METHOD FOR MANUFACTURING A PROCESSED FOOD USING SEPARATE PACKAGING AND MILD HEATING STERILIZATION

Abstract

The present application relates to a processed food distributable at room temperature comprising (a) a first food part comprising a paste, a leafy vegetable, or a combination thereof; and (b) a second food part comprising at least one selected from the group consisting of a meat, a seaweed, a seafood, a root vegetable, a fruit vegetable, and a mushroom, wherein the first and second food parts are separately packaged.

Claims

1. A processed food distributable at room temperature comprising: (a) a first food part comprising a paste, a leafy vegetable, or a combination thereof; and (b) a second food part comprising at least one selected from the group consisting of a meat, a seaweed, a seafood, a root vegetable, a fruit vegetable, and a mushroom, wherein the first and second food parts are separately packaged.

2. The processed food distributable at room temperature of claim 1, wherein the paste is red pepper paste or soybean paste.

3. The processed food distributable at room temperature of claim 1, wherein the leafy vegetable is at least one selected from the group consisting of Korean cabbage, lettuce, spinach, and water parsley.

4. The processed food distributable at room temperature of claim 1, wherein the first food part comprises kimchi.

5. The processed food distributable at room temperature of claim 1, wherein the meat is at least one selected from the group consisting of beef, cow bone, pork, pig bone, chicken, and chicken bone.

6. The processed food distributable at room temperature of claim 1, wherein the seaweed is at least one selected from the group consisting of laver, sea mustard, kelp, green laver, and hizikia fusiforme.

7. The processed food distributable at room temperature of claim 1, wherein the seafood is at least one selected from the group consisting of anchovy, clam, Manila clam, squid, small octopus, webfoot octopus, mussel, crab, shrimp, oceanic bonito, and freshwater snail.

8. The processed food distributable at room temperature of claim 1, wherein the root vegetable is at least one selected from the group consisting of garlic, ginger, onion, potato, radish, carrot, taro, and burdock.

9. The processed food distributable at room temperature of claim 1, wherein the fruit vegetable is at least one selected from the group consisting of cucumber, pumpkin, red pepper, eggplant, bean, and corn.

10. The processed food distributable at room temperature of claim 1, wherein the fruit vegetable is at least one selected from the group consisting of pumpkin, red pepper, and tofu.

11. The processed food distributable at room temperature of claim 1, wherein a concentration of a microorganism in the processed food distributable at room temperature is less than 10.sup.1 CFU/g 1 month, 2 months, 3 months, 4 months, 5 months, or 6 months after a production date at a temperature of 15° C., 25° C., 35° C., or 45° C.

12. A method for preparing a processed food distributable at room temperature, comprising: (a) heating a first food product comprising a paste, a leafy vegetable, or a combination thereof at a temperature between 80° C. and 110° C.; and (b) heating a second food product comprising water and at least one food selected from the group consisting of a meat, a seaweed, a seafood, a root vegetable, and a tofu at a temperature between 115° C. and 123° C.

13. The method of claim 12 for preparing a processed food distributable at room temperature, wherein the heating of (a) further comprises: (a-1) heating at a temperature between 80° C. and 95° C.; followed by (a-2) heating at a temperature between 100° C. and 110° C.

14. The method of claim 12 for preparing a processed food distributable at room temperature, wherein the heating of (b) further comprises: (pre-b) heating at a temperature between 85° C. and 95° C. before the heating at a temperature between 115° C. and 123° C.

15. The method of claim 12 for preparing a processed food distributable at room temperature, wherein the method further comprises: (a-i) and (b-i) packaging the first and second food parts before or after (a) and (b), respectively.

16. The method of claim 12 for preparing a processed food distributable at room temperature, wherein the preparation method further comprises: (pre-a) adjusting pH, salinity, or a sugar content of the first food part to 3.9 to 4.5, 3% to 15%, or 20 Brix % to 60 Brix %, respectively, before (a).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] FIG. 1 shows a picture of kimchi stew and soybean paste stew distributable at room temperature according to an exemplary embodiment.

[0039] FIG. 2 shows data of a retort heated meat stock pouch of the soybean paste stew according to an exemplary embodiment.

[0040] FIG. 3 shows the mechanical measurement of firmness of the texture of kimchi in kimchi stew distributable at room temperature according to an exemplary embodiment.

MODE FOR INVENTION

[0041] Hereinbelow, preferred embodiments of the present application will be provided. However, the embodiments provided are only for illustrative purposes for better understanding of the present application and should not be construed as limiting the present application.

EXAMPLES

Preparation Example 1: Manufacture of Processed Foods (Kimchi Stew and Soybean Paste Stew) Distributable at Room Temperature

[0042] (1) Preparation of Ingredients

[0043] For kimchi stew, tofu, leek, and red pepper were sliced, and a meat broth was prepared by adding a beef leg bone broth, anchovy extract, kelp extract, modified food starch, maltodextrin, and purified salt to distilled water and then boiling. Kimchi including pickled cabbage, red pepper powder, white sugar, garlic, and leek was mixed with red pepper paste, corn oil, and purified salt to prepare a kimchi sauce including kimchi.

