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    14 views16 pages

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    Penina Tarigan

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    us United States c2) Patent Application Publica Fukumori et al. (54) RETORT RICE MEAL PRODUCING SYSTEM. (75) Inventors: Takeshi Fukumori, Tokyo (IP); Kefsht Wakabayashi, Tokyo (1); Faminort Harada, Hiroshima (JP); Toshinort Kawamoto, Hiroshins UP) (73) Assignees: FURUKAWA MEG. CO. (JP); SATAKE CORPOR Tokyo (1P) AD. Tokyo ON, (21) Appl.Noz 4n0.918 (22) PCTTiled: Ape. 18,2011 (86) PCT No, $371 (0,0), (2), (4) Date PeT/sP2011/002224 Oct. 25,2013, Publication Classification (1) Inc ADL IO (2006.01) AAS 2704 (2006.01) (2) US.CL CPC.” A23E 1/10 (2013.01); A475 27704 (2013.01) spc 9/380; 99/971 O9774A1 US 20141 (ON (10) Pub. No.: US 2014/0109774 Al (43) Pub, Date Apr. 24, 2014 on ABSTRACT A retort rice meal producing system is provided capable of total production from raw rice upto a retort rice meal excel- leat in outer appearance by using & simple production pro- The system includes a pressurized steamer mechanism per forming a steam heating process on raw rice under pressut- izing form an gelatnized layer on surface layer art ofthe rnv-rice grain and to make a center part thereof porons, 2 Steamed-tice single granulation mechanism removing sur facelayer moistire fom the steamed rice processed for single rnuation as being conveyed by a conveyer, a quan: titative filling mechanism of measuring the steamed rive sub- jected to single granulation for each pack and filing con fainer with the steamed rice, a packing mechanism further filling the steamed-rcesfilled container filled with the steamed rice with atleast an amount of aliquid such as a rive-cooking liquid required for soaking and moisture absorp- tion and ar for allocating a head space, and sealing the con- {diner a soaking/moisture-absorbing mechanism reversing @ package ofthe sealed container a plurality of times and caus- Jing the rce-cooking liquid to be absorbed iato the steamed rice, anda retort sterilizing apparatus performing a heat reat- ‘ment on the steamed rice eased to absorb the rice-cooking Tiquid up to the center part. ‘US 2014/0109774 AL Apr. 24, 2014 Sheet 1 of 7 Patent Application Publication FIG.1 Ka 8 FS a Ge Oe aL ib 6I : i ae vs ar 4 eS or =| hy Fa oss = i f ( $ be ie & vor ook MF gk wit Ii CAD 3 ey Wy Ww oS ae ; ob A : i ¢ & we ° Patent Application Publication Apr. 24, 2014 Sheet 2 of 7 ‘US 2014/0109774 AL Patent Application Publication Apr. 24, 2014 Sheet 3 of 7 ‘US 2014/0109774 AL FIG.3 Patent Application Publication Apr. 24, 2014 Sheet 4 of 7 ‘US 2014/0109774 AL FIG.5 FIG.6 Patent Application Publication Apr. 24, 2014 Sheet 5 of 7 US 2014/0109774 AI FIG.7 Patent Application Publication Apr. 24, 2014 Sheet 6 of 7 ‘US 2014/0109774 AL N 168 sat az 198 FIG. 10 Patent Application Publication Apr. 24, 2014 Sheet 7 of 7 US 2014/0109774 AI FIG. 23 US 2014/0109774 AI RETORT RICE MEAL PRODUCING SYSTEM ‘TECHNICAL FIELD 10001} The present invention relates to @ retort rice meal producing system of producing retort rice meal ad, ia more ‘detail, toa retort rice meal producing system for otal produe~ tion fom raw rice up to a retort rice mea BACKGROUND ART 10002] In recent years, various types of retort rice meals that can be eaten only by heating in hot water ora microwave ‘oven have been commercially available and many technolo gies for producing retort rice meals have been suggested (refer to Patent Document 1 to Patent Document 3) 10003] For example, Patent Document 3 describes a retort Ficemcal producing apparatus which includes # cooking om- ‘ainer including beating, cooling, and mixing mechanisms, & retort pouch filling apparatus coupled to the cooking con- tainer via a transfer ine witha pumping pump and having & filling nozzle for filling a retort potich with a raw material through the teansfer fine and a sealer hermetically’ sealing an ‘opening ofthe retort pouch filled withthe raw material, and retort sterilizer performing a heat treatment on the hermeti- cally-sealed retort pouch and performing final cooking and Stenlization. 