WO2013061892A1 - 飼料又は食品の製造方法 - Google Patents
飼料又は食品の製造方法 Download PDFInfo
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- WO2013061892A1 WO2013061892A1 PCT/JP2012/077138 JP2012077138W WO2013061892A1 WO 2013061892 A1 WO2013061892 A1 WO 2013061892A1 JP 2012077138 W JP2012077138 W JP 2012077138W WO 2013061892 A1 WO2013061892 A1 WO 2013061892A1
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- outer layer
- starch
- layer composition
- feed
- raw material
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L29/00—Foods or foodstuffs containing additives; Preparation or treatment thereof
- A23L29/20—Foods or foodstuffs containing additives; Preparation or treatment thereof containing gelling or thickening agents
- A23L29/275—Foods or foodstuffs containing additives; Preparation or treatment thereof containing gelling or thickening agents of animal origin, e.g. chitin
- A23L29/281—Proteins, e.g. gelatin or collagen
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23N—MACHINES OR APPARATUS FOR TREATING HARVESTED FRUIT, VEGETABLES OR FLOWER BULBS IN BULK, NOT OTHERWISE PROVIDED FOR; PEELING VEGETABLES OR FRUIT IN BULK; APPARATUS FOR PREPARING ANIMAL FEEDING- STUFFS
- A23N17/00—Apparatus specially adapted for preparing animal feeding-stuffs
- A23N17/005—Apparatus specially adapted for preparing animal feeding-stuffs for shaping by moulding, extrusion, pressing, e.g. pellet-mills
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P10/00—Shaping or working of foodstuffs characterised by the products
- A23P10/30—Encapsulation of particles, e.g. foodstuff additives
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
- A23P20/20—Making of laminated, multi-layered, stuffed or hollow foodstuffs, e.g. by wrapping in preformed edible dough sheets or in edible food containers
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
- A23P30/20—Extruding
- A23P30/25—Co-extrusion of different foodstuffs
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A40/00—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production
- Y02A40/80—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production in fisheries management
- Y02A40/81—Aquaculture, e.g. of fish
- Y02A40/818—Alternative feeds for fish, e.g. in aquacultures
Definitions
- the present invention relates to a method for producing a feed or food having a double structure having an outer layer and an inner layer. More specifically, the present invention relates to a method suitable for mass production of feed and foods in which an inner layer is wrapped in an outer layer using an extruder having a double nozzle.
- a wrapping machine has been widely used as an apparatus for producing food products represented by bun confectionery.
- a wrapping machine is a device that wraps and forms cocoons, ingredients, etc. with an outer shell made of cocoon, flour, or the like.
- Patent Document 5 describes a method of combining an extruder and a cutter in order to produce a multi-layered food from a multi-layered bar-shaped food in which two or more kinds of food materials overlap in a concentric cross section. ing.
- Patent Document 6 describes a double-structured feed that wraps an inner layer with an outer layer and describes that it can be manufactured with a double-nozzle extruder.
- An object of the present invention is to provide a method suitable for mass production of encapsulated feed and food.
- the present inventors tried production using a packaging machine frequently used in the fields of confectionery, bread, etc. Did not go.
- One major problem is that the outer layer needs to be heat-processed separately after being molded by the packaging machine, and the efficiency of transferring and storing the molded product is poor. Therefore, instead of performing the molding and the heat treatment in two separate steps, a method of performing at once was examined. Forming a double structure with an extruder equipped with a double nozzle, and then cutting the envelop with a shutter mechanism while the temperature is high, to produce a feed that completely wraps the inner layer with the outer layer The present invention has been completed by finding out what can be done.
- the gist of the present invention is the feed or food production method of (1) to (8).
- (1) Prepare an outer layer composition raw material in which an auxiliary raw material is added to a protein raw material and / or starch raw material that forms a gel by heating and mixed by stirring, and an inner layer composition wrapped by the outer layer composition.
- heat treatment is applied to the outer layer composition raw material to gel, and at the same time, extrusion molding is performed so as to cover the surface of the inner layer composition, and the columnar molded product that is continuously extruded is fixed using the shutter mechanism.
