U.S. patent application number 11/996668 was filed with the patent office on 2010-09-16 for method for manufacturing a packaged food product.
This patent application is currently assigned to ECHIGOSEIKA CO., LTD.. Invention is credited to Tadao Kosaka, Yoshimi Ohtaki, Akihiko Sasagawa, Akira Yamazaki.
Application Number | 20100233334 11/996668 |
Document ID | / |
Family ID | 37683101 |
Filed Date | 2010-09-16 |
United States Patent
Application |
20100233334 |
Kind Code |
A1 |
Yamazaki; Akira ; et
al. |
September 16, 2010 |
METHOD FOR MANUFACTURING A PACKAGED FOOD PRODUCT
Abstract
A process for producing a food enclosed in sealed containers
which is free from a trouble during production that water spills
from the containers or a perforating jig falls into the containers
and in which a heat treatment can be conducted without causing
quality unevenness. A food (1) is placed in containers (2). The
containers (2) filled with the food (1) are sealed with a primary
film (4) having a through-hole (3) to obtain a
sealed-container-packed food (A). This sealed-container-packed food
(A) is disposed in a heating vessel (7) having a steam inlet part
(5) and a steam discharge part (6). Steam is introduced through the
steam inlet part (5) into the heating vessel (7) to heat the
sealed-container-packed food (A) while discharging the steam
through the steam discharge part (6). Thereafter, a secondary film
(8) is bonded to each container through the primary film (4) so as
to cover the through-hole (3).
Inventors: |
Yamazaki; Akira;
(Nagaoka-shi, JP) ; Ohtaki; Yoshimi; (Nagaoka-shi,
JP) ; Kosaka; Tadao; (Nagaoka-shi, JP) ;
Sasagawa; Akihiko; (Nagaoka-shi, JP) |
Correspondence
Address: |
SUGHRUE MION, PLLC
2100 PENNSYLVANIA AVENUE, N.W., SUITE 800
WASHINGTON
DC
20037
US
|
Assignee: |
ECHIGOSEIKA CO., LTD.
Nagaoka-shi, Niigata
JP
|
Family ID: |
37683101 |
Appl. No.: |
11/996668 |
Filed: |
December 20, 2005 |
PCT Filed: |
December 20, 2005 |
PCT NO: |
PCT/JP2005/023381 |
371 Date: |
January 24, 2008 |
Current U.S.
Class: |
426/396 |
Current CPC
Class: |
A23B 9/14 20130101; A23B
9/18 20130101; B65B 55/14 20130101; B65B 55/18 20130101; A23B 9/025
20130101; A23L 3/12 20130101; A23L 3/3409 20130101 |
Class at
Publication: |
426/396 |
International
Class: |
B65B 55/14 20060101
B65B055/14 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 25, 2005 |
JP |
2005-214657 |
Claims
1. A method for manufacturing a packaged food product,
characterized in comprising: placing a food product in a container,
sealing the container holding the food product using a primary film
having a communicating hole to obtain a packaged food product,
placing the packaged food product inside a heating vessel provided
with a steam inflow part and a steam discharge part, and causing
steam to flow into the heating vessel from said steam inflow part;
and fixing a secondary film so as to cover said communicating hole
from above said primary film after heat-treating the packaged food
product while discharging the steam from said steam discharge
part.
2. The method for manufacturing a packaged food product according
to claim 1, characterized in that a heating temperature inside said
heating vessel is controlled by adjusting an inflow quantity of
steam from said steam inflow part during said heat treatment.
3. The method for manufacturing a packaged food product according
to claim 1, characterized in that said packaged food product
covered by a cover body is placed in said heating vessel, steam is
allowed to flow in from said steam inflow part towards the cover
body, and heat treatment is performed.
4. The method for manufacturing a packaged food product according
to claim 2, characterized in that said packaged food product
covered by a cover body is placed in said heating vessel, steam is
allowed to flow in from said steam inflow part towards the cover
body, and heat treatment is performed.
5. The method for manufacturing a packaged food product according
to any of claims 3 and 4, characterized in that said packaged food
product is covered by said cover body having a sloped roof.
6. The method for manufacturing a packaged food product according
to any of claims 1 through 4, characterized in that a U-shaped,
V-shaped, or X-shaped cut is formed in said primary film, and the
cut is used as said communicating hole.
7. The method for manufacturing a packaged food product according
to claim 5, characterized in that a U-shaped, V-shaped, or X-shaped
cut is formed in said primary film, and the cut is used as said
communicating hole.
8. The method for manufacturing a packaged food product according
to claim 6, characterized in that at the same time as said cut is
formed in the primary film by a cutting tool in said communicating
hole, the edge of the cut is oriented upward, or the edge of the
cut is oriented upward after the cut is formed.
