JP4050850B2 - Method for producing film-packaged plate food - Google Patents

Method for producing film-packaged plate food Download PDF

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Publication number
JP4050850B2
JP4050850B2 JP26356699A JP26356699A JP4050850B2 JP 4050850 B2 JP4050850 B2 JP 4050850B2 JP 26356699 A JP26356699 A JP 26356699A JP 26356699 A JP26356699 A JP 26356699A JP 4050850 B2 JP4050850 B2 JP 4050850B2
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Prior art keywords
film
packaging bag
food
constituent material
heat seal
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JP2001078682A (en
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慎二 小松
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株式会社輝
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/345—Progressively making the joint, e.g. starting from the middle
    • B29C66/3452—Making complete joints by combining partial joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/431—Joining the articles to themselves
    • B29C66/4312—Joining the articles to themselves for making flat seams in tubular or hollow articles, e.g. transversal seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7234—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer
    • B29C66/72341—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer for gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8351—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws
    • B29C66/83511—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws jaws mounted on rollers, cylinders or drums
    • B29C66/83513—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws jaws mounted on rollers, cylinders or drums cooperating jaws mounted on rollers, cylinders or drums and moving in a closed path
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/849—Packaging machines
    • B29C66/8491—Packaging machines welding through a filled container, e.g. tube or bag
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Containers And Plastic Fillers For Packaging (AREA)
  • Packages (AREA)
  • Fish Paste Products (AREA)
  • General Preparation And Processing Of Foods (AREA)
  • Formation And Processing Of Food Products (AREA)

Description

【０００１】
【発明の属する技術分野】
この発明は、未加熱状態で板状に成形されてフィルム包装され、かつ、この成形状態をフィルム包装後の加熱により保形されると共に、当該板状をできる限り崩さない状態で包装袋の開封によって食用に供することが可能な板状食品の製造方法に関する。
【０００２】
【従来の技術】
現在、家庭消費用、業務消費用に提供されるハンバーグ類、かまぼこやはんぺんなどの水産練り製品、加工卵製品、大豆加工製品などの多くは、型枠に構成材料を詰め込んで成形した後、加熱をして固まらせ、その上で袋詰めなどされて流通に乗せられている。
【０００３】
【発明が解決しようとする課題】
しかるに、こうした食品にあっては、前記型枠による成形後に前記袋詰めなどの包装をなす必要があった。また、かかる成形後の包装段階において包装体内に余分なエアが入り込み易く、こうしたエアと包装体内の隙間に起因した食品の品質の低下を経時的に招き易かった。このため、この種の食品にあっては、前記成形後の包装を無菌室で行うなどの包装段階での格別の配慮が必要とされており、また、食品への保存料の添加などを余儀なくされる場合が多かった。
【０００４】
また、前記型枠による成形後に別途包装を行う関係上、食品を薄く仕上げ難いものであり、また、製品の重量、形状を均一に整えるため、前記型枠への構成材料の詰め込みなどに格別の配慮を要させるものであった。
【０００５】
そこでこの発明は、この種の食品を、品質の劣化を生じさせない状態で、所望の厚さの板状をなすように容易に成形・包装できるようにすることを目的とする。
【０００６】
【課題を解決するための手段】
前記目的を達成するために、この発明にあっては、フィルム包装された板状食品の製造方法が、以下の（１）〜（４）の工程を備えたものとした。
（１）界面剥離、層間剥離又は凝集破壊可能に熱シールされるシーラント層を有するフィルムを搬送しながら当該フィルムの搬送方向に沿った向きに連続して施される第一の熱シールと当該搬送方向に交叉する向きに間隔を開けて施される第二の熱シールとにより順次連続して三方シール包装袋又は四方シール包装袋を形成させながら、先順位で施された第二の熱シールと次順位で施される第二の熱シールとの間に加熱により固まる食品の構成材料を未加熱状態で充填させる充填工程
（２）前記次順位で施される第二の熱シールが施されるまでの間で、充填された前記構成材料をしごき広げさせるように一対の締め込みローラ間で前記フィルムを押圧する脱気工程
（３）当該構成材料が充填された包装袋を押圧して充填された当該構成材料を包装袋内に行き渡らせるように均して板状に成形する成形工程
（４）前記板状に成形された食品を納めた包装袋を当該食品の構成材料を固まらせる温度で加熱して当該食品を板状に保形する加熱工程
【０００７】
ここで、加熱により固まる食品の構成材料とは、未加熱状態で流動性を有すると共に加熱すると固化する食品の構成材料であって、典型的には、基本材料として、食肉、食用魚肉、食用貝類、植物性蛋白類、卵類などの一種または二種以上を細切りまたはすりつぶしたものを使用し、この基本材料に対する付加材料として、つなぎ材（パン粉、小麦粉など）、細切りなどした野菜（みじん切りした玉葱など）、調味料、香辛料などの一種または二種以上を適宜の量混ぜ込んだものが予定される。また、かかる構成材料により構成される食品としては、典型的には、ハンバーグ類、かまぼこやはんぺんなどの水産練り製品、加工卵製品、大豆加工製品などが予定される。
【０００８】