- the shutter mechanism is a shutter device provided with a plurality of shutter pieces that can be opened and closed.
- the protein material that forms a gel upon heating is a combination of one or more selected from fish paste, fish paste, krill, gelatin, collagen, gluten, egg white, and soy protein (1) to (5) A method for producing any feed or food.
- the starch raw material which forms a gel by heating is a combination of one or two or more selected from tapioca starch, wheat starch, potato starch, corn starch, bean starch, waxy starch, and processed starch thereof. (1) thru
- the production method of the present invention enables mass production of feed and food with a double structure in which the inner layer is wrapped in the outer layer at high speed.
- FIG. 1 is a schematic diagram showing one embodiment for carrying out the method of the present invention.
- FIG. 2 is a schematic diagram showing one embodiment of a shutter mechanism used in the present invention.
- FIG. 3 is a schematic diagram showing one embodiment of a slide shutter used in the present invention.
- FIG. 4 is a schematic diagram showing one embodiment of a slide shutter used in the present invention.
- the present invention is a method for producing an encasement type feed or food in which an inclusion is wrapped by an outer skin.
- a shutter mechanism that uses an extruder equipped with a double nozzle and heats the outer layer by extrusion cooking and coats the inner layer with the outer layer at the same time, and moves the molded product extruded in a column shape up and down according to the speed of extrusion.
- the cut surface is covered with an outer layer at the same time as being cut into a certain length.
- the extruder used in the present invention may be uniaxial or biaxial as long as it has an extrusion function and a heating function.
- the outer layer composition raw material is supplied to an extruder, kneaded and heated to a temperature at which the outer layer composition raw material forms a heated gel and extruded.
- a nozzle that feeds the inner layer composition to the center of the outer layer composition is disposed near the outlet of the extruder, and the inner layer composition is extruded into the center of the outer layer that is extruded in a cylindrical shape, thereby forming a double structure.
- the heating temperature by the extruder depends on the raw material of the outer layer
- gelation occurs by raising the product temperature to 60 to 110 ° C., preferably 60 to 100 ° C., particularly preferably 70 to 90 ° C. If it can be expanded, it can be produced even at a temperature of 110 ° C. or higher.
- a double-structured molding that is continuously extruded from the extruder is fed vertically downward into the shutter mechanism.
- a slide-type shutter having a structure in which the opening gradually decreases and closes at the center while maintaining a uniform shape by a plurality of shutter pieces is preferable. While the shutter draws the heated gel in the outer layer of the extruded product from the extruder, it creates a constriction, shrinks the opening, and finally cuts in the center. The heated gel coming out of the extruder can be reliably closed by closing it with a shutter before it cools down.
- the thickness of the cut surface of the shutter piece is equal to or greater than the radius of the product to be manufactured in order to reliably cover the cut surface with the outer layer. That is, for example, in the case of a product having a diameter of 26 mm, it is appropriate that the thickness of the cut surface of the shutter piece is about 15 mm, and in the case of a product having a diameter of 18 mm, about 10 mm.
- the shutters used in conventional wrapping machines cannot be applied to the extruder. To match the speed of the extruder, it is necessary to increase the shutter opening / closing speed and the vertical movement speed. Further, since the operation is performed at high speed and the temperature of the heated gel discharged from the extruder is 60 to 100 ° C., the shutter is exposed to a high temperature and expands. Furthermore, if a hard material such as fish meal, which is a feed material, is included, the surface is rubbed and the wear is severe. In order to solve this, first, it is necessary to manufacture the shutter material with a material having heat resistance, slidability and strength. Conventional material Newlite resin has low heat resistance (60 °C) and soft material. In the present invention, it is preferable to use a PEEK (peak) material or an equivalent material. Moreover, you may cool a shutter as needed. Specifically, methods such as compressed air blowing and cooling air blowing can be employed.
- crankshaft drive was adopted. Driven by the rotational movement of the crankshaft, the cutting speed of the shutter device and the vertical speed of the device can be increased. The speed can be adjusted by changing the vertical stroke. By driving in this way, it became possible to increase the cutting speed of the envelope by the shutter to 120 to 140 times / minute or more.
