CZ20003225A3 - Process for producing a fermentation material - Google Patents

Abstract

The method for producing a fermentation material comprises forming a dough by adding water to dried gluten in an amount of from 19 to 60% by weight based on the weight of the dough, pelletizing the dough, and if necessary adding water to adjust the moisture content to 35 to 60% by weight based on the weight of the pellets before sterilizing the pellets by steam. Using one or more fermentation materials, the method for producing koji yields a koji product.

Description

Process for producing fermentation material

Technical field

The present invention relates to a method of pelletizing, and in particular to a method of pelletizing dried gluten material that can be used as a fermentation material to produce fermented products such as soy sauce and flavoring agents and the like.

BACKGROUND OF THE INVENTION

EP-A-0711510 claims a method of producing a fermentation material which comprises using 5 to 100% by weight of dried gluten product and 95 to 0% by weight of wheat using a feedstock to adjust the moisture content material after granulation in the range of 12 to 18 %, and granulation followed by steaming. The steaming is reported to denature wheat gluten. It is further stated that adjusting the moisture content to the desired range will allow granulation, which, after steaming, results in satisfactory denaturation of the protein. The dried gluten product contains dried wheat gluten, dried corn gluten, etc. Fermenting material can be used in the production

2o fermented products such as soy sauce, bowl, seasonings, etc.

However, when steam is fed directly to gluten, saturated steam and vital wheat gluten not only cause problems not only with the formation of undesirable hard clumps, which must be removed by sieving and thus cause losses, but it is also very difficult to achieve a moisture content of 12 to 18% by weight, especially in large-scale production. Vitality causes the elasticity of the wheat gluten dough when water is added.

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4444 4,444 444 44 44. 2 WPI AN 87-189049 discloses a method for producing a koji cooking material by heating flour for denaturing proteins, hydrating to a moisture content of 30 to 50% by weight, granulating and steaming.

SUMMARY OF THE INVENTION

The present inventors have found that these problems can be solved by the devitalization of wheat gluten prior to pelletization. Devitalization is part of the denaturation and can be achieved by heat. After devitalization, water may be added in an amount of from 19 to 60% by weight, depending on the degree of devitalization, to form a paste and allow pelletization. If desired, additional water may be added to the pellets prior to sterilization and further steam denaturation to adjust the moisture content to 35-60% by weight based on the weight of the pellets, which are thus suitable for koji fermentation. No clusters are formed and no losses occur. Devitalization is only necessary if gluten is vital, for example, vital wheat gluten.

Accordingly, the present invention provides a method of making a fermentation material comprising the steps of: adding to the dried gluten water to form a dough in an amount of from 19 to 60% by weight,

2o, based on the weight of the dough, the dough is pelletized and water is added to adjust the moisture content to 35-60% by weight of the pellets prior to steam sterilization of the pellets.

DETAILED DESCRIPTION OF THE INVENTION

In this description, the term "pelletization" is used as a synonym for "granulation".

The dried gluten may be wheat gluten, corn gluten or rice gluten and one or more glutens may be used to produce the pellets. When wheat gluten is used as dried gluten, it is preferable to devitalize the wheat gluten before adding water, although devitalization is not necessary. The devitalization may be carried out by heating to a temperature above 60 ° C, for example by hot air or by contact with a hot surface, in an oven or oven, or by using a steam jacketed vessel. The devitalization may take from 5 s to 3 hours and depends on the temperature used, with longer times generally being required at lower temperatures. For example, the devitalization may be carried out at a temperature of from 60 to 200 ° C for a period of from 3 hours to 5 seconds, preferably from 100 ° C to 120 ° C for 30 to 5 minutes.

Before adding water to the dried gluten, it is preferable to add wheat, such as wheat flour or wheat bran, to the dried gluten as a source of carbohydrates. The amount of wheat added can be up to 90% by weight, preferably from 5 to 50% by weight, and in particular from 10% by weight, based on the weight of the raw material.

The amount of water added to the dried gluten is preferably from 30 to 45% by weight based on the weight of the dough. The amount of water added depends on the vitality of gluten as well as the composition of the raw materials.

