20℃ and overrun about 10%
An air-containing emulsion was obtained. [] The results are as follows: (i) Using oil phase A (mixed oil with a softening point of 32.4°C), the emulsion temperature was about 70°C and was cooled to about 20°C with a residence time of about 4 minutes in the device and then discharged.

【table】

[Table] (ii) Using oil phase B (mixed oil and fat with a softening point of 29.0°C), the emulsion temperature was about 70°C, and the residence time in the device was about 4 minutes, and the temperature was cooled to about 15°C and discharged.

[Table] (iii) Using oil phase C (using a mixed oil with a softening point of 27.1°C), the emulsion temperature was about 70°C, and the residence time in the device was about 5 minutes, and the temperature was cooled to about 15°C and then discharged.

[Table] (iv) Using oil phase D (mixed oil and fat with a softening point of 22.5°C), the emulsion temperature was about 70°C, and the residence time in the device was about 5 minutes, and the temperature was cooled to about 10°C and discharged.

[Table] Examples 9 to 11 and Comparative Examples 10 to 13 75 parts of the aqueous phase prepared in [] was heated to about 60°C, and while stirring with a homomixer, the water phase prepared in [] was heated to about 65°C. 25 parts of heated oil phase A was added and mixed and emulsified for 10 minutes, followed by sterilization by continuing stirring at about 75°C for 60 minutes to obtain an oil-in-water emulsion. Next, this emulsion was introduced into a closed stirring device equipped with cooling equipment, cooled and stirred, and cooled to about 20°C for about 4 minutes while remaining in the device, and then discharged. The results are as follows.

[Table] As a result, when the viscosity of the aqueous phase was far below the lower limit of the present invention range, phase inversion of the emulsion did not occur sufficiently, and the emulsion almost remained as an oil-in-water emulsion (Comparative Examples 1, 5, Ten). Furthermore, even when the viscosity of the aqueous phase was slightly increased, although it was outside the lower limit of the range of the present invention, a water-in-oil type air-containing emulsion or an emulsion with almost no air was obtained, but it was left overnight. Significant phase separation occurred and the product had no commercial value (Comparative Examples 2, 6, 8, 9, 11). In contrast, when the aqueous phase viscosity was within the range of the present invention, products with a good emulsification state and excellent storage stability were obtained in all cases (Examples 1 to 11). If the viscosity of the aqueous phase exceeds the upper limit of the range of the present invention, either the phase inversion is not sufficient and the oil-in-water emulsion remains (Comparative Examples 4 and 13), or the emulsification state is incomplete and some They remained as oil-in-water emulsions (Comparative Examples 3, 7, and 12).

Claims (1)

[Claims] 1. An oil phase of 20 to 45% by weight and an aqueous phase having the following viscosity:
Mix and emulsify 80 to 55% by weight with an emulsifier to form an oil-in-water emulsion, heat sterilize the emulsion, cool and stir using a closed cooling stirrer,
A method for producing a water-in-oil emulsion, which comprises inverting the emulsion into a water-in-oil emulsion while mixing an appropriate amount of gas if necessary. Note: Viscosity of aqueous phase (measured using a B-type viscometer manufactured by Tokyo Keiki Co., Ltd., unit: poise) 20℃ 30~300 40℃ 5~50