- the product encapsulated and cut by the shutter mechanism is a columnar molded product having a constant length and the inner layer completely wrapped by the outer layer, and can be used as feed or food as it is.
- the gel by heating is gelatinized by heating the protein to a temperature of 60 ° C. or higher, or by adding water to the gel or starch that is heated by cooling to 60 ° C. or higher and then heating to 60 ° C. or higher. It means a gel that can.
- the outer layer composition may be anything as long as it wraps the inner layer composition, but the physical properties of the gel formed by heating the protein or the gel formed by heating the starch are its flexibility and extensibility. Therefore, it is suitable for the present invention.
- a protein having gel forming ability such as a simple substance of protein such as fish meat, surimi, krill, gluten, collagen, soybean protein, enzyme-degraded soybean protein, gelatin, egg white or a mixture of two or more of these is preferred.
- As the starch tapioca starch, wheat starch, potato starch, corn starch, bean starch, waxy corn starch, and processed starch thereof are preferable.
- a food material containing a large amount of these proteins and / or starches can also be used.
- the outer layer having a composition containing these proteins and / or starches is fixed with gel by heating, has flexibility, and has a holding power for the inner layer composition, and has a certain strength.
- fish meat surimi as an outer layer composition
- it can be produced using a general method for producing paste products such as kamaboko. Specifically, 2% or more of sodium chloride is added and placed at 10 ° C or higher, preferably 30 ° C to 40 ° C for 10 minutes or longer, and then heated at 80 to 90 ° C for 10 minutes or longer.
- a composition having desirable physical properties can be obtained by mixing egg white: starch: fish meal: water at a weight ratio of 1: 1: 2: 6 and heating.
- auxiliary materials can be added to the outer layer as long as the gel formation is not affected.
- fish meal and fats and oils may be added to the outer layer as long as they do not affect the gelation of the outer layer.
- an additive used as a quality improver such as a fish paste product can be added.
- Starch thickening polysaccharide, isolated soybean protein, baking soda, polymerized phosphate, egg white, transglutaminase, various protease inhibitors, and the like may be added.
- a heated gel mainly composed of starch is excellent in its elasticity and flexibility.
- Gels heated and kneaded with starch are heated, flexible, flexible and stretchable.
- various processed starches have their respective characteristics, and an outer layer having properties such as elasticity, flexibility, and extensibility can be obtained by combining two or more kinds.
- modified starches may be combined, such as a combination of etherified starch and phosphate cross-linked starch.
- a stronger gel can be obtained by adding proteins such as gluten and soy protein to starch. It is also possible to use flour containing gluten instead of gluten.
- auxiliary ingredients include flour such as wheat flour, protein such as soy protein, gluten and egg white, sugar and sugar alcohols such as sugar and starch syrup, carrageenan, agar, gellan gum, pullulan, mannan, xanthan gum, locust bean gum, curd Thickeners such as orchid, pectin, alginic acid and salts thereof, gum arabic, chitosan, dextrin and edible water-soluble cellulose, and salts such as phosphates may be added.
- strength can be given to the outer layer by adding wheat flour to starch.
- the stickiness of the surface after a heating can be suppressed by adding a fixed amount of protein.
- the starch used in the present invention is not particularly limited, but tapioca starch, wheat starch, potato starch, corn starch, bean starch and the like can be used, particularly etherification, acetylation, acetyl crosslinking, ether crosslinking, phosphoric acid crosslinking, Processed starch such as pregelatinized hydroxypropyl phosphate is preferred.
- the feed of the present invention is produced by adding other auxiliary materials such as protein to these starches, adding water, mixing and kneading, wrapping the inner layer with a wrapping machine, and then heating.
- the outer layer raw material and the inner layer raw material are respectively supplied to an extruder having a double nozzle, and the outer layer raw material is mixed and heat-treated, and at the same time, the outer layer raw material and the inner layer raw material are extruded and formed so as to wrap the inner layer.
- the amount of water added to the raw material such as starch may be any amount that can be used for a packaging machine or an extruder, but about 30 to 50% by weight is appropriate.
- the heating temperature may be higher than the temperature at which starch, added protein, etc. gel, and the product temperature should be about 60 to 110 ° C., preferably 70 to 100 ° C., more preferably about 80 to 90 ° C. .