しかして、先ず、前記充填工程において、前記三方包装袋または四方包装袋を、前記界面剥離、層間剥離又は凝集破壊可能に熱シールされるシーラント層を有するフィルムによって形成することとしていることから、本製造方法によって板状に成形され、かつ、加熱により保形されて得られる板状食品は、かかる包装袋を構成する両面のフィルム部を引き離す向きに引っ張ることにより、当該包装袋の任意の一辺側から前記熱シールを壊しての開封により、包装袋から容易に取り出すことができる。
【０００９】
また、前記脱気工程により、前記充填工程によって充填される前記構成材料中に含まれる空気を前記次順位で施される第二の熱シールが施されるまでの間で当該構成材料中からできる限り取り除いて、包装袋に封入された構成材料に余分な空気が残らないようにすることができる。また、前記次順位で施される第二の熱シールが施されるまでの間で前記第一の熱シールによって偏平の筒状にされた前記フィルム内における、前記先順位で施された第二の熱シールと当該次順位で施される第二の熱シールの形成位置までの空間に当該構成材料を密に行き渡らせて、この次順位で施される第二の熱シールが施されて形成された一つの包装袋内に充填隙間に起因した空気が残らないようにすることができる。この結果、前記包装袋に余分な空気をできる限り入り込ませないようにした状態での前記構成材料の封入をなすことができ、こうした空気に起因した当該構成材料から成形される板状食品の変質をできる限り防ぐことができ、長期間の冷凍保存にも耐えられるようにすることができる。
【００１０】
また、前記成形工程により、前記包装袋に充填された前記構成材料を、当該包装袋の内部空間に倣った板状、より具体的には、かかる包装袋に施された前記第一の熱シールの内縁と第二の熱シールの内縁とにより形成された偏平で方形の内部空間に倣った板状をなす板状食品に成形することができる。また、このように成形された板状をなす板状食品は、前記脱気工程とあいまって、その外面を隙間なく前記フィルムに覆われるものとされる。かかる第一の熱シールと第二の熱シールを規則的に形成すれば、連続的に成形される各包装袋に封入された各板状食品を、いずれも略等しい重量、形状を備えた均一な板状食品とすることができ、同規格商品の安定的な供給が可能とされる。また、前記包装袋に前記構成材料を封入した状態で前記成形を行うことから、成形される板状食品を支障なく薄くさせることができ、前記加熱工程においては、当該板状食品を短時間で適切に加熱・固化させることができる。
【００１１】
また、前記加熱工程により、前記成形工程により前記包装袋内にあって略方形の板状に前記構成材料を成形して形成された食品を、当該略方形の板状に保った状態で最終消費者が食に供する段階まで提供できるようにすることができる。また、かかる板状食品の長期間の保存が可能となる。かかる加熱工程における加熱方法としては、温水加熱槽などを用いた湯煎、蒸気加熱器などを用いた蒸煮、高周波による加熱などが予定される。
【００１２】
【発明の実施の形態】
以下、この発明の典型的な実施の形態について説明する。
【００１３】
この実施の形態にかかる製造方法は、略方形の板状に成形された状態でフィルム包装され、かつ、この成形状態を加熱により保形されると共に、包装袋Ｈの開封によって当該板状のまま食用に供し、あるいはさらに加熱調理するなどして食用に供することが可能な板状食品Ｍを製造するためのものである。
【００１４】
すなわち、この実施の形態にかかる製造方法は、図１および図２にその概要を示す各工程１０、２０、３０、４０を含むものである。
【００１５】
第一の工程は、界面剥離、層間剥離又は凝集破壊可能に熱シールされるシーラント層２を有するフィルムＦを搬送しながら当該フィルムＦの搬送方向ｘに沿った向きに連続して施される第一の熱シール８と当該搬送方向ｘに交叉する向きに間隔を開けて施される第二の熱シール９とにより順次連続して三方シール包装袋又は四方シール包装袋を形成させながら、先順位で施された第二の熱シール９と次順位で施される第二の熱シール９との間に板状食品Ｍの構成材料Ｍａを充填させる充填工程１０である。
【００１６】
この充填工程１０において充填される板状食品Ｍの構成材料Ｍａとしては、未加熱状態で流動性を有すると共に加熱すると固化する食品の構成材料、典型的には、基本材料として、食肉、食用魚肉、食用貝類、植物性蛋白類、卵類などの一種または二種以上を細切りまたはすりつぶしたものが予定される。また、この基本材料に対し混ぜ込まれる付加材料として、つなぎ材（パン粉、小麦粉など）、細切りなどした野菜（みじん切りした玉葱など）、調味料、香辛料などの一種または二種以上が予定される。
【００１７】
また、前記三方シール包装袋は、三方シール包装により成形される包装袋である。かかる三方シール包装は、長尺のフィルムＦを二つ折りにした状態で当該フィルムＦの長さ方向を搬送方向ｘに沿わせた状態で搬送しながら、当該フィルムＦの搬送方向ｘに沿った向きに連続して第一の熱シール８を施すと共に、当該搬送方向ｘに交叉する向きに間隔を開けて第二の熱シール９を施して、折り辺ｙ以外の少なくとも三辺にシール部３を形成させて前記構成材料Ｍａを封入した包装袋Ｈを順次連続して形成させるものである。
【００１８】
また、前記四方シール包装袋Ｈは、四方シール包装により成形される包装袋である。かかる四方シール包装は、長尺のフィルムＦを二つ折りにした状態で、または、二枚の長尺フィルムＦ、Ｆを向き合わせた状態で、当該フィルムＦの長さ方向を搬送方向ｘに沿わせた状態で搬送しながら、当該フィルムＦの搬送方向ｘに沿った向きに連続して一対の第一の熱シール８を施すと共に、当該搬送方向ｘに交叉する向きに間隔を開けて第二の熱シール９を施して、少なくとも四辺にシール部３を形成させて前記構成材料Ｍａを封入した包装袋Ｈを順次連続して形成させるものである。
【００１９】
また、前記界面剥離可能に熱シールされるフィルムＦは、例えば、プラスチックを延伸させて形成されたベースフィルム１の一面に、接着層２ａを介して、内側から非延伸のプラスチック層２ｂ、接着フィルム層２ｃ、非延伸のプラスチック層２ｂの三層よりなるシーラント層２を一体に設けさせることにより形成させることができる。かかるフィルムＦによれば、包装袋Ｈの一面側を構成するフィルム部４のシーラント層２の最上面にある当該シーラント層２を構成するプラスチック層２ｂと、包装袋Ｈの他面側を構成するフィルム部４のシーラント層２の最上面にある当該シーラント層２を構成するプラスチック層２ｂとを強固に融着させ合わせない温度で熱シールを施して当該包装袋Ｈを形成させることにより、両面のフィルム部４、４を離れ出す向きに引っ張った際にかかる両面のフィルム部４、４の接触界面２ｄにおいて前記シール部３を壊して当該両面のフィルム部４、４の容易な分離が可能とされる。（図６）
【００２０】
また、かかる層間剥離可能に熱シールされるフィルムＦは、例えば、プラスチックを延伸させて形成されたベースフィルム１の一面に、接着層２ａを介して、内側から非延伸のプラスチック層２ｂ、接着フィルム層２ｃ、非延伸のプラスチック層２ｂの三層よりなるシーラント層２を一体に設けさせることにより形成させることができる。かかるフィルムＦによれば、包装袋Ｈの一面側を構成するフィルム部４のシーラント層２の最上面にある当該シーラント層２を構成するプラスチック層２ｂと、包装袋Ｈの他面側を構成するフィルム部４のシーラント層２の最上面にある当該シーラント層２を構成するプラスチック層２ｂとを強固に融着させ合わせる温度で前記熱シールを施して当該包装袋Ｈを形成させることにより、両面のフィルム部４、４を離れ出す向きに引っ張った際にいずれか一方のフィルム部４におけるシーラント層２を構成する接着フィルム層２ｃと非延伸のプラスチック層２ｂとの層間２ｅにおいて前記シール部３を壊して当該両面のフィルム部４、４の容易な分離が可能とされる。（図７）
【００２１】
また、かかる凝集破壊可能に熱シールされるフィルムＦは、例えば、プラスチックを延伸させて形成されたベースフィルム１の一面に、接着層２ａを介して、アルミニウム箔層２ｆを設けると共に、このアルミニウム箔層２ｆの上面に凝集破壊を生じる熱溶着可能な接着剤層２ｇよりなるシーラント層２を設けさせることにより形成させることができる。かかるフィルムＦによれば、包装袋Ｈを構成する両面のフィルム部４、４を離れ出す向きに引っ張った際に、熱シールにより溶着された双方のフィルム部４、４におけるシーラント層２を構成する接着剤層２ｇにおいて凝集破壊を生じさせることができ、前記シール部３を壊して当該両面のフィルム部４、４の容易な分離が可能とされる。（図８）
【００２２】
