Patent Application
20050260327
The present invention relates to processed foods, such as a potato chip and the like, a manufacturing system for the processed foods, and a manufacturing method for the processed foods.
Most of the conventional processed foods, such as a potato chip and the like, are formed as products by, for example, peeling of raw potatoes, slicing of peeled potatoes, deep-frying of sliced potatoes, and then seasoning of deep-fried potatoes.
In the case of such processed foods as a potato chip and the like, a deep-frying treatment is provided, thus the products contain oil components in quantity, are high in calories, present problems of health maintenance, due to the presence of cholesterol components, and the like, and thus have not always been desirable ones.
Patent Documents 1 proposes a snack food for which no deep-frying is carried out, although raw materials completely different from those of the present invention are used, and a method of manufacturing a snack food that is completely different from that of the present invention is employed.
Patent Documents 1
Patent Publication No. JP/P2000-253846A
The snack food disclosed in Patent Documents 1 is that obtained through a series of steps of peeling of white potatoes, pelletizing, steaming, drying, puffing, seasoning spraying, and drying (Means for Solving the Problem and FIG. 1 in Patent Documents 1).
However, in the case of the snack food of Patent Documents 1, raw white potatoes are used as a raw material, and pelletized for manufacturing the snack food, although the deep-frying step is not included, thus, the production cost is increased, and the product size and the product shape cannot be made uniform, resulting in products being non-uniform in size and shape. In addition, the snack food itself as a product has a finished shape which is substantially flat, and it is difficult to provide the snack food with a curved shape like a conventional potato chip, and the like.
A problem to be solved by the present invention lies in that there is no processed food, such as a potato chip or the like, which has not been deep-fried, is low in calories and well suited for maintaining health, and also can be diversified while being made uniform in product shape.
The most important feature of the processed food of the present invention is that a chip-form material which is obtained by dividing a paste-form material (a material rendered pasty) or lump-form material, or otherwise a dough, produced by mixing a dry potato raw material powder, an auxiliary raw material(s) or a seasoning(s), and water into individual chip-form materials, is baked while being subjected to an appropriate pressure, sandwiched, to form a chip-form product.
According to the present invention, the following effects are achieved.
According to the invention of claim 1 or 2, no deep-frying is performed, thus a processed food which contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, is low in calories and well suited for maintaining health, and uses potato granules, and the like as a main raw material can be provided.
According to the invention of claim 3, no deep-frying is performed, a processed food which contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, is low in calories and well suited for maintaining health, and has a curved-chip shape can be provided.
According to the invention of any of claims 4 to 7, the effects of each invention of the above-mentioned claims 1, 2, and 3 can be achieved while taking in the characteristic scheme of each of the inventions of said claims 4 to 7.
According to the invention of claim 8 or 9, a series of manufacturing steps which use means for forming a paste-form material or lump-form material, using potato granules, and the like as a main raw material, dividing means, and baking means, can be continuously and efficiently carried out for manufacturing a processed food which contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, and is low in calories and well suited for maintaining health.
According to the invention of claim 10, a system which additionally includes means for deformation heating can be used for manufacturing a processed food which contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, is low in calories and well suited for maintaining health, and has a curved shape.
According to the invention of any of claims 11 to 14, the effects of each invention of the above-mentioned claims 8, 9, and 10 can be achieved while taking in the characteristic scheme of each of the inventions of said claims 11 to 14.
According to the invention of claim 15 or 16, a mixing process which uses potato granules and the like as a main raw material for formation of a paste-form material or lump-form material, a dividing process for formation of individual chip-form materials, and a baking process can be continuously and efficiently carried out for manufacturing a processed food which contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, and is low in calories and well suited for maintaining health.
According to the invention of claim 17, a manufacturing process which additionally includes a process for deformation heating can be used for manufacturing a processed food which contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, is low in calories and well suited for maintaining health, and has a curved shape.
According to the invention of any of claims 18 to 21, the effects of each invention of the above-mentioned claims 15, 16, and 17 can be achieved while taking in the characteristic scheme of each of the inventions of said claims 18 to 21.
The purpose of providing processed foods which have not been deep-fried, are low in calories and well suited for maintaining health, and also can be diversified while being made uniform in product shape has been achieved by dividing a paste-form material or lump-form material obtained by mixing a dry raw material powder consisting of potato granules, and the like; an auxiliary raw material(s) or seasoning(s) selected from common salt, Umami seasonings, seaweeds, spices, sesames, cereals, nuts, fishery products, vegetables, and the like; and water into individual chip-form materials, baking each individual chip-form material while appropriately pressurizing and sandwiching it, and deformation heating it to form a product in the form of a curved chip.
Hereinbelow, embodiments of the present invention will be described in detail.
A potato chip 20 as shown in
In the present embodiment, a dry raw material powder consisting of potato granules, and the like is used as a paste-form material or lump-form material, however, in the present invention, a raw material containing a dry powder or a substance in flake form of potato as an ingredient may be used as an alternative to the dry raw material powder consisting of potato granules, and the like.
The manufacturing system and manufacturing process for the potato chip 20 of the present embodiment will be described with reference to
In the present embodiment, a dry raw material powder 1 consisting of potato granules, and the like, having the properties and meeting the specifications as given in
Next, the obtained paste-form material or lump-form material 5 is placed in, for example, a squeezing machine 6 as dividing means having a hopper 7 and a squeezing roller 8, the paste-form material or lump-form material 5 is squeezed to be divided into individual chip-form materials 9.
In the example illustrated, the squeezing machine 6 is shown as that with a mechanism comprising a hopper 7 and a squeezing roller 8, however, in the present invention, the configuration of the squeezing machine is not limited to that of the example illustrated, but as a squeezing mechanism, a pump mechanism (not shown), for example, may be used for squeezing the paste-form material or lump-form material 5.