- the moisture content of the outer layer formed by wrapping the inner layer with the heated starch gel of the present invention is about 25 to 50% by weight. When stored as it is for a long time, it can be refrigerated or frozen. Further, when this feed is further dried to have a water content of 10 to 20% by weight, storage stability can be improved. By combining the drying of the outer layer and the reduction of water activity by adding an additive to the outer layer, a feed that can be stored at room temperature for a long time can be produced. A water content of 10 to 20% by weight and a water activity of 0.8 or less, particularly 0.6 or less are preferred.
- compositions of the composition of the outer layer containing starch can be considered for the composition of the composition of the outer layer containing starch.
- the nutrients and calories required for the feed differ depending on the fish species and the growth stage of the fish.
- the more fish meal or fish oil is added the more precisely the outer layer needs to be prepared.
- the outer layer has a considerable degree of freedom.
- At least 20 to 80% by weight of starch is contained in terms of dry matter.
- the outer layer is added with 25 to 50% by weight of fish meal (in terms of dry matter), the total amount of starch, 20 to 65% by weight, wheat flour 5 to 20% by weight, protein, fats and oils, thickeners, salts, etc. It is preferable to add about 15% by weight.
- wheat flour is preferably strong flour with a high gluten content, but it may also be weak flour.
- additives used as a quality improver for starch foods can be added.
- the composition of the inner layer is mainly composed of fish meal and fats and oils, but other nutritional components known as nutritional components for fish farming such as vitamins and minerals may be added.
- other nutritional components known as nutritional components for fish farming such as vitamins and minerals may be added.
- polysaccharides and hardened oils can be blended, emulsified and stabilized.
- polysaccharides include oil Q (manufactured by Hidden Chemical Co., Ltd.), and examples of hardened oils include Unishort K (manufactured by Fuji Oil Co., Ltd.) and New Fuji Pro SEH (manufactured by Fuji Oil Co., Ltd.).
- the raw material of the conventional formula feed for cultured fish can be added to the composition of an inner layer.
- raw fish, squid meal, krill meal, soybean oil cake, corn gluten meal and other proteins krill oil, whale oil, soybean oil, corn oil, rapeseed oil, hardened oil and other fats, starch, wheat flour, rice flour, tapioca flour, corn Starches such as flour, alginic acid and its salts, sodium carboxymethylcellulose (CMC), guar gum, dextrin, chitosan, curdlan, pectin, carrageenan, mannan, gellan gum, gum arabic, edible water-soluble cellulose and other polysaccharides, vitamins, Such as minerals.
- CMC carboxymethylcellulose
- the composition of the inner layer has an oil / fat content of 20 to 70% by mass, particularly when fed to large cultured fish, the oil / fat content is preferably 30% by mass or more, more preferably 35% by mass or more, and most preferably 45% by mass or more. It mixes so that it may become.
- a large amount of fats and oils has an excellent effect on the growth and growth efficiency of cultured fish.
- the fats and oils content exceeds 70% by mass, other blending components are inevitably reduced, making it difficult to adjust the nutritional balance.
- Fish oil and other vegetable oils and fats have high fluidity and may be used as they are, but preferably Vitacel WF200, Vitacel WF600 or Vitacel WF600 / 30 (manufactured by Rettenmeier), Oil Q No. 50 or Oil Q- Oil-absorbing polysaccharides including dextran such as S (manufactured by Nissho Chemical Co., Ltd.), Pineflow (manufactured by Matsutani Chemical Industry Co., Ltd.), oil-absorbing proteins such as fermented soybean, isoflavone, soybean oil, rapeseed oil or palm oil
- the fluidity can be reduced using a hardened oil obtained by hydrogenating oils and fats. Alternatively, the fluidity can be reduced by emulsifying fish oil.
- the components that lower the fluidity are 10% by mass or less, more preferably 5% by mass or less of the composition of the inner layer.
- oil and fat fish oil is most preferable, but it can be partially replaced with other vegetable oil and fat.
- fish meal which is an essential component of the inner layer
- various fish meals that are usually used as feed materials for fish farming, crustacean powder such as krill, and the like can be used.