9. The method for manufacturing a packaged food product according
to claim 7, characterized in that at the same time as said cut is
formed in the primary film by a cutting tool in said communicating
hole, the edge of the cut is oriented upward, or the edge of the
cut is oriented upward after the cut is formed.
10. The method for manufacturing a packaged food product according
to any of claims 1 through 4, characterized in that a food product
subjected to high-pressure treatment at 1000 atmospheres or higher
is placed in a container, the container holding the food product is
sealed by a primary film that has a communicating hole, and a
packaged food product is obtained.
11. The method for manufacturing a packaged food product according
to claim 5, characterized in that a food product subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container, the container holding the food product is sealed by a
primary film that has a communicating hole, and a packaged food
product is obtained.
12. The method for manufacturing a packaged food product according
to claim 6, characterized in that a food product subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container, the container holding the food product is sealed by a
primary film that has a communicating hole, and a packaged food
product is obtained.
13. The method for manufacturing a packaged food product according
to claim 7, characterized in that a food product subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container, the container holding the food product is sealed by a
primary film that has a communicating hole, and a packaged food
product is obtained.
14. The method for manufacturing a packaged food product according
to claim 8, characterized in that a food product subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container, the container holding the food product is sealed by a
primary film that has a communicating hole, and a packaged food
product is obtained.
15. The method for manufacturing a packaged food product according
to claim 9, characterized in that a food product subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container, the container holding the food product is sealed by a
primary film that has a communicating hole, and a packaged food
product is obtained.
Description
TECHNICAL FIELD
[0001] The present invention relates to a method for manufacturing
package-sealed rice, for example, or another packaged food
product.
BACKGROUND ART
[0002] Package-sealed rice and other packaged food products are
created by a process in which a single serving of rice is placed in
a container and heat treated (fully cooked or half-cooked), and the
container is sealed by a film.
[0003] The present applicant has filed for various patents relating
to the subject of treating food products at high pressure, but
because this high-pressure treatment is based on the use of
hydrostatic pressure, the object treated during high-pressure
treatment must be submerged, and the package must be hermetically
sealed in advance.
[0004] Regardless of whether high-pressure treatment is performed,
sealing the container holding the food product in advance using a
film is extremely effective for preventing contamination of the
container by microorganisms and the like during the transition to
the next step, and preventing water and the like from spilling into
the container.
[0005] However, when the container is hermetically sealed in
advance in this manner, steam forms inside the sealed container due
to heating when the food product is one that requires heat
treatment after sealing, the internal pressure increases, and the
container can break. Heat treatment is therefore performed after a
steam escape hole is formed in the container (see Patent Document
1, for example).
[0006] [Patent Document 1] Japanese Laid-open Patent Application
No. 2000-32965
DISCLOSURE OF THE INVENTION
Problems the Invention is Intended to Solve
[0007] According to Patent Document 1, after the container that
holds the food product is sealed by a film, an escape hole is
formed by a hole-opening tool from above the film. However, since
the hole-opening tool pushes the film downward when the hole is
formed, there is a risk of water spilling into the container, or of
the hole-opening tool falling into the container.
[0008] A heating press is generally used when such a container
holding the food product is heated to 100.degree. C. or higher to
kill microorganisms and cook the product. A safety valve is mounted
to the heating press, and the safety valve opens to release excess
steam when a prescribed pressure is reached.
[0009] However, since the safety valve does not open until the
inside of the heating press reaches a set pressure, the flow
properties of steam inside the heating press are poor, and heat is
transmitted at the start of heating from the bottom part inside the
heating press, which is the part closest to the heat source (e.g.,
burner). Drawbacks therefore occur in that a significant
temperature difference occurs with respect to the upper part inside
the heating press, and uneven quality (uneven heating) occurs
between products placed at the bottom of the hot press and products
placed at the top of the hot press.
[0010] In view of the foregoing drawbacks, an object of the present
invention is to provide an innovative method for manufacturing a
packaged food product that is capable of performing heat treatment
without uneven quality, and without spillage of water into the
container or dropping of the hole-opening tool into the container
during manufacturing.
Means for Solving these Problems
[0011] The main points of the present invention will be described
with reference to the accompanying drawings.
[0012] A first aspect of the present invention relates to a method
for manufacturing a packaged food product, wherein the method is
characterized in comprising placing a food product 1 in a container
2, sealing the container 2 holding the food product 1 using a
primary film 4 having a communicating hole 3 to obtain a packaged
food product A, placing the packaged food product A inside a
heating vessel 7 provided with a steam inflow part 5 and a steam
discharge part 6, and causing steam to flow into the heating vessel
7 from the steam inflow part 5; and fixing a secondary film 8 so as
to cover the communicating hole 3 from above the primary film 4
after heat-treating the packaged food product A while discharging
the steam from the steam discharge part 6.