0004) Inthe apparatus csclosed in Patent Document 3, ia the cooking container, raw rice cleaned and abso ture is partially added to a cooking liquid containing a vise ‘cosityaljusting component, andiskep ata cooking tempera ture fr incomplete cooking. Thea, cooling is performed ‘temperature equal of lover than the cooking temperate, and the remaining raw rice is added and mixed, and then ‘obtained mixtureis pumped and conveyed via the ansferline to fila retort pouch from a filling nozzle i the retort pouch filling apparatus and the opening of the retort pouch is her rtically scaled with the sealer. Then, cooking by beat and 2 sterilizing process are performed inthe retort sterilizer. With this, a retort rice meal is produced. [0005] According to the apparatus disclosed in Patent Document 3, inthe cooking container, the raw ice is partially ‘added to the cooking liquid for incomplete cooking and the the remaining raw rice is added. Therefore, the ratio of rice rains crushed atthe time of pumping and transferring the mixture to break the shape is decreased, and degradation in ‘eating texture and favor ean be prevented 10006] Also, according to the apparatus disclosed i Patent Document 3, in the evoking container, a process of cooling the cooking liquid alter partially adding the raw rice for ‘incomplete cooking is provided. Therefore, it possible to prevent excessive progress of alpharization of mainly the Femaining raw rice to he added aller cooling to cause Viseos- ity which makes i ifficlt to pump and transfer the mixture though the filling linet the retort pouch. PRIOR ART DOCUMENTS Patent Document 0007] {Patent Document 1] Japanese Patent Application Laid-Open No. 6303926 0008} [Patent Document 2} Japanese Patent No. 4613610 {009} {Patent Document 3) Japanese Patent Application Laid-Open No. 2002-152693 Apr. 24, 2014 SUMMARY, Problems to be Solved by the Invention [0010] However, the producing apparatus disclosed in Patent Document 3 has problems thatthe producing process is ‘complicated and energy cost for production is high. [0011] Also, in the retort rice meal produced by the appa ‘aus dielosed in Patent Document 3,10 rice grin groups ‘with differen ice-cooking histories are present, and the rice rains of one ofthe ree grain aroups are crushed toa degree fof not keeping the shape, and therefore it eannot necessarily be sad that an excellent outer appearance is achieved. [0012] Therefore, an object ofthe present invention is to provide a retort rice meal producing system capable of total production from raw rice up toa retort rice meal excelent in outer appearance by using a simple produetion process. ‘Means to Solve the Problems [0013] To achieve the object described above, a retort rice ‘meal producing system of the preseat invention includes « pressurized steamer mechsnisin performing # steam heating process oa raw rice under pressurizing, thereby forming aa agelatinized layer ona surface layer part of the raw rie grain ‘nd making a center part thereof porous, asteamed-ricesingle aranvlation mechanism removing, surfaceslayer moistnre Irom the steamed rice processed by the pressurized steamer ‘mechanism for single granvlation as being conveyed by a conveyer, a quantitative filling mechanism of measuring the steamed rice subjected to single granulation by the steamed- oe single granulation mechanism for each pack and filling @ container with the steamed rie, a packing mechanism further fling the steamed-rce-filled container filed. with the steamed rice by the quantitative filling mechaniso with at Teast an amount of a liquid such as a rice-eooking liquid required for soaking and moisture absorption and ie for allocating « head space, and sealing the container a soaking! ‘moisture-absorbing mechanism reversing @ package of the container sealed by the packing mechanism a plurality of times and eausing the ree-cooking liquid o be absorbed into the steamed rice, anda retort steilizing apparatus performing ‘heat