前記三方包装袋Ｈまたは四方包装袋Ｈを、こうした界面剥離、層間剥離又は凝集破壊可能に熱シールされるシーラント層２を有するフィルムＦによって形成することとしているのは、本製造方法によって得られる板状食品Ｍは、これら包装袋Ｈに封入された状態で板状を保つように加熱されて提供されるものであるため、包装袋Ｈの一辺を切り裂いて開封しただけでは板状食品Ｍの表面に対する包装袋Ｈの内面の密着によって当該板状食品Ｍを包装袋Ｈ内から円滑に取り出すことが困難になるためである。
【００２３】
すなわち、前記三方包装袋または四方包装袋を、こうした界面剥離、層間剥離又は凝集破壊可能に熱シールされるシーラント層２を有するフィルムＦによって形成しておけば、包装袋Ｈの任意の一辺にあるフィルムＦの縁５と、当該フィルムＦの縁５側に向けられたシール部３の外縁との間に未シール部６が形成されるように当該シール部３を施しておくことにより、この未シール部６を剥ぎ取り代として包装袋Ｈの両面のフィルム部４、４を離れ出させる向きに引っ張り操作して当該シール部３を容易に壊すことができ、引き続きかかる引っ張り操作をなすことにより壊された前記一辺にあるシール部３に隣り合う包装袋Ｈの二辺のシール部３、３を連続して壊して、三辺において前記両面のフィルム部４、４を分離させて封入されている板状食品Ｍを容易に取り出すことが可能とされる。（図９ないし図１２）
【００２４】
また、前記界面剥離、層間剥離又は凝集破壊可能に熱シールされるシーラント層２を有するフィルムＦにおけるベースフィルム１は、ナイロン、ポリエチレンテレフタレートまたはポリプロピレン製の延伸フィルムを用いることが好ましい。これは、ナイロン、ポリエチレンテレフタレート製の延伸フィルムは、ガスバリヤ性と剛性に優れているため、封入された板状食品Ｍの外気との接触による変質を生じさせ難く、また、保管時、輸送時のフィルムＦの破損を生じ難いからである。また、ポリプロピレン製の延伸フィルムは、ナイロン、ポリエチレンテレフタレート製の延伸フィルムよりもガスバリヤ性、剛性に若干劣るが、低廉に供給可能だからである。
【００２５】
かかる包装袋Ｈの未シール部６を剥取り代とした開封操作をより容易にする観点からは、この未シール部６において、当該包装袋Ｈの一面側のフィルム部４の縁５が他面側のフィルム部４の縁５よりも内側に位置されるように、この未シール部６において両フィルム部４、４の縁５が位置をズラした状態で、この未シール部６側のシール部３を形成させることが好ましい。（図１０）このように両フィルム部４、４の縁５が位置をズラしていれば、前記開封のための引っ張り操作をなすに先立っての、かかる未シール部６における両フィルム部４の摘まみ持ちをなし易いからである。
【００２６】
また、かかる包装袋Ｈの未シール部６を剥ぎ取り代とした開封操作をより容易にする観点からは、前記未シール部６側にあるシール部３の外縁が、この未シール部６側に向けて頂部３ｂを有するように形成された、山形状あるいは波形状の縁３ａとなるように、当該シール部３を形成しておくことが好ましい。（図１３）このようにかかるシール部３を形成しておけば、前記未シール部６を剥取り代として包装袋Ｈの両面フィルム部４、４を離れ出す向きに引っ張った際に、この引っ張り力を当該シール部３の頂部３ｂに集中させてこの頂部３ｂ側から当該シール部３をより容易に破壊できるからである。
【００２７】
前記板状食品Ｍの構成材料Ｍａの充填は、典型的には、前記第一の熱シール８が施されて偏平の筒状とされる前記フィルムＦの内側に、前記第二の熱シール９を施す熱シール手段１６の直上位置に吐出口１１ａを位置させるように充填管１１を入り込ませ、当該充填管１１を通じて当該吐出口１１ａから連続的に、あるいは、間欠的に、ミンチ状にされるなどして流動性をもった状態で用意された未加熱の前記構成材料Ｍａを送り込ませることによりなすことができる。
【００２８】
また、かかる充填管１１への前記構成材料Ｍａの送り込みは、例えば、図３に示されるように、この構成材料Ｍａの投入ホッパー１２ａと、このホッパー１２ａの下端開口１２ｂに連通される押し出し管部１２ｃと、この押し出し管部１２ｃ内に自重により入り込み、または、強制的に入り込まされた構成材料Ｍａを当該押し出し管部１２ｃの前端側に向けて押し出すように当該押し出し管部１２ｃの中央部に設けられたロータリーポンプ１２ｄとを備え、この押し出し管部１２ｃの前端側を前記充填管１１に連通させた充填装置１２によってなすことができる。（なお、図中符号１２ｅで示されるのは、前記ロータリーポンプのロータ−である。）
【００２９】
また、前記第一の熱シール８は、例えば、図２に示されるように、回転軸線を前記フィルムＦの搬送方向ｘに直交する向きに配した一対の縦熱ロール１５ａ、１５ａから構成される熱シール手段１５により施すことができる。
【００３０】
図２に示される例では、図中符号１３で示される原反フィルムから引き出されるフィルムＦを、符号１４で示される二つ折り手段によって二つ折りにして、このように二つ折りにされたフィルムＦの折り辺ｙ側および折り辺ｙ側と反対の側ｚに沿って一対の前記第一の熱シール８を施す構成が採られている。すなわち、図２に示される例では、前記一対の縦熱ロール１５ａ、１５ａはそれぞれ、その両端部に、二つ折りにされたフィルムＦにおける折り辺ｙ側および当該折り辺ｙ側と反対の側ｚの縁部に、当該フィルムＦを引き込み、かつ、送り出しながら当該フィルムＦの搬送方向ｘに沿って連続的に前記第一の熱シール８を施す外鍔状をなす環状の***部１５ｂを備えている。
【００３１】
そして、かかる一対の縦熱ロール１５ａ、１５ａは、前記***部１５ｂを互いに他の縦熱ロール１５ａに向き合った側で当該他の縦熱ロール１５ａの***部１５ｂに突き当てるように近接させながら、当該近接される***部１５ｂの間に二つ折りにされたフィルムＦを前記二つ折り手段１４の側から引き込み、かつ、引き込まれた当該フィルムＦを前記第二の熱シール９を施す熱シール手段１６の側に送り出すように、他方の縦熱ロール１５ａに対して逆向きに回転される構成としてある。
【００３２】
また、前記第二の熱シール９は、例えば、図２に示されるように、回転軸線を前記フィルムＦの搬送方向ｘに直交する向きに配した一対の横熱ロール１６ａ、１６ａから構成される熱シール手段１６により施すことができる。
【００３３】
図２に示される例では、かかる一対の横熱ロール１６ａ、１６ａは、前記一対の縦熱ロール１５ａ、１５ａにより前記第一の熱シール８の施されたフィルムＦに対し、当該フィルムＦを引き込み、かつ、送り出しながら所定間隔を開けて順次に前記第二の熱シール９を施す突条部１６ｃを当該横熱ロール１６ａの回転軸線方向に沿って突き出し状に備えている。
【００３４】
この実施の形態にあっては、当該横熱ロール１６ａは、その両端側にそれぞれ外鍔状部１６ｄを有すると共に、この外鍔状部１６ｄ間に亙って前記突条部１６ｃを有している。この突条部１６ｃは、この実施の形態にあっては、かかる横熱ロール１６ａの回転方向に亙って間隔を開けて複数か所形成されている。そして、一対の横熱ロール１６ａ、１６ａの突条部１６ｃがそれぞれ、当該横熱ロール１６ａの回転に伴って他方の横熱ロール１６ａに向き合う側において、順次に他方の横熱ロール１６ａの突条部１６ｃに突き当てられるように近接され、かかる一対の横熱ロール１６ａ、１６ａ間に引き込まれる長尺フィルムＦに対し断続的に当該突条部１６ｃによって前記第二の熱シール９を施す構成としてある。
【００３５】
次いで、第二の工程は、前記次順位で施される第二の熱シール９が施されるまでの間で、充填された前記構成材料Ｍａを押し広げるように前記フィルムＦを押圧する脱気工程２０である。
【００３６】
この脱気工程２０は、第一に、前記充填工程１０により充填される前記構成材料Ｍａ中に含まれる空気を前記次順位で施される第二の熱シール９が施されるまでの間で当該構成材料Ｍａ中からできる限り取り除いて、包装袋Ｈに封入された構成材料Ｍａに余分な空気が残らないようにするためになされる。また、第二に、前記次順位で施される第二の熱シール９が施されるまでの間で前記第一の熱シール８によって偏平の筒状にされた前記フィルムＦ内における、前記先順位で施された第二の熱シール９と当該次順位で施される第二の熱シール９の形成位置までの空間に当該構成材料Ｍａを密に行き渡らせて、この次順位で施される第二の熱シール９が施されて形成された一つの包装袋Ｈ内に充填隙間に起因した空気が残らないようにするためになされる。
【００３７】
この脱気工程２０により、前記包装袋Ｈに余分な空気をできる限り入り込ませないようにした状態での前記構成材料Ｍａの封入をなすことができ、こうした空気に起因した当該構成材料Ｍａから成形される板状食品Ｍの変質をできる限り防ぐことができる。
【００３８】