[0013] A second aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
first aspect, characterized in that a heating temperature inside
the heating vessel 7 is controlled by adjusting an inflow quantity
of steam from the steam inflow part 5 during the heat
treatment.
[0014] A third aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
first aspect, characterized in that the packaged food product A
covered by a cover body 9 is placed in the heating vessel 7, steam
is allowed to flow in from the steam inflow part 5 towards the
cover body 9, and heat treatment is performed.
[0015] A fourth aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
second aspect, characterized in that the packaged food product A
covered by a cover body 9 is placed in the heating vessel 7, steam
is allowed to flow in from the steam inflow part 5 towards the
cover body 9, and heat treatment is performed.
[0016] A fifth aspect of the present invention relates to the
method for manufacturing a packaged food product according to any
of the third and fourth aspects, characterized in that the packaged
food product A is covered by the cover body 9 having an sloped roof
9A.
[0017] A sixth aspect of the present invention relates to the
method for manufacturing a packaged food product according to any
of the first through fourth aspects, characterized in that a
U-shaped, V-shaped, or X-shaped cut 3 is formed in the primary film
4, and the cut 3 is used as the communicating hole 3.
[0018] A seventh aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
fifth aspect, characterized in that a U-shaped, V-shaped, or
X-shaped cut 3 is formed in the primary film 4, and the cut 3 is
used as the communicating hole 3.
[0019] An eighth aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
sixth aspect, characterized in that at the same time as the cut 3
is formed in the primary film 4 by a cutting tool in the
communicating hole 3, an upward edge 3A of the cut 3 is oriented
upward, or the edge 3A of the cut 3 is oriented upward after the
cut 3 is formed.
[0020] A ninth aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
seventh aspect, characterized in that at the same time as the cut
is formed in the primary film 4 by a cutting tool in the
communicating hole 3, an edge 3A of the cut 3 is oriented upward,
or the edge 3A of the cut 3 is oriented upward after the cut 3 is
formed.
[0021] A tenth aspect of the present invention relates to the
method for manufacturing a packaged food product according to any
of the first through fourth aspects, characterized in that a food
product 1 subjected to high-pressure treatment at 1000 atmospheres
or higher is placed in a container 2, the container 2 holding the
food product 1 is sealed by a primary film 4 that has a
communicating hole 3, and a packaged food product A is
obtained.
[0022] An eleventh aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
fifth aspect, characterized in that a food product 1 subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container 2, the container 2 holding the food product 1 is sealed
by a primary film 4 that has a communicating hole 3, and a packaged
food product A is obtained.
[0023] A twelfth aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
sixth aspect, characterized in that a food product 1 subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container 2, the container 2 holding the food product 1 is sealed
by a primary film 4 that has a communicating hole 3, and a packaged
food product A is obtained.
[0024] A thirteenth aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
seventh aspect, characterized in that a food product 1 subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container 2, the container 2 holding the food product 1 is sealed
by a primary film 4 that has a communicating hole 3, and a packaged
food product A is obtained.
[0025] A fourteenth aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
eighth aspect, characterized in that a food product 1 subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container 2, the container 2 holding the food product 1 is sealed
by a primary film 4 that has a communicating hole 3, and a packaged
food product A is obtained.
[0026] A fifteenth aspect of the present invention relates to the
method for manufacturing a packaged food product according to the
ninth aspect, characterized in that a food product 1 subjected to
high-pressure treatment at 1000 atmospheres or higher is placed in
a container 2, the container 2 holding the food product 1 is sealed
by a primary film 4 that has a communicating hole 3, and a packaged
food product A is obtained.
EFFECTS OF THE INVENTION
[0027] The present invention as described above is an extremely
practical, innovative method for manufacturing a packaged food
product whereby a container holding the food product is sealed by a
primary film in which a communicating hole is formed in advance,
and water inside the container therefore does not spill due to
downward pushing of the film by the hole-opening tool, and the
hole-opening tool does not drop into the container, as in the
conventional technique. The operating speed of the conveyor device
in the manufacturing line can therefore be increased, and enhanced
production efficiency can be anticipated. Heat treatment is not
performed using an existing hot press provided with a safety valve,
but a heating vessel provided with a steam inflow part and a steam
discharge part is instead used in the present invention, and the
packaged food product is heat treated while the steam is discharged
from the steam discharge part at the same time as the steam is
caused to flow into the heating vessel from the steam inflow part.