treatment on the steamed rice up tothe center par, the steamed rice caused by the soaking/moisture-absorbing ‘mechanism to absorb the rice-cooking liquid [0014] In the retor rice meal producing system deseribed above, with the process in the pressurized steamer mecha- nism on raw rice having an approximately normal or lower ‘moisture content, steamed rice is formed with an gelatinized Jayer formed on the surlace layer part and a porous state appearing atthe center part. With this, inthe soaking/moi tureabsorbing mechanism, the speod of moisture absorption tote steamed rice ean be inereased and the moisture absorp: tion amount ean be significantly inereased. Also, inthe pock- ‘ng mechanism, the filling amount ofthe liquid such as the rioe-cooking liguid forthe container filled with the steamed rive is adjusted, and the package after the container is sealed js filled with air to allocate a head space therein. In the soaking/moisture-absorbing mechanism, the tempering time for easing the rioe-cooking liquid to be absorbed into the steamed rice as reversing the package a predetermined num- ber of times is adjusted, for example. With his, the moisture ahsorption state of the steamed rice in the package and the ‘mount of liquid lef unabsorbed i the steamed rice in the package can be adjusted. Therefore, the eating texture can be US 2014/0109774 AI freely adjusted according to the type of rice a ‘cooked, and a rice meal without viscosity and av Efets ofthe Invention 10015] With the structure described above, the retort rice ‘meal producing system of the present invention is capable of total prodcton from raw rice up toa retort rice mel excel- Jeat in outer appearance by using a simple production pro- BRIEF DESCRIPTION OF THE DRAWINGS. 10016] FIG. 1 depicts a schematic view ofan entire flow of ‘retort rice meal producing system of the present invention. 10017] FIG. 2depictsa front view of heat steamer mecha- nism ofthe present invention, [0018] FIG. 3 depicts a side view of the heat steamer mechanism of the present invention [0019] FIG. 4 depts front view ofa steamed-rice single tranulation mechanism of the present ivention, 0020] FIG. § depicts a perspective section view of the steamed-rce single granulation mechanism of the present 10021] _ FIG. 6 depicts a front view of a quantitative filling ‘mechanism of the present invention, 10022] FIG. 7 depicts a font view of a packing mechanism ‘ofthe present inventio 10023] FIG. 8 depicts « plan view ofthe packing mecha- nism ofthe present invention, 10024] FIG. 9 depicts a front view ofa soaking moishure- absorbing mechanism of the present invention [0025] _ FIG. 10 depicts a front view of a quantitative filling mechanism and @ packing mechanism of another embodi- ‘ment of the present invention, 10026] _ FIG. 11 depicts side view ofthe quantitative filling ‘mechanism and the packing mechanisms othe other embodi- ‘meat ofthe present invention, DETAILED DESCRIPTION OF EMBODIMENTS 10027] A retort rice meal producing system ofthe present Invention isa retort rice meal producing system in which, for ‘example, a pressuring, heating, and steaming process is per- ormed on raw rice having a moisture content equal {0 oF higher than 996 and equal to oF lower than 13%, with & pressure of 0.07 to 0.38 MPa and a temperature condition of 115 to 150 degroes Celsis for one to five mites to form an clatinized layer of 0.3 t 0.8 mm on a surface layer part oF Fice grains and to make a center part thereof porous, 8 con- tainer (such as a pouch ora tray container) i filled with the resultant rice together with @ predetermined amount of & rice-cooking liquid without cooling and sealed, and the rice trains are soaked into the rce-cooking liquid to cause the rice-cooking Tiguid 10 be absorbed! into the rice grains, thereby allowing the degree of depth of alpharization and moisture of the cooked rice to beadjuste based on the water absorption state of the rice grains and the amount of the rice-cooking liquid in the container. Details ofthe retort rice cal producing system are described below by