- the fish meal content is 30 to 70% by mass, preferably 30% by mass or more, more preferably 35% by mass or more, and most preferably 45% by mass or more. It is preferable to add excipients such as binding polysaccharides, hardened oils and emulsifiers to the inner layer composition so that the inner layer composition does not easily collapse.
- the water activity may be adjusted in consideration of the storage stability of the feed of the present invention.
- the water activity can be adjusted by adjusting the composition of the inner layer and the outer layer.
- the water activity of the composition of the inner layer can be lowered by adjusting the amount of water added.
- Salts salt, sodium malate, sodium lactate, etc.
- sugars sacgar, lactose, maltose, sorbit, etc.
- sugar alcohols amino acids, nucleic acid related substances, organic acids, alcohols, propylene glycolose, glycerin, starches
- the water activity of the composition may be adjusted by adding a water activity regulator such as proteins.
- the components of the outer layer can be designed according to the same standard even for food.
- the composition of the inner layer may be any material as long as it has physical properties that can be fed from the extruder nozzle.
- the inner layer may be raw or processed, and may be a single material or a cooked product.
- the outer layer composition raw material supply device 1 mixes the outer layer composition raw materials and feeds them to the extruder 3 with a pump.
- the inner layer composition supply device 2 sends the separately mixed and manufactured inner layer composition from the nozzle 5 to the discharge port 4 of the extruder by a pump.
- the outer layer composition raw material is kneaded in the extruder 3 and then heated to become a heated gel.
- the outer layer is extruded in a cylindrical shape at the discharge port, and the inside is filled with the inner layer composition inserted from the nozzle 5 and discharged in a double-structured columnar shape.
- the discharged double-structured columnar object is conveyed by a conveyor and inserted into the shutter mechanism 6 in a vertically downward direction.
- the shutter mechanism 6 cuts the envelope with a certain length, and a double-structured molded product is completed.
- the extruder used a biaxial type device (Buhler) with a discharge capacity of 1 t / h and rotating in the same direction.
- a shutter mechanism having the configuration shown in FIG. 2 was used as a shutter mechanism capable of covering and cutting in accordance with the discharge speed of the extruder.
- the shutter device moves up and down according to the discharge speed of the extruder. That is, the motor 8 whose rotational speed is controlled rotates the crankshaft 9, the rotational movement of the crankshaft 9 is converted into vertical movement by the connecting rod 10, and the shutter device 12 connected to the linear guide 11 is moved up and down by the vertical movement.
- the shutter is a sliding slide shutter 13, and a motor 14 whose rotational speed is controlled rotates the crankshaft 15, and the rotational motion of the crankshaft 15 is converted into a back-and-forth motion by the connecting rod 16 and is connected to the connecting rod 16.
- FIG. 3 is a top view of the opening / closing mechanism.
- the shutter piece is made of PEEK as a material that can withstand expansion due to heating and wear due to high-speed operation. Resins without heat resistance could not withstand high speed operation.
- the shutter mechanism the same mechanism as that of the automatic cutting machine shutter (Patent 3377964) of Leon Automatic Co., Ltd. was used.
- FIG. 4 six shutter pieces 19 are fixed by slide pins 20, and the left and right drawings show an open state and a closed state.
- the present invention can provide a method for producing a large amount of feed, food, etc. having a double structure of an outer layer and an inner layer at high speed.