The dough can be pelletized by conventional means such as screw presses, meat choppers, or pelletizing machines. The pellets may either have a cylindrical shape with a diameter of from about 1 to 10 mm, preferably from 2 to 8 mm, and in particular from 4 to 6 mm, or they may have a spherical shape with a diameter of from 1 to 10 mm, preferably from 2 to 8 mm. and in particular from 4 to 6 mm.

The water added to the pellets prior to steam sterilization preferably increases the moisture content to 40 to 50% by weight based on the weight of the pellets.

After cooling, the pellets may be converted into a koji by mixing with carbohydrates, inoculation with Aspergillus bacteria, and fermenting the koji substrate for an additional two days. The cubicle may then be converted into a flavoring agent by conventional methods or as described in EP 0640294 or related patent applications.

Applicants EP-A-96114850.9 (EP 0829205) and EP-A-96202309.9 (EP 0824873), which are hereby incorporated by reference. The use of the pellets of the present invention in koji fermentation provides a good yield of hydrolysis due to easy disintegration during hydrolysis.

This process can preferably be carried out continuously, for example using the principle of a noodle production line, but with a lower accuracy of dough thickness and noodle diameter. The continuous process includes mixing the ingredients (dried devitalized gluten, wheat flour, wheat bran), pelletizing, adding water, steaming, cooling and inoculating spore suspensions. The substrate is then fed to a koji fermentation machine and subjected to subsequent hydrolysis.

DETAILED DESCRIPTION OF THE INVENTION

The following examples illustrate the invention.

Example 1 kg of vital wheat gluten was devitalized by heating to 100 ° C in a steam jacketed mixer for 30 min. The thus devitalized wheat gluten was mixed with 2.5 kg of wheat bran

12.5 kg of wheat flour. Water was added to the mixture to obtain a moisture content of 33% by weight. The dough was then fed into a mower to form cylindrical pellets with a diameter of 5 mm. Additional water was introduced into the pellets so that the moisture content of the pellets was 47% by weight. The pellets were then steamed at 100 ° C for 10 min and then cooled to less than 40 ° C. The cooled pellets were mixed with a liquid suspension of 25 g of Aspergillus oryzae spore inoculum. Fermentation of the koji was performed for 42 hours at 27-33 ° C. The mature koji was hydrolyzed by adding water to give a hydrolyzate with a total solids content of 20.2% by weight. Hydrolysis was

3o performed at 4 ° C 2 weeks before two weeks of moromi fermentation when ·· ΦΦ

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- 5 ΦΦΦ salt was added to a concentration of 12% by weight. The Moromi was pressed and the pure sauce was heat treated at 90 ° C for 20 min. The product thus prepared had a light color, a good taste and an excellent aroma.

Example 2

Water was added directly to a mixture of 35 kg of rice gluten,

2.5 kg of wheat bran and 12.5 kg of wheat flour to obtain a moisture content of 45% by weight. The dough formed was then fed into a mower to form cylindrical pellets with a diameter of 5 mm. The same procedure as described in Example 1 was used for steaming, koji and sauce production.

The product thus obtained had a light color, good taste and excellent aroma.

Example 3

The same procedure as in Example 2 was followed except that powdered corn glutan was used instead of powdered rice gluten and the moisture content of the dough before pelletizing was 35% by weight.

Additional water was added to the pellets prior to steaming such that the moisture content of the pellets was 47% by weight.

The product thus produced had a light color, good taste and excellent aroma.

Example 4

The same procedure as described in Example 1 was followed except that 35 kg of devitalized wheat gluten was mixed with 2 kg of wheat bran and 4 kg of wheat flour and was 9 9 99 9 9

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- 6 water added to obtain a moisture content before pelletizing of 40% by weight.

Example 5

The same procedure as described in Example 1 was followed except that 35 kg of devitalized wheat gluten was mixed with 5 kg of vital wheat gluten, 2.4 kg of wheat bran and 4.7 kg of wheat flour and water was added to obtain a moisture content before pelletizing 33% by weight.