Steam therefore flows satisfactorily in the heating vessel,
temperature differences do not easily occur, and a substantially
uniform temperature is maintained in all regions, whereby each
packaged food product is heat-treated at a substantially uniform
temperature even when large quantities of packaged food products
are accommodated in the heating vessel and heat-treated. Products
that are free of uneven quality (uneven heating) can therefore be
manufactured in large quantities.
[0028] The second aspect of the present invention provides an even
more practical method for manufacturing a packaged food product,
wherein the heat treatment temperature can easily be adjusted by
adjusting the flow rate of steam into the heating vessel, the
inside of the heating vessel can be pressurized to normal pressure
or higher by adjusting the flow rate of steam, and heat treatment
can be performed at a temperature of 100.degree. C. or higher, the
same as in an existing hot press.
[0029] The third and fourth aspects of the present invention
provide an even more practical method for manufacturing a packaged
food product, wherein the packaged food product is covered by a
cover body, the steam is caused to flow towards the cover body, and
heat treatment is performed. Moisture (drainage) that occurs during
heat treatment therefore easily adheres to the cover body, and the
drainage adhering to the cover body runs off along the cover body.
It is therefore difficult for the drainage to penetrate into the
container from the communicating hole of the primary film.
[0030] The fifth aspect of the present invention provides an even
more practical method for manufacturing a packaged food product,
wherein the packaged food product is covered by a cover body having
a sloped roof. It is therefore even more difficult for drainage to
adhere to the primary cover of the packaged food product, and the
drainage slope of the sloped roof is also set so that drainage
adhering to the internal surface of the sloped roof is conducted
down the internal surface, whereby a structure can easily be
designed and implemented for reliably preventing drainage that
adheres to the internal surface of the sloped roof from falling
onto the primary cover. It is therefore even more difficult for the
drainage to penetrate into the container from the communicating
hole of the primary film.
[0031] In the sixth and seventh aspects of the present invention, a
cut is formed in which the edge of the cut remains, and the cut is
used as a communicating hole, rather than forming a round or square
through-hole in the primary film. Since the presence of the edge of
the cut ensures that the communicating hole is not always opened
wide, it is difficult for moisture (drainage) adhering on the
primary film to penetrate from the communicating hole, and the
communicating hole can be obtained merely by forming a simple cut.
A method for manufacturing a packaged food product can therefore be
obtained that provides ease of manufacturing and even greater
practicality.
[0032] The eighth and ninth aspects of the present invention
provide an even more practical method for manufacturing a packaged
food product, wherein the edge of the cut is oriented upward, and
moisture (drainage) that occurs on the primary film during heat
treatment is therefore blocked from penetrating into the cut by the
upward-oriented edge. It is therefore difficult for drainage to
penetrate into the container from the cut (communicating hole).
[0033] The tenth through fifteenth aspects of the present invention
provide an even more practical method for manufacturing a packaged
food product, wherein a good-tasting starch food product is
obtained in which the degree of gelatinization is enhanced by
high-pressure treatment at 1000 atmospheres or higher in a case in
which the food product includes starch, for example, and a larger
quantity of food products can be processed in a single
high-pressure treatment than by the technique according to Patent
Document 1. Such effects as enhanced production efficiency are
therefore obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a perspective view showing the packaged food
product of the present example;
[0035] FIG. 2 is a front view and a side view showing a state in
which the packaged food product of the present example is
accommodated in the cover body;
[0036] FIG. 3 is a front view showing the heat treatment of the
present example;
[0037] FIG. 4 is a front view and a side view showing a state in
which the secondary film is sealed on the packaged food product of
the present example; and
[0038] FIG. 5 is a perspective view showing the completed state of
the packaged food product of the present example.
KEY
[0039] 1 food product [0040] 2 container [0041] 3 communicating
hole (cut) [0042] 3A edge [0043] 4 primary film [0044] 5 steam
inflow part [0045] 6 steam discharge part [0046] 7 heating vessel
[0047] 8 secondary film [0048] 9 cover body [0049] 9A sloped roof
[0050] A packaged food product
BEST MODE FOR CARRYING OUT THE INVENTION
[0051] Preferred embodiments (the manner in which the present
invention is implemented) of the present invention are briefly
described below with reference to the diagrams while indicating the
effects of the present invention.
[0052] A food product 1 is placed in a container 2, the container 2
holding the food product 1 is sealed by a primary film 4 in which a
communicating hole 3 is provided, and a packaged food product A is
obtained.
[0053] Specifically, instead of forming a hole in the film after
the container holding the food product is sealed by the film as in
the technique described in Patent Document 1, the container 2
holding the food product 1 is sealed by the primary film 4 in which
the communicating hole 3 is formed in advance. There is therefore
no spillage of water into the container, or dropping of the
hole-opening tool into the container due to downward pressure on
the film by the hole-opening tool.