図１および図２に示される例にあっては、前記充填管１１の吐出口１１ａと一対の横熱ロール１６ａ、１６ａとの間に、前記フィルムＦの搬送方向ｘに直交する向きに回転軸線を向けた一対の絞り込みローラ２１、２１を上下に二組設け、この一対の絞り込みローラ２１、２１間を前記構成材料Ｍａを充填されたフィルムＦが通り抜けるようにして、かかる脱気工程２０をなすようにしてある。すなわち、この例にあっては、前記一対の絞り込みローラ２１、２１によって、構成材料Ｍａを充填されたフィルムＦは当該構成材料ＭａをフィルムＦ内にあってしごき広げさせるように押圧されるものとされ、これにより、前記充填管１１から供給された前記構成材料Ｍａに含まれる空気などを前記一対の横熱ロール１６ａ、１６ａによる前記次順位で施される第二の熱シール９の形成前に上方に抜け出させるものとしてある。
【００３９】
次いで、第三の工程は、前記構成材料Ｍａが充填された包装袋Ｈを押圧して充填された当該構成材料Ｍａを包装袋Ｈ内に行き渡らせるように均して板状の板状食品Ｍに成形する成形工程３０である。
【００４０】
この成形工程３０は、第一に、前記包装袋Ｈに充填された前記構成材料Ｍａを、当該包装袋Ｈの内部空間７に倣った板状、より具体的には、かかる包装袋Ｈに施された前記第一の熱シール８の内縁と第二の熱シール９の内縁とにより形成された偏平で方形の内部空間７に倣った板状をなす板状食品Ｍに成形するためになされる。かかる第一の熱シール８と第二の熱シール９とは、前記縦熱ロール１５ａと横熱ロール１６ａにより規則的に形成可能とされることから、連続的に成形される各包装袋Ｈ、Ｈ…に封入された各板状食品Ｍ、Ｍ…は、いずれも略等しい均一な板状食品Ｍとされ、同規格商品の安定的な供給が可能とされる。なお、三方シール包装袋および四方シール包装袋にあっては、前記フィルムＦの搬送方向ｘに沿った第一の熱シール８が当該包装袋Ｈの両側間に一か所以上別途に施されて当該包装袋Ｈが二以上の内部空間７、７…を持つように形成される場合もあり、こうした場合には、一つの包装袋Ｈ内に方形の板状をなす二以上の板状食品Ｍを成形させて、封入させることができる。こうした包装袋Ｈの内部空間７を二以上形成させる第一の熱シール８は、前記一対の縦熱ロール１５ａ、１５ａの中間部に前記のような鍔状の***部１５ｂを設けておくことで形成することができる。また、各熱シール８、９の内縁がなす隅部がアール状をなすように当該各熱シール８、９を施すようにしておけば、隅部をやや丸めさせた板状をなす板状食品Ｍを成形することができる。
【００４１】
また、この成形工程３０は、第二に、前記包装袋Ｈに充填された前記構成材料Ｍａを板状をなす板状食品Ｍとすることにより、後述の加熱工程４０において、当該板状食品Ｍを短時間で適切に加熱・固化させることができるようにするものである。
【００４２】
図１および図２に示される例では、前記一対の横熱ロール１６ａ、１６ａの次順位位置に、前記フィルムＦの搬送方向ｘに直交する向きに回転軸線を向けた一対の均しローラ３１、３１を設け、この一対の均しローラ３１、３１間を連続状態に形成され、前記構成材料Ｍａを封入させた包装袋Ｈが通り抜ける構成としてあり、この均しローラ３１により包装袋Ｈの内部空間７全体に前記構成材料Ｍａが均一な厚さで押し広げられるようにして、かかる成形をなすようにしてある。
【００４３】
また、かかる図１および図２に示される例では、前記一対の均しローラ３１、３１の次順位位置には、連続状態に形成された包装袋Ｈを搬送させる送りローラ３２が設けてあると共に、この送りローラ３２の次順位位置にはかかる連続状態に形成された包装袋Ｈに対し、前記第二の熱シール９の幅内においてカッティングを施して個別の包装袋Ｈに切り分ける切断手段３３が設けてある。
【００４４】
そして、この切断手段３３により、切り分けられた包装袋Ｈがガイドプレート３４上を滑り落ちて、後述する冷却装置４１に当該包装袋Ｈを一つづつ送り込むベルトコンベヤ３５の荷受け側の端部３５ａ上に送り込まれる構成としてある。（図４）
【００４５】
また、この図１および図２に示される例では、かかるベルトコンベヤ３５上に、当該ベルトコンベヤ３５により搬送される包装袋Ｈに上方から下面を押し当てるように配された周回ベルト３６ａを備えた押圧手段３６が設けられており、（図１、図４）この押圧手段３６と当該ベルトコンベヤ３５との間においても各包装袋Ｈ、Ｈ…の内部空間７全体に前記構成材料Ｍａを均一な厚さで押し広げるものとされ、この図１および図２に示される例にあっては、この押圧手段３６も前記成形工程３０を実行するものとしてある。
【００４６】
次いで、第四の工程は、均されて板状とされた板状食品Ｍを納めた包装袋Ｈを加熱して当該板状食品Ｍを保形する加熱工程４０である。
【００４７】
この加熱工程４０は、第一に、前記成形工程３０により前記包装袋Ｈ内にあって略方形の板状に前記構成材料Ｍａを成形して形成された板状食品Ｍを、当該略方形の板状に保った状態で最終消費者が食に供する段階まで提供できるようにするためになされるものである。
【００４８】
また、第二に、前記板状食品Ｍの長期間の保存を可能とさせるためになされるものである。
【００４９】
かかる加熱は、例えば、温水加熱装置４１に前記包装袋Ｈを送り込んでなされる。
【００５０】
図５は、前記ベルトコンベヤ３５の荷下ろし側の端部３５ｂから前記包装袋Ｈを荷受け搬送するベルトコンベヤ４２を、温水の溜め込まれた加熱槽４１ａ内に当該包装袋Ｈを漬け込みながら搬送するように配した温水加熱装置４１によって、かかる加熱をなす例を示したものである。同図中、符号４３で示されるのは、かかる温水加熱装置４１における加熱槽４１ａ内において前記ベルトコンベヤ４２上に下面を位置させて当該ベルトコンベヤ４２と同じ向きに走行される押さえ走行ベルトであり、この押さえ走行ベルト４３によって前記加熱槽４１ａ内において前記ベルトコンアベヤ４２上を搬送される前記包装袋Ｈの浮き上がりが阻止される。また、この例では、前記温水加熱装置４１に続いて冷水の溜め込まれた冷却槽５０ａを備えた冷却装置５０が配されており、前記ベルトコンベヤ４２が、前記加熱槽４１ａ内を搬送された包装袋Ｈを引き続きこの冷却槽５０ａ内に順次に送り込み冷水に漬け込みながら当該冷却槽５０ａ内を搬送させるように、当該加熱槽４１ａから冷却槽５０ａに亘って設けてある。かかる例ではまた、この冷却槽５０ａ側にも当該冷却槽５０ａ内において前記ベルトコンベヤ４２上を搬送される前記包装袋Ｈの浮き上がりを阻止する押さえ走行ベルト５１が配されている。
【００５１】
【発明の効果】
この発明にかかるフィルム包装された板状食品の製造方法によれば、加熱により固まる食品の構成材料からフィルム包装された板状食品を容易かつ安定的に、しかも、製造ラインをいたずらに複雑にすることなく、製造することができる。
【図面の簡単な説明】
【図１】実施の形態にかかる製造方法の概要を示す側面構成図
【図２】実施の形態にかかる製造方法の概要を示す斜視構成図
【図３】充填装置の構成例を示す側面構成図
【図４】成形工程３０の実施例を示す斜視構成図
【図５】加熱工程４０の実施例を示す斜視構成図
【図６】界面剥離の原理を示す拡大断面図
【図７】層間剥離の原理を示す拡大断面図
【図８】凝集破壊の原理を示す拡大断面図
【図９】製造されたフィルムＦ包装された板状食品Ｍの斜視図
【図１０】図９におけるＡ−Ａ線断面図
【図１１】図９の包装袋Ｈを開封して板状食品Ｍを取り出した状態を示す斜視図
【図１２】図１１に示されるように取り出された板状食品Ｍの斜視図
【図１３】図９と構成の一部を異ならせている製造されたフィルムＦ包装された板状食品Ｍの斜視図
【符号の説明】
Ｆ フィルム
２ シーラント層
８ 第一の熱シール
９ 第二の熱シール
Ｈ 包装袋
Ｍａ 構成材料
１０ 充填工程
２０ 脱気工程
３０ 成形工程
４０ 加熱工程[0001]
BACKGROUND OF THE INVENTION
This invention is formed into a plate shape in an unheated state and film-wrapped, and the formed state is maintained by heating after film packaging, and the packaging bag is opened in a state where the plate shape is not destroyed as much as possible. It relates to a method for producing a plate-like food that can be used for food.