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Abstract
Description
また、特許文献5には、多層包被食品を、2種類以上の食品材料が断面同心円状に重なってなる多層棒状食品から高能率に製するために、押し出し機とカッターを組み合わせる方法が記載されている。
包被タイプの飼料や食品を製造する場合に、外層と内層を包餡機により成形した後に、成形物を加熱処理する方法は、工程が2段階になり、加熱前の成形物の型崩れを起こさないように加熱処理工程に移送するのに手間がかるなど、大量生産に適しているとはいえない。本発明は、包被タイプの飼料や食品を大量生産するのに適した方法を提供することを課題とする。
(1)加熱によりゲルを形成する蛋白質原料及び/又は澱粉原料に副原料を添加し撹拌混合した外層組成物原料、及び、外層組成物によって包みこまれる内層組成物を調製し、二重ノズルを備えたエクストルーダを用いて、外層組成物原料に加熱処理を加えゲル化しながら、同時に内層組成物の表面を覆うように押出成形し、シャッター機構を用いて、連続的に押し出される柱状成形物を一定の長さに切断すると同時に、ゲル化した外層組成物によって切断面を包被させることを特徴とするゲル化した外層組成物で内層を包みこんだ飼料又は食品の製造方法。
(2)シャッター機構が複数のシャッター片を開閉自在に設けたシャッター装置である(1)の飼料又は食品の製造方法。
(3)シャッター片が6枚以上組み合わされたものである(3)の飼料又は食品の製造方法。
(4)シャッターが耐熱性のある素材で製造されている(1)ないし(3)いずれかの飼料又は食品の製造方法。
(5)シャッター機構がクランクシャフト駆動である(1)ないし(4)いずれかの飼料又は食品の製造方法。
(6)加熱によりゲルを形成する蛋白質原料が魚肉すり身、魚肉落し身、オキアミ、ゼラチン、コラーゲン、グルテン、卵白、大豆蛋白質から選ばれる1つ又は2つ以上を組み合わせたものである(1)ないし(5)いずれかの飼料又は食品の製造方法。
(7)加熱によりゲルを形成する澱粉原料がタピオカ澱粉、小麦澱粉、馬鈴薯澱粉、トウモロコシ澱粉、豆澱粉、ワキシーコンスターチ、及びそれらの加工澱粉から選ばれる1つ又は2つ以上を組み合わせたものである(1)ないし(5)いずれかの飼料又は食品の製造方法。
(8)エクストルーダによる加熱温度が60~110℃である(1)ないし(7)いずれかの飼料又は食品の製造方法。
エクストルーダによる加熱温度は外層原料によるが、品温を60~110℃、好ましくは60~100℃、特に好ましくは70~90℃に昇温させることによりゲル化する。膨化しても差し支えなければ、温度が110℃以上でも製造可能である。押し出された際に外層が膨化するのを望まない場合には、さらに外層組成物原料を脱気しておくのが好ましい。
エクストルーダから連続的に押し出されてくる二重構造の成形物を垂直下向きにシャッター機構に送り込む。
シャッターの形状は具体的には、レオン自動機株式会社の特許3016246、特許3377964、特許3415072、実用新案平5-25432、株式会社コバートの特許2641033などに記載されているシャッターを用いることができる。特にシャッター片が6枚以上組み合わされ、開口部が正多角形の形状のままで開閉するものを用いると外層が均等に引き寄せられるので好ましい。
また、シャッター片の切断面の厚みは、外層により切断面を確実に覆うために製造する製品の半径以上の厚みとするのが好ましい。すなわち、例えば直径26mmの製品の場合、シャッター片の切断面の厚みを15mm程度、直径18mmの製品の場合は10mm程度にするのが適当である。
シャッター機構で包被切断した生産物は、一定の長さで外層により内層が完全に包み込まれた柱状の成形物であり、そのまま飼料や食品として用いることができる。
本発明において加熱によるゲルとは、蛋白質を60℃以上に加熱する、あるいは、60℃以上に加熱後冷却することによりできるゲルや澱粉に水分を加えて60℃以上に加熱することにより糊化してできるゲルを意味する。
例えば、魚肉すり身を外層組成物として用いる場合、一般的なかまぼこなどの練製品の製造方法を用いて製造することができる。具体的には、2%以上の食塩を加え10℃以上、好ましくは30℃~40℃で10分以上置いてから、80~90℃で10分以上加熱する。あるいは卵白を用いる場合、例えば、卵白:澱粉:魚粉:水を1:1:2:6の重量比率で混合し、加熱することにより、望ましい物性の組成物を得ることができる。