using the drawings Apr. 24, 2014 First Embodiment 1. Raw Material Rice [0028] Inthe present invention, any species of Japonicarioe (short-grain species, Japanese type), Indica see (long-gruin species, Indian type), and Javanica rice (lange-grain species, Tava ype) ean be use as rw material rice, Also, presWashed Fee ar wet-polishe rice is preferable for se a aw material rice, but normal polished rice may be used. The raw material rice as these described above for use has an approximately ‘normal moisture content or moisture content lower than 15%, ‘whichis lower than hatof normal ee, preferably 9%t0 14%, more preferably 9% to 13% futher preferably 11% to 12%, [0029] The pre-washed rice refers to rice obtained by ade nga moisture equal to of lower than 15% or slime substance orbran zemoval to polished rice and polishing the surface of the polished rie to remove bran lel i fine grooves on the surlace. Also, the wel-polished rice fers to rice obtained by polishing rice by adding water equal to or ower than 1% t0 remove most bran ff on polished ree. Ifthe pre washed rice or the wet-polished rice is used, sewage disposal plant for ‘waste water occuring due to rice polishing is not required. 2. Description of Entire Flaw of the Retort Rice Meal Producing System in the Embodiment of the Present Invention [0030] FIG. 1 isan entre fow ofa retort rice meal proiue- ing system ofthe preset invention, Inthe present embodi- ‘ment, aretor rice mea is produced by using thers material oe with he low as described below, However, the retort rice ‘eal producing system of the present invention docs not require each of the structures ofthe entire fow of FIG. 1 as indispensables, and part of the structures may be omitted, another structure may be added, or a structure may be ‘place or moxie. (1) With a measuring mechanism 1, the raw material rice (pre-swashed rice) is measured and dispensed forone tray (4.0 eg) to be brought into a pressurized steamer mechanism 2 described below, (2) Twenty trays 3 each having a spread of 40 kg. of raw ‘materal rice measured are brought into a pressurizing and heating furnace othe pressurized steamer mechanism 2, and the raw material rice is pressurized ad heated with saturated vapor stat predetermined pressure and temperatureto form fan gelatinized layeron surface layerpart and reforms center part thereof as porous. G) With a steamed-rice single granulation mechanism 4 ‘moisture on the surface layer of the steamed rie brought out {rom the pressurizing and heating furnace of the pressurized steamer mechanism 2 is removed, and the steamed rice as a block-shaped chunk aller being pressurized and heated inthe pressurizing and heating fumaceis loosened for single gram lation, (4) With a vibration feeder § vibrating the steamed rice sub- {ected to single granulation, the steamed rice is supplied litle by litte to the next mechanism, that is, bucket 7 ofa bucket conveyer 6 (5) With the bucket conveyer 6, the steamed rice is vertically conveyed ans supplied tothe next mechanism, that iy an ‘upperhopper ofa metering machine 9 ofa quantitative filling ‘mechanism 8 (6) Inthe metering machine 9, the steamed rice is measured or one pockage with measuring box set ina predetermined US 2014/0109774 AI ‘capacity, and the steamed sive for one package is intem teally throw into a bow Hf of a bowl throwing conveyer 10. (7) To the steamed rice thrown ito the bow 11 by the meter ing machine 9, a necessary ingredient is automatically or manually added as appropriate, and the steamed rice is cone veyed by the bowl throwing conveyer 10 to. packing mech- nism 12 to be thrown into/a pouch, (6) inthe packing mechanism 12, the pouch withthe steamed rice thrown thereinto is filled with a necessary rice-cooking liguid such asa seasoned liquid and enclosed to contain inert ts, and then the pouch is sealed. (0) By an X-ray inspection apparatus 13 of an inspection ‘chanism, an inspoction i performed regarding admixture ‘ofany foreign substancein the pouch and, by aweight inspec tion apparatus 14 ofthe inspection mechanism, the