US-12622454-B2 - Manufacturing method for starch-containing composition for heat cooking

US12622454B2US 12622454 B2US12622454 B2US 12622454B2US-12622454-B2

Abstract

A manufacturing method for a starch-containing composition that is not prone to collapsing shape in a liquid during heat cooking, is highly lusterless, and has excellent appearance which utilizes an extruder including a feeder for loading a food material and a die for discharging the food material after kneading and shaping. The screw has a first flight, a kneading, and a second flight section, and the barrel has a bend section at the first-half of the second flight section of the screw. A composition containing at least 3.0 mass % insoluble dietary fiber, at least 10.0 mass % starch, at least 3.0 mass % protein, and a dry-basis water content of at least 25 mass % is prepared.; The composition is then heated under pressure, kneaded, and depressurized until the degree of gelatinization is lowered by at least 6 mass %.

Inventors

Makoto Suzuki
Kiyoshi Endo
Yusuke Tange
Kota Ono
Mariko Nakamura

Assignees

MIZKAN HOLDINGS CO., LTD.

Dates

Publication Date: 20260512
Application Date: 20230207
Priority Date: 20200807

Claims (20)

1 . A method for producing a composition using an extruder comprising: a screw to be rotated by a motor; a barrel surrounding the circumference of the screw comprising a tip side and a base side; a feeder, attached to the base side of the barrel, for injecting a food material; and a die section, attached to the tip side of the barrel, for molding and discharging a kneaded food material; and a vent section integrated with the die section as a single unit, the barrel being free of a vent section; wherein the composition contains starch and is used for heat cooking, and the screw includes, from the base side to the tip side, at least a first flight section and a kneading section, the method comprising: (i) preparing the composition with an insoluble dietary fiber content of 3.0 mass % or more in terms of wet mass basis, a starch content of 10.0 mass % or more in terms of wet mass basis, a protein content of 3.0 mass % or more in terms of wet mass basis, and a dry mass basis moisture content of more than 45 mass %; (ii) heating the composition prepared at step (i) along a course from the first flight section to the kneading section under a pressure of 0.01 MPa or higher and 50 MPa or lower so as to reach a temperature of 105° C. or more but 200° C. or less at the kneading section under pressurized conditions, while kneading the composition with an SME value of 350 kJ/kg or more; (iii) cooling the composition heated at step (ii) under a pressure of 0.01 MPa or higher and 50 MPa or lower to a temperature of less than 100° C.; (iv) depressurizing the composition cooled at step (iii), from a pressurized state at the kneading section to atmospheric pressure or less at the vent section.
2 . The method according to claim 1 , wherein the screw further includes a second flight section on the tip side of the kneading section.
3 . The method according to claim 1 , wherein the highest temperature of the composition kneaded at step (ii) is decreased by 20° C. or more along a course from the kneading section to an outlet of the die section.
4 . The method according to claim 1 , wherein a groove-like structure is formed on the inner wall of the barrel in an area of 30% or less of the total length of the kneading section.
5 . The method according to claim 2 , wherein a cooling equipment is provided at any position between the kneading section and the second flight section and/or the die section.
6 . The method according to claim 1 , wherein an average thread groove depth in a region corresponding to the last 80% of the total length of the first flight section is smaller than the average thread groove depth in a region corresponding to the first 20% of the total length of the first flight section from the base side start point of the first flight section.
7 . The method according to claim 2 , wherein the average thread groove depth in a region corresponding to the last 80% of the total length of the second flight section is smaller than the average thread groove depth in a region corresponding to the first 20% of the total length of the second flight section from the base side start point of the second flight section.
8 . The method according to claim 2 , wherein an average thread groove pitch in a region corresponding to the last 80% of the total length of the second flight section is larger than the average thread groove pitch in a region corresponding to the first 20% of the total length of the second flight section from the base side start point of the second flight section.
9 . The method according to claim 1 , wherein when the composition is subjected to treatment under Procedure A followed by ultrasonication, and then measurement for the particle diameter distribution, the d 50 and/or d 90 obtained from the particle diameter distribution is less than 450 μm, wherein Procedure A comprises 6 mass % aqueous suspension of the composition is treated with 0.4 volume % of protease and 0.02 mass % of α-amylase at 20° C. for 3 days.
10 . The method according to claim 1 , wherein the degree of gelatinization of the starch in the composition after kneading at step (ii) is 30 mass % or more.