飼料の場合、外層のゲル化に影響を与えない範囲で外層にも魚粉、油脂を添加してもよい。用いるゲルの種類にもよるが、外層には魚粉を60重量%程度まで、また、油脂を30重量%まで添加することが可能である。魚粉を20~30重量%及び油脂を5~10重量%程度添加するのが好ましい。
外層のゲルの品質をよりよくするために、魚肉練製品などの品質改良剤として用いられている添加物を添加することができる。澱粉、増粘多糖類、分離大豆蛋白、重曹、重合リン酸塩、卵白、トランスグルタミナーゼ、各種プロテアーゼインヒビター、などを添加してもよい。特に、ゲル強度を強化するために、寒天、ジェランガム、プルラン、澱粉、マンナン、カラギーナン、キサンタンガム、ローカストビーンガム、カードラン、ペクチン、アルギン酸及びその塩類、アラビアガム、キトサン、デキストリン、可食性水溶性セルロースなどの増粘剤を適宜配合してもよい。
副原料として用いる場合、小麦粉はグルテン含有量の多い強力粉が好ましいが、薄力粉でもよい。
外層の品質をよりよくするために、澱粉食品の品質改良剤として用いられている添加物を添加することができる。
さらに、内層の組成物には、従来の養殖魚用配合飼料の原材料を添加することができる。例えば、生魚類、イカミール、オキアミミール、大豆油かす、コーングルテンミールなどのタンパク質、オキアミ油、鯨油、大豆油、コーン油、菜種油、硬化油などの油脂、澱粉、小麦粉、米粉、タピオカ粉、トウモロコシ粉などのデンプン質、アルギン酸及びその塩類、カルボキシメチルセルロースナトリウム(CMC)、グァガム、デキストリン、キトサン、カードラン、ペクチン、カラギーナン、マンナン、ジェランガム、アラビアガム、可食性水溶性セルロースなどの多糖類、ビタミン、ミネラル類などである。
内層の必須成分である魚粉は通常養魚用飼料原料として用いられている各種魚粉、オキアミなどの甲殻類の粉末などが利用できる。魚粉含量を30~70質量%、好ましくは30質量%以上、より好ましくは35質量%以上、最も好ましくは45質量%以上となるように配合する。内層の組成物が崩れにくいように、内層組成物に結着性のある多糖類、硬化油、乳化剤などの賦形剤を添加しておくのが好ましい。
高速での生産を可能とするため、エクストルーダは吐出能力1t/hの同方向回転完全噛み合い型2軸タイプの装置(Buhler社製)を用いた。
シャッターはスライド式のスライドシャッター13であり、回転スピードを制御したモーター14がクランクシャフト15を回転させ、クランクシャフト15の回転運動を連結棒16により前後運動に変換し、連結棒16と連結された駆動レバー17を前後運動させ、駆動レバー17の前後運動をハウジング18内にあるギア類で回転運動に変換することにより、開閉する。図3はこの開閉の機構を上から見た図である。カム機構を使わず、モーター14でクランクシャフトを回転させる方式を用いたことにより、装置の強度を高めることができ、スピードアップすることができる。また、シャッター片は加熱による膨張、高速運転による磨耗に耐える素材としてPEEK材を用いた。熱耐性のない樹脂では、高速運転に耐えなかった。
シャッターの機構はレオン自動機株式会社の包被切断機シャッター(特許3377964)と同様の機構を用いた。図4に示すように6枚のシャッター片19がスライドピン20で固定されており、左右の図は開いた状態と閉じた状態を示している。
タピオカ澱粉(エーテル化澱粉)18重量%、ワキシー澱粉(α化ヒドロキシプロピルリン酸架橋澱粉)4重量%、豆澱粉(アセチル化澱粉)1重量%、分離大豆タンパク粉体(ニューフジプロSEH:不二製油社製)3重量%、オキアミミール3重量%、小麦粉3重量%、グルテン1重量%、カラギーナン0.5重量%、リン酸水素二ナトリウム0.5重量%、卵白3重量%、魚粉20重量%、水あめ3重量%、魚油2重量%、水40重量%をサイレントカッターを用いて混合し、外層用組成物原料とした。
魚粉60重量%、魚油36重量%、硬化油1.2重量%、オキアミミール3重量%、ビタミン2.5重量%、ミネラル1重量%、リン酸カルシウム1.2重量%、有機酸0.1重量%をミキサーを用い混合し、内層組成物とした。
これらを実施例1の製造装置の外層組成物原料供給装置1と内層組成物供給装置2からそれぞれ送りこみ、エクストルーダにより、スクリュー回転数450rpm、吐出温度90℃、出口圧力45barの条件で混合、加熱した。実施例1の装置により、145個/分の生産が可能であり、切断面は外層により包被され、内層物が漏れ出てくることはなかった。