[0054] In a common manufacturing line for this type of packaged
food product A, the container is moved to the next step by a belt
conveyor or other conveyor device, but the inside of the container
is sometimes contaminated at this time by dust, debris, airborne
bacteria, and the like in the manufacturing line, and water inside
the container can be spilled by recoil of the conveyor device. Such
measures as reducing the operating speed must be taken to prevent
spillage. However, dust and the like can be prevented from
penetrating into the container 2 by using the primary film 4 to
seal the container 2, as in the present invention, and water and
the like inside the container 2 does not spill even when the
operating speed of the conveyor device is increased. Production
efficiency can therefore be enhanced.
[0055] The packaged food product A is placed inside a heating
vessel 7 provided with a steam inflow part 5 and a steam discharge
part 6, steam is caused to flow into the heating vessel 7 from the
steam inflow part 5, the packaged food product A is heat treated
while the steam is discharged from the steam discharge part 6, and
the food product 1 inside the container 2 is cooked or semi-cooked
(a state in which cooking is completed by the consumer heating the
product in a microwave oven or the like).
[0056] Specifically, when the inside of the heating vessel reaches
the prescribed pressure, instead of heat treating using an existing
hot press provided with a safety valve for releasing the steam, the
packaged food product A is heat treated in the present invention
while the steam is continuously discharged from the steam discharge
part 6 as the steam flows into the heating vessel from the steam
inflow part 5. Steam therefore flows satisfactorily in the heating
vessel 7, whereby temperature differences do not easily occur
inside the heating vessel 1 (*1) even at the start of heating, and
a substantially uniform temperature is maintained in all regions
inside the heating vessel 7. Consequently, each packaged food
product A is heat-treated at a substantially uniform temperature
even when large quantities of packaged food products A are
accommodated in the heating vessel 7 and heat-treated. Products
that are free of uneven quality (uneven heating) can therefore be
manufactured in large quantities.
[0057] Steam forms inside the container 2, and the internal
pressure increases due to heating at this time, but since the steam
can escape to the outside of the container 2 from the communicating
hole 3, the packaged food product A does not rupture during
heating.
[0058] In this heat treatment, the heating temperature inside the
heating vessel 7 can be controlled by adjusting the flow rate of
steam from the steam inflow part 5.
[0059] Specifically, in an existing hot press, the heating
temperature is determined according to the manner in which a
pressure (spindle weight, spring, or screw as the safety valve) at
which a safety valve operates is set. Therefore, the weight,
spring, or screw must be separately adjusted according to the
cooking application/purpose in order to modify the operation of the
safety valve. However, in the present invention, the pressure
inside the heating vessel 7 increases the more the flow rate of
steam is increased using a device for forcing the inflow of steam,
for example, and heat treatment can be performed at a high
temperature. Conversely, the flow rate of steam may be reduced in
the case of low-temperature heating, and this temperature
adjustment can be easily performed. The heating vessel 7 may also,
of course, be pressurized to normal pressure or higher by adjusting
the flow rate of steam, heat treatment can be performed at a
temperature of 100.degree. C. or higher, the same as in an existing
hot press, and it is possible to adapt to various cooking
applications/purposes.
[0060] When the steam exchanges heat with the packaged food product
A during this heat treatment, condensation occurs, water (drainage)
forms, and the water can penetrate into the container from the
communicating hole 3 and can wet the packaged food product A.
[0061] To prevent this problem, the packaged food product A is
covered by a cover body 9, for example, and the flow of steam is
directed towards the cover body 9 to perform the heat treatment.
The drainage thereby adheres to the cover body 9 and is less likely
to adhere to the packaged food product A, and it is therefore
difficult for the moisture to penetrate into the container 2.
[0062] The packaged food product A is also covered by the cover
body 9 having a sloped roof 9A, for example. It is therefore even
more difficult for drainage to adhere to the primary cover 4 of the
packaged food product A, and the drainage slope of the sloped roof
9A is also set so that drainage adhering to the internal surface of
the sloped roof 9A is conducted down the internal surface, whereby
a structure can easily be designed and implemented for reliably
preventing drainage that adheres to the internal surface of the
sloped roof 9A from falling onto the primary cover 4. It is
therefore even more difficult for the drainage to penetrate into
the container 2 from the communicating hole 3 of the primary film
4.
[0063] For example, moisture can be prevented from penetrating into
the container 2 from the communicating hole 3 even by forming a
U-shaped, V-shaped, or X-shaped cut 3 in the primary film 4 and
using the cut 3 as the communicating hole 3, and orienting the edge
3A upward in the cut 3 as the communicating hole 3.