[0002]
[Prior art]
Currently, many hamburgers, fish paste products such as kamaboko and hanpen, processed egg products, processed soybean products, etc., which are provided for household consumption and business consumption, are molded and filled with components and then heated. It is then hardened and then packed in a bag and put on circulation.
[0003]
[Problems to be solved by the invention]
However, in such foods, it is necessary to make packaging such as bagging after molding by the mold. In addition, excess air easily enters the package in the packaging stage after the molding, and it is easy to cause deterioration in food quality due to the gap between the air and the package over time. For this reason, in this type of food, special consideration is required at the packaging stage such as packaging after molding in a sterile room, and preservatives must be added to the food. It was often done.
[0004]
In addition, it is difficult to finish the food thinly due to the separate packaging after molding by the mold, and in order to evenly adjust the weight and shape of the product, it is exceptional to stuff the constituent materials into the mold It was something that required consideration.
[0005]
Accordingly, an object of the present invention is to make it possible to easily form and package this type of food so as to form a plate having a desired thickness in a state where quality is not deteriorated.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, in the present invention, a method for producing a plate-shaped food packaged with a film includes the following steps (1) to (4).
(1) The first heat seal and the conveyance which are continuously applied in the direction along the conveyance direction of the film while conveying the film having the sealant layer which is heat-sealed so as to be capable of interfacial peeling, delamination or cohesive failure A second heat seal applied in a first order while forming a three-side seal packaging bag or a four-side seal packaging bag in succession by a second heat seal applied at intervals in the direction crossing the direction; Filling process for filling food components that are hardened by heating in a non-heated state with the second heat seal applied in the next order
(2) Until the second heat seal applied in the next order is applied, the filled constituent material is Between a pair of tightening rollers to spread Degassing step of pressing the film
(3) A molding step of pressing the packaging bag filled with the constituent material and forming the filled constituent material into a plate shape so that the constituent material is spread throughout the packaging bag.
(4) A heating step in which the packaging bag containing the food formed in the plate shape is heated at a temperature at which the constituent material of the food is solidified to keep the food in a plate shape
[0007]
Here, the constituent material of food that hardens by heating is a constituent material of food that has fluidity in an unheated state and solidifies when heated. Typically, as a basic material, meat, edible fish meat, edible shellfish , Vegetable protein, eggs or other chopped or crushed ones, and as an additional material to this basic material, binders (bread crumbs, flour, etc.), shredded vegetables (chopped onions) Etc.), or a mixture of one or more seasonings, spices, etc., in an appropriate amount. In addition, foods composed of such constituent materials typically include hamburgers, fish paste products such as kamaboko and hampen, processed egg products, and processed soybean products.
[0008]
First, in the filling step, the three-side packaging bag or the four-side packaging bag is formed by a film having a sealant layer that is heat-sealed so as to be capable of interfacial peeling, delamination, or cohesive failure. A plate-shaped food product that is formed into a plate shape by a manufacturing method and that is shaped by heating can be obtained by pulling the film parts on both sides of the packaging bag in the direction of separating them, and by placing one side of the packaging bag. Can be easily taken out from the packaging bag by opening the heat seal.
[0009]
Further, the degassing step allows the air contained in the constituent material filled in the filling step to be contained in the constituent material until the second heat seal applied in the next order is applied. As much as possible, it is possible to prevent excess air from remaining in the constituent material enclosed in the packaging bag. In addition, in the film that has been flattened by the first heat seal until the second heat seal applied in the next order is applied, the second applied in the previous order. The material is densely distributed in the space up to the formation position of the second heat seal and the second heat seal applied in the next order, and the second heat seal applied in the next order is applied and formed. It is possible to prevent the air due to the filling gap from remaining in one packaged bag. As a result, it is possible to enclose the constituent material in a state in which excess air is prevented from entering the packaging bag as much as possible, and alteration of the plate-like food molded from the constituent material due to such air Can be prevented as much as possible, and can withstand long-term frozen storage.
[0010]
Further, the constituent material filled in the packaging bag by the molding step is formed into a plate shape following the internal space of the packaging bag, more specifically, the first heat seal applied to the packaging bag. It is possible to form a plate-like food having a plate shape that follows the flat and square inner space formed by the inner edge of the second heat seal and the inner edge of the second heat seal. Moreover, the plate-shaped food which makes the plate shape shape | molded in this way shall be covered with the said film without the clearance gap with the said deaeration process. If the first heat seal and the second heat seal are regularly formed, each plate-shaped food enclosed in each continuously formed packaging bag has a uniform and substantially uniform weight and shape. Plate-like food, and the stable supply of the standardized product is possible. In addition, since the molding is performed in a state in which the constituent materials are sealed in the packaging bag, the plate-like food to be molded can be thinned without any trouble, and in the heating step, the plate-like food can be reduced in a short time. It can be heated and solidified appropriately.
[0011]
In addition, by the heating step, the food that is formed in the packaging bag by forming the constituent material into a substantially rectangular plate shape by the forming step is finally consumed in a state of keeping the substantially rectangular plate shape. Can be provided until the person provides food. In addition, the plate-like food can be stored for a long time. As a heating method in such a heating process, hot water bath using a hot water heating tank or the like, steaming using a steam heater or the like, heating by high frequency, etc. are planned.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, typical embodiments of the present invention will be described.
[0013]
In the manufacturing method according to this embodiment, the film is packaged in a state of being formed into a substantially square plate shape, and the molded state is maintained by heating, and the plate shape is maintained by opening the packaging bag H. This is for producing a plate-like food M that can be used for food or can be used for food by further cooking.
[0014]
That is, the manufacturing method according to this embodiment includes steps 10, 20, 30, and 40, the outline of which is shown in FIGS.