[0044] For soybean paste stew, potatoes, tofu, an onion, shiitake, king oyster mushroom, kelp extract, and purified salt were added to distilled water to prepare a broth. Soybean paste, clam extract, purified salt, kelp extract, and red pepper powder were mixed to prepare a soybean paste sauce.

[0045] (2) Sterilization of Broth

[0046] The broths prepared in (1) for kimchi stew and soybean paste stew were packaged in separate pouches and sealed to be retort heated.

[0047] Specifically, the broths include a large quantity of solids; thus, two-step retort heating comprising pre-heating at 95° C. for 15 minutes and heat sterilization at 121° C. for 15 minutes for a rapid temperature increase of the center part was employed.

[0048] (3) Sterilization of Sauce

[0049] As the kimchi sauce includes kimchi and red pepper paste, and the soybean paste sauce includes soybean paste, the retort sterilization was not performed for the sauces to prevent deterioration of flavor and texture; instead, considering pH, salinity, and sugar contents, heat sterilization was performed at a temperature lower than 121° C. after mixing an organic acid, salt, and sugar.

[0050] Specifically, lactic acid was added to the kimchi sauce in an amount of 2.0% (w/w) based on the weight of the sauce to adjust pH to 4.3, and purified salt and sugar were added to the soybean paste sauce to adjust the salinity and sugar content to about 10% and 40 Brix %, respectively. Nisin, a commercial natural bacteriocin antibiotic agent, was added to the soybean paste sauce in an amount of 0.1% (w/w), and 0.5% (w/w) of calcium lactate was added to the kimchi sauce to enhance the texture.

[0051] Each sauce was then packaged in a separate pouch and sealed, followed by heating the kimchi sauce at 105° C. for 20 minutes and soybean paste sauce at 95° C. for 20 minutes.

[0052] (4) Manufacture of Finished Product

[0053] The finished products of kimchi stew and soybean paste stew distributable at room temperature provide the broth pouch prepared in (2) together with the sauce pouch prepared in (3) (FIG. 1).

Experimental Example 1: Examination of the Effect of Sterilizing Broths and Sauces

[0054] The disinfection and sterilization effects of the broths and sauces prepared in (2) and (3) of Preparation Example 1 were observed to determine whether they can be distributable at room temperature. Commercially available kimchi stew and soybean paste stew were used as controls. The strength of heating sterilization (Fo) was measured using a wireless data logger, and the number of microorganisms was measured by a clone coefficient method after incubating at 37° C. for 48 hours using a proper medium for each microorganism. The proper media used for the total microorganisms, thermostable microorganisms, and fungi (mold and yeast) were Plate Count Agar (PCA), Tryptic Soy Agar (TSA), and Potat dextrose Agar (PDA), respectively.

[0055] As a result, the total microorganisms, thermostable microorganisms, and fungi disappeared from the controls and the broths and kimchi sauce prepared in (2) and (3) of the Preparation Example as shown in the table below. In addition, no growth thereof was observed when stored for 6 months to 12 months at 10° C., 25° C., 35° C., and 45° C. (cold, room temperature, and heat storage), indicating that the initial sterile condition was retained. The sauce concentrate for soybean paste stew did not reach its complete sterile status; however, the remaining microorganisms did not grow due to salinity and Brix, which demonstrates the feasibility of room temperature distribution. Additionally, compared to the soybean paste sauce prepared without adding nisin, that prepared in (3) of the Preparation Example showed a decrease in the microorganisms from 10.sup.1 CFU/g to 10.sup.2 CFU/g without having nisin added, thereby indicating that the microorganism stability was improved by the addition of nisin.

TABLE-US-00001 TABLE 1 Result of sterilization of broths and sauces Thermostable Total microorganisms (CFU/g) microorganisms (CFU/g) Fungi (CFU/g) Post- Post- Post- sterilization sterilization sterilization and 6 to and 6 to and 6 to Sterilization Pre- 12 months Pre- 12 months Pre- 12 months conditions sterilization after storage sterilization after storage sterilization after storage Control 121.1° C., 10.sup.4 0 10.sup.2 0 10.sup.1 0 (retort combined 25 minute kimchi stew) heat sterilization Preparational Example 1 pH adjustment 10.sup.3 0 10.sup.2 0 10.sup.1 0 (kimchi sauce) (4.3) + heating sterilization at 105° C. Preparational Example 1 95° C..fwdarw.121° C. 10.sup.4 0 10.sup.2 0 10.sup.1 0 (broth for kimchi stew) Two-step heating sterilization Control 121.1° C. 10.sup.6 0 10.sup.5 0 10.sup.2 0 (retort combined 30 minute soybean paste stew) heating sterilization Preparational Example 1 Adjustment of salinity 10.sup.6 10.sup.2~10.sup.3 10.sup.4 10.sup.1~10.sup.2 10.sup.2 0 (soybean paste sauce) and Brix + heating (Bacteriostatic) (Bacteriostatic) sterilization at 95° C. Preparational Example 1 Adjustment of salinity 10.sup.6 10.sup.1~10.sup.2 10.sup.4 10.sup.1~10.sup.2 10.sup.2 0 (soybean paste sauce) and Brix + nisin + (Bacteriostatic) (Bacteriostatic) heating sterilization at 95° C. Preparational Example 1 95° C..fwdarw.121° C. 10.sup.4 0 10.sup.2 0 10.sup.1 0 (broth for soybean Two-step paste stew) heating sterilization