1 外層組成物原料供給装置
2 内層組成物供給装置
3 加熱機能付きエクストルーダ
4 吐出口
5 ノズル
6 シャッター機構
7 コンベア
8 モーター
9 クランクシャフト
10 連結棒
11 リニアガイド
12 シャッター装置
13 スライドシャッター
14 モーター
15 クランクシャフト
16 連結棒
17 駆動レバー
18 ハウジング
19 シャッター片
20 スライドピン
21 ノブボルト
Claims (8)
- 加熱によりゲルを形成する蛋白質原料及び/又は澱粉原料に副原料を添加し撹拌混合した外層組成物原料、及び、外層組成物によって包みこまれる内層組成物を調製し、二重ノズルを備えたエクストルーダを用いて、外層組成物原料に加熱処理を加えゲル化しながら、同時に内層組成物の表面を覆うように押出成形し、シャッター機構を用いて、連続的に押し出される柱状成形物を一定の長さに切断すると同時に、ゲル化した外層組成物によって切断面を包被させることを特徴とするゲル化した外層組成物で内層を包みこんだ飼料又は食品の製造方法。
- シャッター機構が複数のシャッター片を開閉自在に設けたシャッター装置である請求項1の飼料又は食品の製造方法。
- シャッター片が6枚以上組み合わされたものである請求項3の飼料又は食品の製造方法。
- シャッターが耐熱性のある素材で製造されている請求項1ないし3いずれかの飼料又は食品の製造方法。
- シャッター機構がクランクシャフト駆動である請求項1ないし4いずれかの飼料又は食品の製造方法。
- 加熱によりゲルを形成する蛋白質原料が魚肉すり身、魚肉落し身、オキアミ、ゼラチン、コラーゲン、グルテン、卵白、大豆蛋白質から選ばれる1つ又は2つ以上を組み合わせたものである請求項1ないし5いずれかの飼料又は食品の製造方法。
- 加熱によりゲルを形成する澱粉原料がタピオカ澱粉、小麦澱粉、馬鈴薯澱粉、トウモロコシ澱粉、豆澱粉、ワキシーコンスターチ、及びそれらの加工澱粉から選ばれる1つ又は2つ以上を組み合わせたものである請求項1ないし5いずれかの飼料又は食品の製造方法。
- エクストルーダによる加熱温度が60~110℃である請求項1ないし7いずれかの飼料又は食品の製造方法。
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JP2015119644A (ja) * | 2013-12-20 | 2015-07-02 | ジェックス株式会社 | 観賞魚用固形餌 |
WO2019039472A1 (ja) | 2017-08-22 | 2019-02-28 | 日本水産株式会社 | マグロ類養殖魚及びその用途、並びにマグロ類養殖魚の作出方法 |
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US20240090535A1 (en) | 2024-03-21 |
RS56696B1 (sr) | 2018-03-30 |
PT2772144T (pt) | 2017-12-20 |
EP2772144A4 (en) | 2015-06-17 |
US20140287124A1 (en) | 2014-09-25 |
CN103929983B (zh) | 2016-04-06 |
MX2014004964A (es) | 2014-05-22 |
JPWO2013061892A1 (ja) | 2015-04-02 |
CY1119734T1 (el) | 2018-06-27 |
JP6472479B2 (ja) | 2019-02-20 |
ES2655545T3 (es) | 2018-02-20 |
JP2017176179A (ja) | 2017-10-05 |
HRP20171940T1 (hr) | 2018-02-09 |
AU2012330090A1 (en) | 2014-05-22 |
AU2012330090B2 (en) | 2016-09-01 |
EP2772144A1 (en) | 2014-09-03 |
CN103929983A (zh) | 2014-07-16 |
EP2772144B1 (en) | 2017-12-06 |
MX346111B (es) | 2017-03-08 |
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