[0015]
The first step is performed continuously in the direction along the transport direction x of the film F while transporting the film F having the sealant layer 2 that is heat-sealed so as to be capable of interfacial debonding, delamination or cohesive failure. While forming a three-side seal packaging bag or a four-side seal packaging bag successively in succession by one heat seal 8 and a second heat seal 9 provided at intervals in the direction crossing the conveyance direction x, It is the filling process 10 in which the constituent material Ma of the plate-like food M is filled between the second heat seal 9 applied in step 2 and the second heat seal 9 applied in the next order.
[0016]
The constituent material Ma of the plate-like food M to be filled in the filling step 10 is a constituent material of food that has fluidity in an unheated state and solidifies when heated, typically, meat, edible fish meat as a basic material. In addition, one or two or more kinds of edible shellfish, vegetable protein, eggs, etc., are chopped or ground. Further, as an additional material to be mixed into this basic material, one or more kinds of binders (bread crumbs, wheat flour, etc.), shredded vegetables (chopped onions, etc.), seasonings, spices, etc. are planned.
[0017]
The three-side sealed packaging bag is a packaging bag formed by three-side sealed packaging. Such a three-side seal packaging is a direction along the transport direction x of the film F while transporting the film F in a state where the length direction of the film F is aligned with the transport direction x in a state where the long film F is folded in half. The first heat seal 8 is applied continuously, and the second heat seal 9 is applied at intervals in the direction crossing the conveyance direction x, so that the seal portion 3 is provided on at least three sides other than the folding side y. The packaging bags H that are formed and enclose the constituent material Ma are successively formed.
[0018]
The four-side sealed packaging bag H is a packaging bag formed by four-side sealed packaging. In such a four-side sealed package, the length direction of the film F is aligned with the conveyance direction x in a state where the long film F is folded in two or in a state where the two long films F and F face each other. A pair of first heat seals 8 are continuously applied in the direction along the transport direction x of the film F while being transported in the state of being moved, and the second in a direction crossing the transport direction x. The sealing bag 3 is formed on at least four sides, and the packaging bags H in which the constituent material Ma is enclosed are successively formed.
[0019]
The film F to be heat-sealed so as to be able to peel off at the interface is, for example, a non-stretched plastic layer 2b, an adhesive film on one surface of a base film 1 formed by stretching a plastic via an adhesive layer 2a. It can be formed by integrally providing a sealant layer 2 composed of three layers of a layer 2c and an unstretched plastic layer 2b. According to this film F, the plastic layer 2b which comprises the said sealant layer 2 in the uppermost surface of the sealant layer 2 of the film part 4 which comprises the one surface side of the packaging bag H, and the other surface side of the packaging bag H are comprised. By forming the packaging bag H by heat sealing at a temperature at which the plastic layer 2b constituting the sealant layer 2 on the uppermost surface of the sealant layer 2 of the film part 4 is firmly fused and bonded, When the film portions 4 and 4 are pulled away from each other, the seal portion 3 is broken at the contact interface 2d of the double-sided film portions 4 and 4 so that the film portions 4 and 4 on both sides can be easily separated. The (Fig. 6)
[0020]
In addition, the film F that is heat-sealed so as to be delaminated is, for example, an unstretched plastic layer 2b or an adhesive film on one surface of a base film 1 formed by stretching a plastic via an adhesive layer 2a. It can be formed by integrally providing a sealant layer 2 composed of three layers of a layer 2c and an unstretched plastic layer 2b. According to this film F, the plastic layer 2b which comprises the said sealant layer 2 in the uppermost surface of the sealant layer 2 of the film part 4 which comprises the one surface side of the packaging bag H, and the other surface side of the packaging bag H are comprised. By forming the packaging bag H by applying the heat seal at a temperature at which the plastic layer 2b constituting the sealant layer 2 on the uppermost surface of the sealant layer 2 of the film part 4 is firmly fused and bonded, When the film parts 4 and 4 are pulled away from each other, the seal part 3 is broken in the interlayer 2e between the adhesive film layer 2c and the non-stretched plastic layer 2b constituting the sealant layer 2 in either one of the film parts 4. Thus, the film portions 4 and 4 on both sides can be easily separated. (Fig. 7)
[0021]
The film F that is heat-sealed so as to be capable of cohesive failure is provided with an aluminum foil layer 2f on one surface of a base film 1 formed by stretching a plastic via an adhesive layer 2a. It can be formed by providing a sealant layer 2 composed of a heat-weldable adhesive layer 2g that causes cohesive failure on the upper surface of the layer 2f. According to such a film F, when the film portions 4 and 4 on both sides constituting the packaging bag H are pulled in the direction of leaving, the sealant layer 2 in both the film portions 4 and 4 welded by heat sealing is formed. Cohesive failure can be caused in the adhesive layer 2g, and the sealing portion 3 can be broken to easily separate the film portions 4 and 4 on both sides. (Fig. 8)
[0022]
The three-side packaging bag H or the four-side packaging bag H is formed by the film F having the sealant layer 2 that is heat-sealed so as to be capable of interfacial peeling, delamination or cohesive failure. Since the packaged food M is heated and provided so as to maintain a plate shape in the state of being enclosed in the packaging bag H, the surface of the plate-shaped food M is simply opened by cutting one side of the packaging bag H. This is because it becomes difficult to smoothly remove the plate-like food M from the packaging bag H due to the close contact of the inner surface of the packaging bag H with respect to the packaging bag H.
[0023]
That is, if the three-sided packaging bag or the four-sided packaging bag is formed by the film F having the sealant layer 2 that is heat-sealed so as to be capable of interfacial peeling, delamination, or cohesive failure, the three-sided packaging bag is on any side of the packaging bag H By applying the seal portion 3 so that an unsealed portion 6 is formed between the edge 5 of the film F and the outer edge of the seal portion 3 directed toward the edge 5 of the film F, The sealing part 6 can be easily broken by pulling the film parts 4 and 4 on both sides of the packaging bag H in the direction of separating them with the allowance for peeling off. The two sealing portions 3 and 3 of the packaging bag H adjacent to the sealing portion 3 on the one side are continuously broken, and the film portions 4 and 4 on both sides are separated and sealed on three sides. It is can be taken out Jo food M easily. (FIGS. 9 to 12)
[0024]
The base film 1 in the film F having the sealant layer 2 that is heat-sealed so as to be capable of interfacial peeling, delamination, or cohesive failure is preferably a stretched film made of nylon, polyethylene terephthalate, or polypropylene. This is because stretched films made of nylon and polyethylene terephthalate are excellent in gas barrier properties and rigidity, so that it is difficult for the encapsulated plate-like food M to be altered by contact with the outside air, and during storage and transportation. This is because the film F is hardly damaged. Also, a stretched film made of polypropylene is slightly inferior in gas barrier properties and rigidity to a stretched film made of nylon or polyethylene terephthalate, but can be supplied at a low cost.
[0025]
From the viewpoint of facilitating the opening operation using the unsealed portion 6 of the packaging bag H as a peeling allowance, the edge 5 of the film portion 4 on the one surface side of the packaging bag H is the other surface in the unsealed portion 6. The seal portion on the unsealed portion 6 side in a state where the edges 5 of the film portions 4 and 4 are shifted in position in the unsealed portion 6 so as to be located inside the edge 5 of the film portion 4 on the side. 3 is preferably formed. (FIG. 10) If the edges 5 of the film portions 4 and 4 are displaced in this way, the two film portions 4 in the unsealed portion 6 before the pulling operation for opening is performed. This is because it is easy to hold it.
[0026]
Further, from the viewpoint of facilitating the opening operation using the unsealed portion 6 of the packaging bag H as a stripping allowance, the outer edge of the seal portion 3 on the unsealed portion 6 side is on the unsealed portion 6 side. It is preferable that the seal portion 3 is formed so as to be a mountain-shaped or wave-shaped edge 3a formed so as to have the top portion 3b. (FIG. 13) If such a seal part 3 is formed in this way, when the unsealed part 6 is used as a stripping allowance and the double-sided film parts 4 and 4 of the packaging bag H are pulled away from each other, this pulling is performed. This is because the force can be concentrated on the top portion 3b of the seal portion 3 and the seal portion 3 can be easily broken from the top portion 3b side.