Next, each individual chip-form material 9 is fed to a sandwiching baking machine 10, which is baking means for baking while sandwiching the chip-form material 9.
In the present invention, the mechanism or method of the sandwiching baking machine is not limited to that of the respective embodiments illustrated, but it may be any mechanism or method, provided that it is a mechanism or method with which the chip-form material 9 is baked while being sandwiched from above and under, for instance, as in the example illustrated, or a mechanism or method with which said chip-form material 9 is heated to be baked while being sandwiched between thermally conductive plates.
The sandwiching baking machine 10 in the present embodiment illustrated conveys said chip-form material 9, while applying an appropriate pressure thereto, sandwiching it between a lower conveyor 11 and an upper conveyor 12 which, each having a conveying chain or conveying belt 13 at both ends, for example, are configured to turn, being supported by the conveying chains or conveying belts 13 at respective both ends, consisting, for example, of sheets made of iron or sheets made of a casting, or otherwise sheets made of copper, or the like that are rotatably formed; bakes both sides of the chip-form material 9 with flames and heat from a lower burner 14 and an upper burner 15; and conveys it out to the subsequent stage.
In the present invention, electric heaters may be used instead of the lower burner 14 and the upper burner 15 as shown in the drawing. In the present invention, although it is not shown, the sandwiching baking machine may also be configured to bake said chip-form material 9 while sandwiching it between a turntable and a vertically moving plate, wherein the turntable consists of a sheet made of iron or a sheet made of a casting, or otherwise a sheet made of copper, or the like adapted to rotate on a flat surface, and the vertically moving plate consists of a sheet made of iron or a sheet made of a casting, or otherwise a sheet made of copper, or the like that moves up and down above this turntable.
Further, as the best embodiment, the chip-form material 9 is sandwiched baked at a temperature of approx. 100° C. to 200° C. and a pressure of 0.5 to 5.0 kg/cm2.
The chip-form material 9 conveyed out from said sandwiching baking machine 10 can be a potato chip 20 which is, for example, flat and rectangular or is in the shape of a thin, elliptical or circular disk as shown in
Further, as the shape of the potato chip 20, a thin, circular disk, a thin, elliptical disk, a stick, and the like are also possible, as well as a rectangle.
In
According to the potato chip 20, which is a processed food obtained by the manufacturing system and manufacturing process for the potato chip 20 of the present embodiment, a dry powder of potato is used as a main component and no deep-frying process is provided, thus a health food that contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, and is low in calories and well suited for maintaining health can be produced.
According to the manufacturing system and manufacturing process for the potato chip 20 of the present embodiment, a series of manufacturing steps of generating a paste-form material or lump-form material 5 with a mixing machine 4, transforming it into individual chip-form materials 9 with a squeezing machine 6, and baking each individual chip-form material 9 to a potato chip 20 with a baking machine 10 while appropriately pressurizing and sandwiching it, can be continuously and efficiently carried out for manufacturing a potato chip 20 as a health food that contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment manufactured, and is low in calories and well suited for maintaining health.
Next, an alternative embodiment of the present invention will be described with reference to
This alternative embodiment is characterized in that, as deformation heating means for heating a chip-form material (a chip-form article) 9 to form a potato chip 20A, which is a product in the form of a curved chip (in curled form, twisted form, or the like), a gas oven 18 is inserted between the sandwiching baking machine 10 and the post treatment stage 17 in the manufacturing system and manufacturing process as shown in
In the present invention, an electric heater, or the like may be used instead of the gas oven 18 as shown in the drawing.
According to the manufacturing system and manufacturing process of this alternative embodiment, properly setting the time period for baking both sides of the chip-form material 9 in said baking machine 10 while appropriately pressurizing and sandwiching it, and the time period for heating in the gas oven 18 makes it possible to manufacture a curved potato chip 20A (in a curled shape) as shown in
The chip-form material 9 which is taken out from said gas oven 18 can be a potato chip 20A as shown in
According to the potato chip 20A, which is obtained by the manufacturing system and manufacturing process of this alternative embodiment, deep-frying is not performed, thus a health food which contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, is low in calories and well suited for maintaining health, and further has a curved shape different from that of said potato chip 20 can be produced.
According to the manufacturing system and manufacturing process for the potato chip 20A pertaining to this alternative embodiment, a series of manufacturing steps of generating a paste-form material or lump-form material 5 with a mixing machine 4, transforming it into individual chip-form materials 9 with a squeezing machine 6, baking each individual chip-form material 9 to a potato chip 20 with a baking machine 10, while appropriately pressurizing and sandwiching it, and deformation heating it with a gas oven 18 can be continuously and efficiently carried out for manufacturing a potato chip 20A in a curved shape as a health food that contains no oil components like those of a potato chip subjected to a conventional deep-frying treatment, and is low in calories and well suited for maintaining health.
As previously described, with the manufacturing system and manufacturing process for the potato chip 20A of this alternative embodiment, the mechanism or method of said sandwiching baking machine 10 is not limited to the example illustrated, but it may be any mechanism or method, provided that it is a mechanism or method with which the chip-form material 9 is baked while being sandwiched from above and under, for instance, as in the example illustrated, or a mechanism or method with which said chip-form material 9 is heated to be baked while being sandwiched between thermally conductive plates.
The present invention is widely applicable to various processed foods made from such materials as root and tuber crops other than potato, corns, beans, and the like, and as manufacturing means therefor, as well as being applied to the above-mentioned potato chips and as manufacturing means therefor.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2004-151007 | May 2004 | JP | national |