11 . The method according to claim 1 , wherein the composition after the kneading at step (ii) or after the depressurization at step (iv) satisfies the requirement(s) (a) and/or (b) below: (a) when 6% suspension of a crushed product of the composition is observed, the number of starch grain structures observed is 300/mm 2 or less, (b) when 14 mass % aqueous slurry of a crushed product of the composition is subjected to measurement with a rapid visco-analyzer with elevating the temperature from 50° C. to 140° C. at a rate of 12.5° C./min, the peak temperature of gelatinization obtained is lower than 120° C.
12 . The method according to claim 1 , wherein the composition contains an edible plant, having a ratio of the content of starch contained in the edible plant to the total starch content in the composition of 30 mass % or more.
13 . The method according to claim 12 , wherein the edible plant is a pulse, selected from one or more of Pisum, Phaseolus, Cajanus, Vigna, Vicia, Cicer, Glycine and Lens species.
14 . The method according to claim 13 , wherein the composition contains the pulse at a ratio of 50 mass % or more in terms of dry mass basis.
15 . The method according to claim 1 , wherein the composition is a product having a specific gravity of 1.0 or more.
16 . The method according to claim 1 , further comprising the step of: (v) crushing the composition from step (iv) to produce a crushed composition.
17 . The method according to claim 16 , further comprising the step of: (vi) agglomerating the crushed composition from step (v) to produce a crushed composition agglomerate.
18 . The method according to claim 2 , wherein the extruder further comprises a flow retarding structure located between a tip side end point of the second flight section and the die section.
19 . A method for producing a composition using an extruder comprising: a screw to be rotated by a motor; a barrel surrounding the circumference of the screw comprising a tip side and a base side; a feeder, attached to the base side of the barrel, for injecting a food material; a die section, attached to the tip side of the barrel, for molding and discharging a kneaded food material; and a vent section integrated with the die section as a single unit, the barrel being free of a vent section; wherein: the composition contains starch and is used for heat cooking, and the screw includes, from the base side to the tip side, at least a first flight section and a kneading section, the method comprising: (i) preparing the composition with an insoluble dietary fiber content of 3.0 mass % or more in terms of wet mass basis, a starch content of 10.0 mass % or more in terms of wet mass basis, a protein content of 3.0 mass % or more in terms of wet mass basis, and a dry mass basis moisture content of more than 25 mass %; (ii) heating the composition prepared at step (i) along a course from the first flight section to the kneading section so as to reach a temperature of 100° C. or more but 200 C or less at the kneading section under pressurized conditions, while kneading the composition with an SME value of 350 kJ/kg or more; (iii) cooling the composition heated at step (ii) under a pressure of 0.01 MPa or higher and 50 MPa or lower to a temperature of less than 100° C.; (iv) depressurizing the composition cooled at step (iii), from a pressurized state at the kneading section to atmospheric pressure or less at the vent section; (v) adjusting the dry mass basis moisture content of the composition obtained at step (iv) to less than 15 mass %; (vi) crushing the composition obtained at step (v) to obtain a crushed composition; (vii) agglomerating the crushed composition to obtain a crushed composition agglomerate.
20 . A method for producing a composition using an extruder comprising: a screw to be rotated by a motor; a barrel surrounding the circumference of the screw comprising a tip side and a base side; a feeder, attached to the base side of the barrel, for injecting a food material; a die section, attached to the tip side of the barrel, for molding and discharging a kneaded food material; and a vent section integrated with the die section as a single unit, the barrel being free of a vent section; wherein: the composition contains starch and is used for heat cooking, and the screw includes, from the base side to the tip side, at least a first flight section and a kneading section, the method comprising: (i) preparing the composition comprising a pulse with seed skin, the composition comprising an insoluble dietary fiber content of 3.0 mass % or more in terms of wet mass basis, a starch content of 10.0 mass % or more in terms of wet mass basis, a protein content of 3.0 mass % or more and 60 mass % or less in terms of wet mass basis, and a dry mass basis moisture content of more than 45 mass %; (ii) heating the composition prepared at step (i) along a course from the first flight section to the kneading section under a pressure of 0.01 MPa or higher and 50 MPa or lower so as to reach a temperature of 105° C. or more but 200° C. or less at the kneading section, while kneading the composition with an SME value of 550 kJ/kg or more; (iii) cooling the composition heated at step (ii) under a pressure of 0.01 MPa or higher and 50 MPa or lower to a temperature of less than 90° C.; (iv) depressurizing the composition cooled at step (iii), from a pressurized state at the kneading section to atmospheric pressure or less at the vent section; (v) adjusting the dry mass basis moisture content of the composition obtained at step (iv) to less than 15 mass %.