[0027]
The filling of the constituent material Ma of the plate-like food M is typically performed by placing the second heat seal 9 on the inner side of the film F which is formed into a flat cylindrical shape by applying the first heat seal 8. The filling tube 11 is inserted so that the discharge port 11a is positioned immediately above the heat sealing means 16 for applying the heat sealing means 16, and the discharge tube 11a is continuously or intermittently minced through the filling tube 11. For example, the unheated constituent material Ma prepared in a fluid state can be fed.
[0028]
In addition, for example, as shown in FIG. 3, the feeding of the constituent material Ma to the filling pipe 11 is performed by a feeding hopper 12a of the constituent material Ma and an extruded pipe portion communicated with the lower end opening 12b of the hopper 12a. 12c and the extruded tube portion 12c are provided at the center of the extruded tube portion 12c so as to extrude into the extruded tube portion 12c by its own weight or forcibly enter the constituent material Ma toward the front end side of the extruded tube portion 12c. The filling device 12 includes a rotary pump 12d, and the front end side of the extruded tube portion 12c communicates with the filling tube 11. (Note that the reference numeral 12e in the figure represents the rotor of the rotary pump.)
[0029]
The first heat seal 8 is composed of a pair of vertical heat rolls 15a and 15a in which the rotation axis is arranged in a direction orthogonal to the transport direction x of the film F as shown in FIG. It can be applied by heat sealing means 15.
[0030]
In the example shown in FIG. 2, the film F drawn from the raw film indicated by reference numeral 13 in the drawing is folded in half by the two-folding means indicated by reference numeral 14, and the film F thus folded is folded. A configuration is adopted in which a pair of the first heat seals 8 are provided along the folding side y side and the side z opposite to the folding side y side. That is, in the example shown in FIG. 2, the pair of longitudinally heated rolls 15 a and 15 a are respectively provided at both ends thereof with the folded side y side and the side z opposite to the folded side y side of the film F folded in half. An annular raised portion 15b having an outer casing shape that continuously applies the first heat seal 8 along the transport direction x of the film F while pulling in and feeding out the film F is provided at the edge of Yes.
[0031]
Then, the pair of vertical heat rolls 15a and 15a are arranged so that the raised portions 15b are brought close to the raised portions 15b of the other vertical heated rolls 15a on the side facing the other vertical heated roll 15a. The heat sealing means 16 for drawing the film F folded in half between the adjacent raised portions 15b from the side of the double folding means 14 and applying the second heat seal 9 to the drawn film F. It is set as the structure rotated in the reverse direction with respect to the other vertical heat roll 15a so that it may send out to the side of this.
[0032]
The second heat seal 9 is composed of a pair of transverse heat rolls 16a and 16a in which the rotation axis is arranged in a direction perpendicular to the transport direction x of the film F as shown in FIG. It can be applied by heat sealing means 16.
[0033]
In the example shown in FIG. 2, the pair of transverse heat rolls 16a and 16a draws the film F into the film F to which the first heat seal 8 has been applied by the pair of vertical heat rolls 15a and 15a. In addition, a protruding portion 16c that sequentially applies the second heat seal 9 with a predetermined interval while being fed out is provided in a protruding shape along the rotational axis direction of the transverse heat roll 16a.
[0034]
In this embodiment, the transverse heat roll 16a has outer flange-shaped portions 16d on both ends thereof, and has the ridge portion 16c between the outer flange-shaped portions 16d. Yes. In the present embodiment, the protrusions 16c are formed at a plurality of locations at intervals in the rotational direction of the transverse heat roll 16a. And the protrusion 16c of a pair of transverse heating rolls 16a and 16a is the protrusion of the other transverse heating roll 16a sequentially on the side facing the other transverse heating roll 16a as the transverse heating roll 16a rotates. As a configuration in which the second heat seal 9 is intermittently applied to the long film F which is brought close to the portion 16c and is drawn between the pair of transverse heat rolls 16a and 16a by the protruding portion 16c. is there.
[0035]
Next, in the second step, degassing is performed by pressing the film F so as to spread the filled constituent material Ma until the second heat seal 9 applied in the next order is applied. Step 20.
[0036]
This deaeration step 20 is first performed until the second heat seal 9 is applied, in which the air contained in the constituent material Ma filled in the filling step 10 is given in the next order. This is done to remove as much as possible from the constituent material Ma so that excess air does not remain in the constituent material Ma enclosed in the packaging bag H. Second, the tip in the film F formed into a flat cylindrical shape by the first heat seal 8 until the second heat seal 9 applied in the next order is applied. The constituent material Ma is densely distributed in the space up to the formation position of the second heat seal 9 applied in order and the second heat seal 9 applied in the next order, and applied in this order. This is done so that air caused by the filling gap does not remain in one packaging bag H formed by applying the second heat seal 9.
[0037]
By this deaeration step 20, the constituent material Ma can be sealed in a state where extra air is prevented from entering the packaging bag H as much as possible, and molding is performed from the constituent material Ma caused by such air. It is possible to prevent the plate-like food M from being altered as much as possible.
[0038]
In the example shown in FIG. 1 and FIG. 2, the rotation axis is in the direction perpendicular to the transport direction x of the film F between the discharge port 11 a of the filling tube 11 and the pair of transverse heat rolls 16 a and 16 a. The pair of squeezing rollers 21 and 21 facing each other are provided in two sets on the top and bottom, and the film F filled with the constituent material Ma passes between the pair of squeezing rollers 21 and 21 to perform the deaeration step 20. It is like that. That is, in this example, the film F filled with the constituent material Ma is pressed by the pair of squeezing rollers 21 and 21 so as to spread the constituent material Ma in the film F and squeeze out. Thus, before forming the second heat seal 9 in which the air contained in the constituent material Ma supplied from the filling tube 11 is applied in the next order by the pair of transverse heat rolls 16a, 16a. It is intended to escape upward.
[0039]
Next, in the third step, the plate-like plate-like food M is averaged so as to spread the component material Ma filled in the packaging bag H by pressing the packaging bag H filled with the component material Ma. It is the shaping | molding process 30 shape | molded into.
[0040]
This forming step 30 is first performed by applying the constituent material Ma filled in the packaging bag H to a plate shape following the internal space 7 of the packaging bag H, more specifically, to the packaging bag H. It is made to form a plate-like food M having a plate shape following the flat and square inner space 7 formed by the inner edge of the first heat seal 8 and the inner edge of the second heat seal 9. . Since the first heat seal 8 and the second heat seal 9 can be regularly formed by the vertical heat roll 15a and the horizontal heat roll 16a, each packaging bag H that is continuously formed, Each of the plate-like foods M, M,... Enclosed in H... Is a uniform plate-like food M that is substantially equal, and can stably supply the same standard product. In the three-side sealed packaging bag and the four-side sealed packaging bag, the first heat seal 8 along the transport direction x of the film F is separately provided at one or more places between both sides of the packaging bag H. In some cases, the packaging bag H is formed so as to have two or more inner spaces 7, 7..., And in such a case, two or more plate-like foods M forming a rectangular plate shape in one packaging bag H. Can be molded and encapsulated. The first heat seal 8 for forming two or more internal spaces 7 of the packaging bag H is provided with a bowl-shaped raised portion 15b as described above at an intermediate portion between the pair of vertical heat rolls 15a and 15a. Can be formed. In addition, if the heat seals 8 and 9 are applied so that the corners formed by the inner edges of the heat seals 8 and 9 are rounded, the plate-like food having a plate shape with slightly rounded corners. M can be molded.