[0056] Further, the data for temperature and strength (Fo value) of retort heating sterilization were obtained, and as a result, the processed food with separately packaged broth and sauce had an Fo value as much as 1.7 times higher under the same heating sterilization conditions due to the more rapid temperature increase, compared to the combined retort-sterilized process food. In other words, the processed food with separately packaged broth and sauce can exhibit the same heating sterilization effect with 1.8 times shorter retort heating time than the combined retort-sterilized process food. This confirms that the processed food with separately packaged broth and sauce has an advantage of reduced damage to the ingredients included in the broth caused by high temperature (Table 2 and FIG. 2).

TABLE-US-00002 TABLE 2 Comparison of F.sub.0 under same Comparison of retort conditions when retort conditions reaching same F.sub.0 Heating Heating Classification sterilization F.sub.0 sterilization F.sub.0 Miscellaneous (Package) conditions values Conclusion conditions values Conclusion (Notes) Combined Heating at 3.36 Heating at 5.76 F.sub.0 value: pouch 90° C. for 15 90° C. for 15 Strength of heat (control) minutes minutes sterilization of followed by followed by microorganisms 121.1° C. for 121.1° C. for (F.sub.0 = 1 at 121.1° C. 10 minutes 18 minutes for 1 minute) Separate 5.76 F.sub.0 value Heating at 5.76 F.sub.0 value pouch (present increased 90° C. for 15 decreased disclosure 1.7 = fold by minutes 1.8-fold by improved followed by improved heat heat transfer 121.1° C. for transfer rate rate 10 minutes

Experimental Example 2: Measurement of Kimchi Texture

[0057] To specifically measure the enhanced texture of the kimchi stew prepared in Preparation Example 1, the mechanical firmness of the kimchi was measured using a texture analyzer (TA-XTPLUS, Stable micro system Co. Ltd., Surrey, England).

[0058] Specifically, the firmness was measured using a 5 mm plunger under the conditions of 2.0 mm/sec pretest speed, 1.0 mm/sec test speed, and 2.0 mm/sec and 20% strain. Each measured value was the result of 20 repeated measurements of the same location, and the accuracy of the experimental data was pursued according to Chauvenet's criterion by having an average value of the measurements excluding an outlier value as a measured value (p<0.05).

[0059] As a result, compared to the firmness (0.4 kgf) of the commercially available retort-sterilized kimchi, that of the kimchi in the kimchi sauce prepared in (3) of the Preparation Example was remarkably enhanced, about twice as high (0.8 kgf). Further, the firmness of the kimchi prepared in (3) of Preparation Example without adding calcium (0.7 kgf) was about twice that of the control, indicating that the texture of kimchi in the kimchi was enhanced by separated sterilization of the sauce and broth (FIG. 3).

Experimental Example 3: Sensory Evaluation of Kimchi Stew and Soybean Paste Stew Having Separately Packaged Sauce and Broth

[0060] The kimchi stew and soybean paste stew prepared in Preparation Example 1 were compared with the control (combined retort-sterilized product) to measure sensory enhancement.

[0061] Specifically, 15 panelists were involved for the sensory evaluation to compare taste quality (such as overall taste, texture of vegetables, appearance (color), etc.) of the kimchi stew and soybean paste stew prepared in Preparation Example 1.

[0062] As a result, the kimchi stew and soybean paste stew prepared in Preparation Example 1 showed a superior sensory quality, that is, a statistically significant difference of 0.3 to 0.5, compared to the control in terms of overall taste, texture of vegetables, appearance (color), etc. (Table 3).

TABLE-US-00003 TABLE 3 Result of sensory evaluation Preparation and Overall taste Texture of Appearance Menu Sample sterilization methods (five point-scale) vegetables (color) Storability Kimchi Control Retort combined kimchi stew 3.5.sup.b 3.4.sup.b 3.5.sup.b Distributable stew (heating at 121° C. for 25 min) at room temperature Preparation Separate sterilization 4.0.sup.a 3.9.sup.a 3.8.sup.a Distributable Example 1 at room temperature Soybean Control Retort combined soybean paste stew 3.4.sup.b 3.4.sup.b 3.4.sup.b Distributable paste stew (heating at 121° C. for 30 min) at room temperature Preparation Separate sterilization 3.9.sup.a 3.8.sup.a 3.9.sup.a Distributable Example 1 at room temperature * Significant difference verification (p < 0.05), no significant difference in regard to the same superscript