Description

TECHNICAL FIELD One or more embodiments of the present invention relate to a composition containing starch for heat cooking. BACKGROUND Recently, food products have been required to combine not only good taste but also a beautiful appearance. In particular, there has been a demand for foods with a highly matte appearance to give a natural impression when photographed. However, there are no conventional compositions for heat cooking that are less prone to shape disintegration during heat cooking and, at the same time, have a highly matte appearance. In this regard, a method conventionally known to the art prevents vegetable tissues from collapsing and losing shape when stewing vegetables by using, as an anti-disintegration agent during stewing, a sugar composition containing 35 mass % or more of maltotriose relative to the total solid content (Patent Literature 1). However, the anti-disintegration agent during stewing described in Patent Literature 1 imparts the unique flavor and texture of maltotriose to the food product, and that the high content of sugar results in a composition with lack of a matte texture and with an inferior appearance. PATENT LITERATURE [Patent Literature 1] JP2015-181417 A One or more embodiments of the present invention are directed to providing a method for producing a starch-containing composition for heat cooking which does not easily disintegrate in shape during heat cooking in liquid, and which has a highly matte texture and an excellent appearance. Through intensive efforts in view of various plant starches and their processing conditions, the present inventors have found that a composition that has both a matte appearance and resistance to disintegration during heat cooking can be produced by a method in which a composition containing certain amounts of starch and moisture is pressurized, heated and kneaded, and then rapidly depressurized and cooled using an extruder capable of rapid depressurization with cooling, to thereby disintegration the starch grains in the raw material and then to form an aged starch layer on the surface of the composition while creating a strong starch matrix structure inside the composition. Based on these findings, the present inventors have further conducted diligent research, and have finally completed the following inventions. Specifically, aspects of one or more embodiments of the present invention include the following. [Aspect 1]A method for producing a starch-containing composition for heat cooking using an extruder comprising: a screw to be rotated by a motor;a barrel surrounding the circumference of the screw;a feeder, attached to the base side of the barrel, for injecting a food material; anda die section, attached to the tip side of the barrel, for molding and discharging a kneaded food material;wherein the screw includes, from the base side to the tip side, at least a first flight section and a kneading section, andthe barrel has a vent section at a position around the tip side on the kneading section of the screw,the method comprising the steps of: (i) preparing a composition with an insoluble dietary fiber content of 3.0 mass % or more in terms of wet mass basis, a starch content of 10.0 mass % or more in terms of wet mass basis, a protein content of 3.0 mass % or more in terms of wet mass basis, and a dry mass basis moisture content of more than 25 mass %; (ii) heating the composition prepared at step (i) along a course from the first flight section to the kneading section so as to reach a temperature of 100° C. or more but 200° C. or less at the kneading section under pressurized conditions, while kneading the composition with an SME value of 350 kJ/kg or more; (iii) depressurizing the composition kneaded at step (ii), from the pressurized state at the kneading section to atmospheric pressure or less at the vent section; and (iv) lowering the degree of gelatinization in the composition kneaded at step (ii) by 6 mass % or more at the kneading section and onward. [Aspect 2] The method according to Aspect 1, wherein the vent section and the die section are integrated as a single unit. [Aspect 3] The method according to Aspect 1, wherein the screw further includes a second flight section on the tip side of the kneading section, and the vent section is located on a position of the barrel corresponding to the first half of the second flight section. [Aspect 4] The method according to any one of Aspects 1 to 3, wherein the composition kneaded at step (ii) is cooled by 20° C. or more along a course from the kneading section to the die section. [Aspect 5] The method according to Aspect 3 or 4, wherein the second flight section includes a flow retarding structure between the tip side end point and the die section. [Aspect 6] The method according to any one of Aspects 1 to 5, wherein a groove-like structure is formed on the inner wall of the barrel in an area of 30% or less of the total length of the kneading section. [Aspect 7] The method