[0041]
In addition, secondly, in the molding step 30, the constituent material Ma filled in the packaging bag H is made into a plate-like food M having a plate shape, so that the plate-like food M is heated in the heating step 40 described later. Can be appropriately heated and solidified in a short time.
[0042]
In the example shown in FIG. 1 and FIG. 2, a pair of leveling rollers 31 having a rotation axis oriented in a direction perpendicular to the transport direction x of the film F at the next rank position of the pair of transverse heating rolls 16 a, 16 a, 31 is formed in a continuous state between the pair of leveling rollers 31, 31, and the packaging bag H enclosing the constituent material Ma passes through the interior space of the packaging bag H by the leveling roller 31. 7 is formed so that the constituent material Ma is spread over the entire surface with a uniform thickness.
[0043]
In the example shown in FIGS. 1 and 2, a feed roller 32 that conveys the packaging bag H formed in a continuous state is provided at the next rank position of the pair of leveling rollers 31, 31. A cutting means 33 for cutting the packaging bag H formed in such a continuous state at the next rank position of the feed roller 32 within the width of the second heat seal 9 and dividing the packaging bag H into individual packaging bags H is provided. It is provided.
[0044]
Then, by this cutting means 33, the cut packaging bag H slides down on the guide plate 34, and on the end 35 a on the load receiving side of the belt conveyor 35 that feeds the packaging bag H one by one into the cooling device 41 described later. It is configured to be sent to. (Fig. 4)
[0045]
Further, in the example shown in FIGS. 1 and 2, the belt conveyor 35 is provided with a circling belt 36 a arranged so as to press the lower surface from above on the packaging bag H conveyed by the belt conveyor 35. A pressing means 36 is provided. (FIGS. 1 and 4) Even between the pressing means 36 and the belt conveyor 35, the constituent material Ma is uniformly distributed in the entire internal space 7 of each packaging bag H, H. In the example shown in FIGS. 1 and 2, the pressing means 36 also executes the molding step 30.
[0046]
Next, the fourth step is a heating step 40 in which the packaging bag H containing the plate-like food M that has been flattened into a plate shape is heated to keep the plate-like food M in shape.
[0047]
In this heating step 40, first, the plate-like food M formed by forming the constituent material Ma into the substantially square plate shape in the packaging bag H by the molding step 30 is formed into the substantially square shape. It is made so that it can be provided until the end consumer eats it while keeping it in a plate shape.
[0048]
Secondly, the plate-like food M is made to be preserved for a long time.
[0049]
Such heating is performed, for example, by feeding the packaging bag H into the hot water heating device 41.
[0050]
FIG. 5 shows that the belt conveyor 42 that receives and conveys the packaging bag H from the end 35b on the unloading side of the belt conveyor 35 is conveyed while the packaging bag H is immersed in the heating tank 41a in which hot water is stored. An example in which such heating is performed by the hot water heating device 41 arranged in FIG. In the figure, reference numeral 43 indicates a pressing travel belt that travels in the same direction as the belt conveyor 42 with its lower surface positioned on the belt conveyor 42 in the heating tank 41a of the hot water heater 41. The press traveling belt 43 prevents the packaging bag H, which is conveyed on the belt conveyor 42 in the heating tank 41a, from being lifted. Moreover, in this example, the cooling device 50 provided with the cooling tank 50a in which the cold water was stored following the said hot water heating device 41 is arranged, and the said belt conveyor 42 is the packaging conveyed in the said heating tank 41a. The bag H is provided from the heating tank 41a to the cooling tank 50a so that the bag H is continuously fed into the cooling tank 50a and immersed in the cold water so as to be conveyed through the cooling tank 50a. In this example, a holding belt 51 for preventing the packaging bag H conveyed on the belt conveyor 42 from being lifted in the cooling tank 50a is also provided on the cooling tank 50a side.
[0051]
【The invention's effect】
According to the method for producing a film-packaged plate-like food according to the present invention, the plate-shaped food packaged in a film is easily and stably made from the constituent material of the food that is hardened by heating, and the production line is complicated. It can be manufactured without.
[Brief description of the drawings]
FIG. 1 is a side configuration diagram showing an outline of a manufacturing method according to an embodiment.
FIG. 2 is a perspective configuration diagram showing an outline of the manufacturing method according to the embodiment.
FIG. 3 is a side configuration diagram showing a configuration example of a filling device.
FIG. 4 is a perspective configuration diagram showing an example of the molding step 30.
FIG. 5 is a perspective configuration diagram showing an example of the heating process 40;
FIG. 6 is an enlarged sectional view showing the principle of interfacial peeling.
FIG. 7 is an enlarged sectional view showing the principle of delamination
FIG. 8 is an enlarged cross-sectional view showing the principle of cohesive failure
FIG. 9 is a perspective view of a plate-like food M packaged with the manufactured film F.
10 is a cross-sectional view taken along line AA in FIG.
11 is a perspective view showing a state where the packaging bag H of FIG. 9 is opened and the plate-like food M is taken out. FIG.
12 is a perspective view of the plate-like food M taken out as shown in FIG.
FIG. 13 is a perspective view of a plate-like food M packaged with a manufactured film F having a part of the configuration different from that of FIG.
[Explanation of symbols]
F film
2 Sealant layer
8 First heat seal
9 Second heat seal
H Packaging bag
Ma Constituent material
10 Filling process
20 Deaeration process
30 Molding process
40 Heating process

Claims (1)

界面剥離、層間剥離又は凝集破壊可能に熱シールされるシーラント層を有するフィルムを搬送しながら当該フィルムの搬送方向に沿った向きに連続して施される第一の熱シールと当該搬送方向に交叉する向きに間隔を開けて施される第二の熱シールとにより順次連続して三方シール包装袋又は四方シール包装袋を形成させながら、先順位で施された第二の熱シールと次順位で施される第二の熱シールとの間に加熱により固まる食品の構成材料を未加熱状態で充填させる充填工程と、
前記次順位で施される第二の熱シールが施されるまでの間で、充填された前記構成材料をしごき広げさせるように一対の締め込みローラ間で前記フィルムを押圧する脱気工程と、
当該構成材料が充填された包装袋を押圧して充填された当該構成材料を包装袋内に行き渡らせるように均して板状に成形する成形工程と、
前記板状に成形された食品を納めた包装袋を当該食品の構成材料を固まらせる温度で加熱して当該食品を板状に保形する加熱工程とを備えることを特徴とするフィルム包装された板状食品の製造方法。While transporting a film having a sealant layer that is heat-sealed so that interfacial debonding, delamination or cohesive failure can be achieved, crossing in the transport direction with the first heat seal applied continuously in the direction along the transport direction of the film While forming a three-side seal packaging bag or a four-side seal packaging bag sequentially and sequentially with a second heat seal applied at intervals in the direction of A filling step of filling the constituent material of the food set by heating in an unheated state between the second heat seal to be applied;
A deaeration step of pressing the film between a pair of tightening rollers so as to squeeze out the filled constituent material until the second heat seal applied in the next order is applied,
A molding step of pressing the packaging bag filled with the constituent material and shaping the filled constituent material into a plate shape so as to spread throughout the packaging bag;
A film package comprising: a heating bag that heats a packaging bag containing the food formed in a plate shape at a temperature at which the constituent material of the food is solidified and retains the food in a plate shape A method for producing plate food.
JP26356699A 1999-09-17 1999-09-17 Method for producing film-packaged plate food Expired - Lifetime JP4050850B2 (en)

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