weight of the pouich is inspected, (10) Any pouch determined by the inspection mechanism asa ‘defective product is brought out ofthe system by a sereening mechanism 15. (11) With the poucl reversed by conveyers of « plurality of Stages of a soaking/moisture-absorbing mechanism 16, the pouch i heated with warm ar at 60 to 80 degrees Celsis to tiiformily soak the steamed rie into the riee-cooking liquid to promote moisture absorption into the steamed rie. (12) Witha retort sterilizing apparatus 19, heating processis performedn the center par the steamed rice absorbing the Floe-cooking liquid at 120 degree Celsius for four minutes oF ‘under temperature conditions which can bring equivalent effects, With his heating process, the steamed rice in a miss ture absorbing state is alpharized to the center pat. Flere, the ‘depth of alpharization described above varies depending oo the moisture absorbing state of the steamed rie. 3, Details of Each Mechanis Producing System 10031] Details of each mechanism of the retort rice meal producing system are described below. of the Retort Rice Meal (1) Measoring Mechanism [0032] The measuring mechanism 1 is, for example, a batch-iype measuring machine which dispenses preswashed white rice with a weight for one tray. As the measuring machine, a known measuring machine, GHPISE manufae- tured by SATAKE Corporation, was used, bu, asa matter of ‘cours, the measuring mochanism 1 isnot restricted 1 this ‘Thismeasnring machine GHPISBean measure 0.510 1Skgat ‘onetime Inthe present embodiment, 4.0 kg for one tray is sdispensed, and the rice is distributed to each tray’ 3 for the pressurized steamer, and then the trays 3 are stacked, with ten ‘ona frontrow andten ona rear row, anddelivered by acar for sacking ona shelf of the pressurized steamer meclianism 2 [0033] "Note in the present embodiment that shite rice is processed as pre-washed rice before measured by the mea- ‘ring mechanism 1 (2) Pressurized Steamer Mechanism 10034] The presurized steamer mechanism 2s formed of the pressurizing and heating furnace, sterilizing the raw rice Jn the pressurizing. and heating furnace and performing @ steam heating process on the ra rice under pressure to form ‘an gelatinized layer the surface layer part and to make the ‘center part porcis, For example, twenty trays 3 cach having 3 spread of approximately 40 ky of pre-washed rie measured Apr. 24, 2014 by the measuring mechanism 1 are introduced by a cart 21 into the pressurizing and heating furnace, and a pressurizing. eating, and steaming process is performed witha pressure of (0.07 to 0.38 MPa at a temperature of 115 to 150 degrees Celsius [035] Here, an example is shown using a steam-circula- ‘ion-type cooking sterilizing apparatus 100-18 manufactured by BIOCON (IAPAN) LTD. as the pressuring and heating fimace of the pressurized steamer mechanism 2, but the pressurized steamer mechanism 2 is not restricted to this Apparat. Any model can be used as longas the pressurizing fan heating furmace can process pre-washed rice under @ pressurizing and heating vapor witha pressure of 0.07 100.38 ‘MPuata temperatureof 115 to 1SOdeprees Celsius farone five minutes [0036] A steam-circulation-type cooking sterilizing appa- ‘ats manufactured by BIOCON (JAPAN) LTD. depicted! in FIG. 2 and FIG. 3 has full sizes with, approximately 1,500 ‘mm jn lateral width, 2,700 mm in depth, and 2,100 mam in Deight, and a furnace 2 hue an inser diameter of 1,000 maa Anda straight barrel fength of 1.500 mm. Inside the furnace 2A, atoul of twenty ays 3 can be accommodated, that is, ten Stags ina front row and tn stages in a back rw, each tray’3 ‘having a thickness of 30 mm. The capability of processing ‘iw material rice is SO kg/batch, The inside ofthe furnace 2 bas a structure in which dew condensation water inthe fur nace donot drip to the trays 3. The furnaces 2, a frame 2C, ‘anda id 2B are all made of sainlss steel, and he furnace 24 ‘nd the steam pipe are covered with an insulating material for ood, [0037] ‘The steam-

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