[0064] Specifically, moisture easily penetrates into the container
2 along the edge 3A when the edge 3A of the cut 3 faces downward
and leads into the primary film 4. However, when the edge 3A is
oriented upward, the moisture is blocked from penetrating into the
cut 3 by the upward-oriented edge 3A. It is therefore difficult for
moisture to penetrate into the container 2 from the cut 3.
[0065] After heat treatment is completed, the product is finished
by sealing a secondary film 8 so as to cover the communicating hole
3 from above the primary film 4.
[0066] It is preferred in this finishing that the inside of the
container 2 be gas-exchanged, or that an deoxidant be sealed
together with the product to enhance shelf life. However, since the
communicating hole 3 can be utilized as a gas
introduction/discharge hole at this time, gas exchange can easily
be performed, and when an deoxidant is used, the deoxidant can be
prevented from being mistakenly eaten by sealing the deoxidant
between the primary film 4 and the secondary film 8.
[0067] In a case in which the food product 1 includes starch, for
example, a good-tasting starch food product having an enhanced
degree of gelatinization is obtained by a process in which a food
product 1 that is high-pressure-treated at 1000 atmospheres or
higher in advance is placed in a container 2, the container 2
holding the food product 1 is sealed using a primary film 4 in
which a communicating hole 3 is formed, and the packaged food
product A is obtained, whereby the pressure history of the
high-pressure treatment remains in the food product 1, and the
aforementioned heat treatment is then performed (for a detailed
description, see Japanese Patent No. 3420521 and Japanese Laid-open
Patent Application No. 2000-152756).
[0068] In Japanese Laid-open Patent Application No. 2000-32965
cited as Patent Document 1, high-pressure treatment is performed
after sealing rice and water in a container in advance, but when
this method is used, the quantity processed in a single cycle of
high-pressure treatment (the quantity of packaged food products A
that can be placed in the high-pressure treatment device at once)
is not large in terms of the convenience of placing each container
in the high-pressure treatment device. In this regard, by sealing
the food product 1 into the container 2 after performing
high-pressure treatment of the food product 1 in advance, the
quantity of the food product 1 that can be put in and processed is
greater than when the containers 2 are placed in the high-pressure
treatment device, the efficiency of each cycle of high-pressure
treatment is significantly enhanced, and production efficiency is
enhanced.
EXAMPLES
[0069] Examples of the present invention are described below with
reference to the diagrams.
[0070] The present example is of a case in which the present
invention is applied to a method for manufacturing package-sealed
rice (packaged food product A) that can be heated in a microwave
oven or other cooking device, in which water and uncooked rice
(hereinafter referred to as uncooked rice 1) as the food product 1
are placed in an open-top shallow container 2, and a film is sealed
to form a hermetic seal on the entire peripheral edge part of the
open top, of the container 2.
[0071] Specifically, the container 2 holding the uncooked rice 1
and an appropriate quantity of water is sealed by the primary film
4 in which the communicating hole 3 is provided, and the packaged
food product A is obtained. The "appropriate quantity" of water is
a quantity of water whereby such handling problems as water
improperly flowing out of the container 2 do not occur when the
consumer opens the packaged food product A, and whereby a space is
formed for the uncooked rice 1 to absorb the water and expand
during cooking inside the container 2, and the uncooked rice 3 (*2)
is satisfactorily steamed.
[0072] The communicating hole 3 is formed in advance in the primary
film 4.
[0073] In the drawings, a U-shaped cut 3 is formed in two locations
in the primary film 4, and each of the cuts 3 is a communicating
hole 3. The cuts 3 as communicating holes 3 are cut and formed in
the present example by the upward movement of a cutting tool from
below the primary film 4, the edges 3A of the cuts 3 are
simultaneously oriented upward so that the edges 3A do not descend
below the primary film 4. The edges 3A are oriented upward so that
moisture (drainage) that condenses when heat exchange between the
packaged food product A and the steam is performed during the heat
treatment described hereinafter does not penetrate into the
container 2 from the communicating holes 3 when the drainage
adheres to the packaged food product A. Specifically, a
configuration is adopted in which the path of flow is changed so
that drops of water flowing on the primary film 4 bypass the
communicating holes 3 by coming in contact with the upward-oriented
edges 3A that are provided so as to block the cuts 3, and it is
difficult for the water drops to penetrate into the container 2
from the communicating holes 3.
[0074] The communicating holes 3 may also be formed by forming
V-shaped or X-shaped cuts 3 in the primary film 4. Communicating
holes 3 having another shape may also be formed, but the
communicating holes 3 are preferably configured so as to have edges
3A for blocking the communicating holes 3 and inhibiting the entry
of moisture through the communicating holes 3, and not as round or
square holes that are always open.
[0075] The upward creasing of the edges 3A may be performed after
the cuts are formed, and not necessarily at the same time as the
cuts 3 are formed. The edges 3A of the cuts 3 may also be oriented
upward after the cuts 3 are cut and formed by downward movement of
the cutting tool from above the primary film 4.