Example 6

A similar procedure to that described in Example 1 was followed except that the devitalization of wheat gluten was carried out by direct feeding of superheated steam at 0.1 MPa and 150 ° C to the wheat gluten before mixing with carbohydrates and pelleting.

Example 7

The same procedure was used as in Example 1 except that the devitalization of wheat gluten was carried out in a fluid bed dryer with an inlet air temperature set at 110 ° C.

Example 8

The same procedure was used as in Example 1 except that the pellet diameter was 3 mm.

• ·

- 7 Example 9

The same procedure as described in Example 1 was followed except that the pelletization was carried out using a screw press.

Example 10

The same procedure as described in Example 1 was followed except that the pelletizer used produced spherical granules with granules having a diameter of 3 to 8 mm.

io Example 11

The same procedure as described in Example 1 was followed except that 25 kg of corn gluten pellets prepared as described in Example 3 were fermented together with wheat gluten pellets.

Example 12

The same procedure as described in Example 3 was followed except that 35 kg of wheat gluten devitalized as described in Example 1 was mixed with 35 kg of rice gluten, 5 kg of wheat bran and 25 kg of wheat flour prior to pelletization.

Example 13

The same procedure as described in Example 11 was followed except that 40 kg of steamed defatted soya flour was used instead of corn gluten.

• • •

- 8 Example 14

The same procedure as described in Example 1 was followed except that wheat flour and wheat bran were mixed with vital wheat gluten prior to devitalization.

Example 15

The same procedure as described in Example 1 was followed except that lactic acid bacteria inoculum was added to the steamed pellets prior to fermentation at 7x10 ⁵ cfu / g and hydrolysis was carried out at 35 ° C for 2 days. After hydrolysis, compression was performed and salt was added to a concentration of 12% by weight.

Example 16

A similar procedure to that described in Example 1 was followed except that the devitalization step was omitted and water was added to the mixture of wheat gluten, wheat bran and wheat flour to obtain a moisture content of 20% by weight.

Claims (12)

PATENT CLAIMS Process for producing a fermentation material, characterized by: 5 comprising the steps of: making the dough by adding water to the dried gluten in an amount of from 19 to 60% by weight based on the weight of the dough, pelleting the dough and, if necessary, adding water to adjust the moisture content of from 35 to 60 60% by weight, based on the weight of the pellets, prior to steam sterilization of the pellets. Method according to claim 1, characterized in that one or more glutens are used for the production of pellets. 15 Dec The method of claim 1, wherein the dried gluten is wheat gluten, corn gluten, or rice gluten. A method according to claim 1, characterized in that 20 that when wheat gluten is used as dried gluten, the wheat gluten is devitalized prior to the addition of water. The process according to claim 4, wherein the devitalization is carried out at a temperature of from 60 ° C to 200 ° C after 25 for 3 hours to 5 seconds. - 10 The method of claim 4, wherein the devitalization is carried out by superheated steam, hot air, in an oven, in an oven or in a vessel with a steam jacket. 5 7. The process of claim 1 wherein wheat is added to the dried gluten prior to adding water to the dried gluten and pelletizing. A process according to claim 4, characterized in that wheat is added to the dried gluten before the devitalization of the wheat gluten. Method according to claim 7 or 8, characterized in that the wheat is in the form of wheat flour or 15 wheat bran. Method according to claim 1, characterized in that the dough is pelletized by a screw press, a meat chopper or a pelletizing machine. Method according to claim 1, characterized in that the pellets have a cylindrical or spherical shape with an average diameter of from 1 to 10 mm. A koji article made by a method for producing a koji using one or more fermentation materials obtained by the method of any preceding claim. - 11 13. 5 14. 15 Dec The koji article produced by the method of claim 12 and together with other protein substrates. Process for producing a koji product, characterized in that the pellets obtained by the process according to any one of the preceding claims are mixed with carbohydrates, inoculated with Aspergillus bacteria and the nursing substrate fermented for a period of time to produce fermented koji to produce enzymes capable of hydrolyzing proteins and carbohydrates. A nursing seasoning composition according to any one of claims 12 or 13.