[0076] It is known that the degree of gelatinization increases, and
taste improves when heat treatment is performed after high-pressure
treatment of the uncooked rice 1 (grain) in advance at 1000
atmospheres or higher. However, a larger quantity of the uncooked
rice 1 can be accommodated, and the amount of uncooked rice 1
processed in a single cycle of high-pressure treatment increases
when the uncooked rice 1 alone is stored inside the processing
vessel in advance prior to be packed into the container 2, and
production efficiency is enhanced when the uncooked rice 1 is
subsequently packed into the container 2 relative to packing the
uncooked rice 1 into the container 2 and performing high-pressure
treatment for each container 2 in the treatment vessel (device), as
in the technique according to Patent Document 1.
[0077] The packaged food product A is then placed in a heating
vessel 7 provided with a steam inflow part 5 and a steam discharge
part 6, and the packaged food product A is heat-treated while steam
at a pressure of 1.0 atmosphere (absolute pressure) or higher is
caused to flow into the heating vessel 7 from the steam inflow part
5, and the steam is discharged from the steam discharge part 6.
[0078] The heating vessel 7 of the present example is configured so
as to have thermal insulation properties as well as pressure
resistance that enables a prescribed steam pressure to be
maintained, and is provided with a deck 7A inside at the bottom for
mounting the packaged food product A. The heating vessel 7 and the
deck 7A are preferably composed of stainless steel, for example, so
as to have corrosion resistance.
[0079] The steam inflow part 5 is provided at the lower part of the
heating vessel 7, and the steam discharge part 6 is provided at the
upper part of the heating vessel 7.
[0080] Accordingly, a configuration is adopted in which the inside
of the heating vessel 7 is heated, and the steam that flows into
the heating vessel 7 from the vapor inflow part 5 at the bottom
part is naturally discharged from the steam discharge part 6 at the
upper part when steam is caused to flow into the heating vessel
7.
[0081] The positions of the steam inflow part 5 and the steam
discharge part 6 in relation to the heating vessel 7 are not
limited by the present example.
[0082] A configuration is adopted in the present example in which
the pressure inside the heating vessel 7 is maintained at normal
pressure or higher, and heat treatment can be performed at a
temperature of 100.degree. C. or higher.
[0083] More specifically, a configuration is adopted in which the
diameter of the steam inflow vent of the steam inflow part 5 is set
so as to be larger than the steam discharge vent of the steam
discharge part 6, and the inside of the heating vessel 7 can be
maintained at normal pressure or higher according to the difference
(the inflow quantity of steam is greater than the discharge
quantity) between the inflow quantity and the discharge quantity of
steam as a result of the difference in vent diameters.
[0084] A temperature sensor (not shown) is provided in the vicinity
of the steam discharge part 6, and the temperature of heating
inside the heating vessel 7 can be controlled according to the
cooking application/purpose by adjusting the inflow quantity of
steam from the steam inflow part 5.
[0085] In the present example, the packaged food product A is
covered by the cover body 9, and the flow of steam is directed
towards the cover body 9 from the steam inflow part 5 to perform
heat treatment.
[0086] More specifically, the cover body 9 has an elongated
cylindrical case shape, and is configured so that a plurality of
packaged food product A can be slid into the cover body 9 from the
side, and heat treatment can be performed in a state in which
multiple columns of cover bodies 9 are stacked in multiple levels
on the deck 7A inside the heating vessel 7.
[0087] The cover body 9 is also made of a metal having good thermal
conductivity, for example, and is configured so that the packaged
food product A is satisfactorily heated via the cover body 9.
[0088] Consequently, through the use of the cover body 9,
positioning and arrangement of the packaged food product A inside
the heating vessel 7 are facilitated, this positioning can be
automated using robots or the like, and excellent workability and
mass production properties are obtained.
[0089] The cylindrical cover body 9 is formed so that the lower
part from the middle is box-shaped in cross-section, and the upper
part from the middle is wide at the bottom and shaped like a gabled
roof (sloped roof 9A) in cross-section, and the cover body 9 is
configured so that a collar part 2A on the periphery of the
container 2 can be mounted and accommodated on a step portion 9B
that occurs due to the difference in the width of the middle part
of the cover body 9.
[0090] As shown in FIG. 2, the drainage slope angle .theta. of the
sloped roof 9A of the cover body 9 is set in a range in which tan
.theta.= 1/100 to 1.
[0091] The slope of the sloped roof 9A is set so that moisture
adhering to the internal surface of the sloped roof 9A does not
fall vertically, but flows down along the internal surface of the
sloped roof 9A. Specifically, a configuration is adopted in which
condensed moisture (drainage) adheres to the cover body 9 when the
steam flowing in towards the cover body 9 from the steam inflow
part 5 exchanges heat with the cover body 9, but the set slope
prevents the drainage from falling onto the primary film 4 and
flowing in from the communicating hole 3 even when drainage adheres
to the internal surface of the sloped roof 9A.
[0092] A value of tan .theta. equal to 1 (45.degree.) or higher is
not preferred, because the space inside the sloped roof 9A is too
wide, and the storage (placement) efficiency of the cover body 9 in
the heating vessel 7 decreases.
[0093] The heat treatment can be more specifically described as
pre-cooking for obtaining the manufactured product.
[0094] Two types of cooking are selected for this pre-cooking, in
which the product is pre-cooked (steamed) rice that is reheated in
a household microwave oven or the like, or the product is
semi-cooked rice that is heated and steamed in a household
microwave oven or the like. Specifically, in the case of the former
type of product, the food product 1 (uncooked rice 1) is cooked to
completion (steaming) by the heat treatment, and in the case of the
latter type of product, the food product 1 (uncooked rice 1) is
cooked to semi-completion by the heat treatment.
[0095] At this time, heat treatment is performed without closing
the communicating hole 3, the communicating hole 3 is utilized as a
steam escape hole for the heat treatment, and the internal pressure
of the food product package 1 of the packaged food product A is
prevented from increasing and rupturing the container during heat
treatment.
[0096] Since this heat treatment can be performed at a temperature
of 100.degree. C. or higher by adjusting the inflow quantity of
steam from the steam inflow part 5, the heat treatment can be used
for various cooking purposes, sterilization purposes, and the
like.
[0097] Since the inside of the heating vessel 7 can be set to and
maintained (held) at a constant pressure, pressure is applied to
the food product 1 (uncooked rice 1 in the present example) equally
from all directions, at which time the steam as the heat source is
transmitted to the food product 1 equally from all directions, and
the food product 1 is therefore uniformly heated without
unevenness.
[0098] In particular, since moisture included in the food product 1
does not boil under pressure, the moisture in the food product 1
does not evaporate, and advantages are gained in that the food
product 1 (food) can be heat treated with no change in the moisture
content or weight thereof, and the aroma component in the food
product 1 is also made less likely to evaporate by the application
of outside pressure.
[0099] After the heat treatment, a secondary film 8 is sealed over
the primary film 4 so as to cover the communicating hole 3.
[0100] More specifically, a film having substantially the same
shape as the primary film 4 is used as the secondary film 8, and
the entire peripheral edge part of the back surface (lower surface)
of the secondary film 8 is sealed to the entire peripheral edge
part of the external surface (upper surface) of the primary film
4.
[0101] Before the secondary film 8 is sealed, the air inside the
container 2 is gas-exchanged, or a deoxidant (not shown) is sealed
inside to enhance shelf life.
[0102] When gas exchange is performed, the gas exchange can be
performed using the communicating hole 3.
[0103] For example, since communicating holes 3 are provided in two
locations of the primary film 4 in the present example, gas
exchange can be performed efficiently by introducing gas to the
container 2 from one of the communicating holes 3 while discharging
the air inside the container 2 from the other communicating hole
3.
[0104] When a deoxidant is sealed inside, the deoxidant can be
sealed in the gap between the external surface of the primary film
4 of the back surface (internal surface) of the secondary film 8.
Specifically, the gap between the two films 4, 8 is communicated
with the inside of the container 2 via the communicating holes 3,
the deoxidizing effects can act via the communicating holes 3, and
the deoxidant 6 (*3) can be sealed in the gap without the use of an
adhesive.
[0105] In this case, the strength of the seal between the secondary
film 8 and the primary film 4 can be set so that the primary film 4
also peels off of the container 2 together with the secondary film
8 when the secondary film 8 is peeled from the container 2 (when
the upper opening part of the container 2 is opened).
[0106] In the case of a packaged food product A such as
package-sealed rice, there is a risk of the deoxidant being
mistaken for dried food flakes for sprinkling over cooked rice, and
eaten (since the contents of the deoxidant resemble sesame and
salt, the risk of mistakenly eating the deoxidant is considered to
be significant in the case of cooked rice). However, a
configuration is adopted in which the deoxidant is sealed between
the primary film 4 and the secondary film 8 in the manner described
above, and since the secondary film 8 does not separate from the
primary film 4 even when the secondary film 8 is peeled away to
open the container 2, the deoxidant cannot easily be removed, and
the risk of mistakenly ingesting the deoxidant can be significantly
reduced.
[0107] The present invention is not limited by the present example,
and the specific configuration of the constituent elements may be
designed as appropriate.
* * * * *