JP3704401B2

JP3704401B2 - Edible container manufacturing method and manufacturing apparatus

Info

Publication number: JP3704401B2
Application number: JP20528596A
Authority: JP
Inventors: 滋隆小川
Original assignee: 株式会社ライジンテック
Priority date: 1996-07-15
Filing date: 1996-07-15
Publication date: 2005-10-12
Anticipated expiration: 2016-07-15
Also published as: JPH1028518A

Description

【０００１】
【発明の属する技術分野】
本発明は可食容器の製造方法及び製造装置に関し、さらに詳しくは通常コーンカップと呼称されているアイスクリーム、シャーベット又はクリームなどを盛り込む可食容器を外観的な形状を損なうことなく高収量で製造するための方法及び装置に関する。以下、本明細書では可食容器として円錐状のものを主として説明するが、本発明の可食容器は円錐状のものの他、角錐状、切頭円錐又は切頭角錐状のもの又はこれらを組合せたもの、さらにこれらに装飾的模様や段差をつけたものなども対象とする。
【０００２】
【従来の技術】
かなり古い時代から、小麦粉を主原料にしてバッター（水種とも称される）を調整し、これを雄型と雌型の両者からなる焼金型に流し込んで挟み焼方式で円錐型の可食容器が製造されてきた。焼成機としても円盤状の円周部分を焼型が移動しながら加熱するロータリー方式や、金型がキャタピラ式で水平・上下に移動しながら加熱される方式のように、大型の量産型のものが開発されている。
【０００３】
可食容器の製造では、焼成とともに金型内部の温度が上昇し、澱粉の加熱糊化・膨潤によって蒸気が発生し、金型内部の圧力が高くなる。これに対して従来の製造装置では、金型内部の圧力で雄型をいったん持ち上げ、それによって生じた雄型と雌型の間隙から内部の蒸気を排出するようにしていた。
【０００４】
しかしながら、この間隙から蒸気だけでなく、内部に充填したバッターも一部噴出し、この吹き出したバッターがそのまま焼成されて製品にバリが生じていた。このバリは後で取り除かれる必要があるが、その時に製品の上縁部が欠けたり、表層が剥離したりしていた。
【０００５】
可食容器は上縁部が十分な強度を持ち、滑らかで外観的に美しいものであることが要求される。一般的なコーンカップは口径が３０〜７０ｍｍ、長さが６０〜１５０ｍｍ、容積が６０〜１５０ｃｍ³ のものが多く、かかる要求をこれら全ての製品で満足することは難しかった。
近年では可食容器に求められる性質は食品として安全であること、美味であることはもちろんのこと、外観的な形状、模様、美観も特に要求されるようになっている。
【０００６】
【発明が解決しようとする課題】
本発明者らは可食容器の製造方法及び製造装置において、特に製品上縁部に欠陥がないものを高収量で製造することについて、かねてから研究しつづけてきた。製品上縁部の欠陥としては、前述のように焼成後バリと呼ばれるハミダシ部分を製品から取り除いた後の上縁部が滑らかさに欠け、部分的に表面皮層の剥離や欠けを多く生ずることであった。
【０００７】
従来この種の製造装置では、雄型のつば部が雌型の上部の面に密着した後、その雄型上部に押さえロックが降りてくるが、このロック状態に少しのゆとりを設け、雄型と雌型の空隙内部から発生した膨張空気・蒸気により雄型を少し持ち上げるようにし、それによって生じた雄型つば部と雌型上部との間隙から膨張空気・蒸気を金型から追い出しバッターが均一に金型空隙内部に拡散し、同時にその一部が上昇し金型から排出し、そのはみ出し部が焼成されて上部でバリとなるものであった。このバリ部分は原材料固形分の５％以上に達し、最終製品になるまでにバリ取りされる必要があった。
【０００８】
本発明はかかる従来技術の現状に鑑み創案されたものであり、その目的はバリ部分が実質的に生じない外観的に優れた可食容器を高収量で製造するための方法及び装置を提供することにある。
【０００９】
【課題を解決するための手段】
本発明者らは、種々の焼成条件、バッターの配合、調整条件等について検討を加えてきたなかで、加熱により金型内に発生した膨張空気・蒸気を追い出す手段として、各種形状のもなかの焼成時に行われているような、雌型の上縁角部に切り込みを設置することを試みたが、円錐型の金型では問題解決と結びつかず、雌型上縁部表面はすべて平滑とし、金型内部で発生した膨張空気・蒸気を排出し内部のバッターが上部に上昇し雄型と雌型の空隙の全部分に均一にバッターが広がりその一部が膨張空気・蒸気とともに金型外部にあふれ出るための特定の排出溝を、雌型上部表面に密着する雄型のつば部分に設置すること、さらに該排出溝部分以外の雌雄両金型の接触する面を完全に密着、嵌合するような構造とすること、および両金型の密着状態が維持できるようなロック機構を設けることの組合せ等により、前記目的を達成できることを見出し、本発明の完成に至った。
【００１０】
即ち、本発明は雄型と雌型の金型を用いて小麦粉を主原料とする可食容器を焼成する製造方法において、雌型の上部の面と接触する雄型のつば部の面に、金型内部に充填したバッターの加熱により発生する蒸気を外部へ排出するための溝を複数個設けた金型を用いて、雌雄両金型の接触する面を完全に密着させて焼成することを特徴とする可食容器の製造方法である。
【００１１】
本発明の製造方法の好ましい態様では、雌型にバッターを充填し、雄型が雌型に嵌合するときに、内部のバッターが雄型と雌型の空隙に均一に広がるように雄型を複数回上下運動させる。かくすることによって、バッターは空隙に均一に広がるのみならず、既に予熱されている金型から伝熱されて澱粉の糊化・膨潤が均一に始まり製品の各部が均質な膨潤と焼成が行われる。
【００１２】
また、本発明は雄型と雌型の金型を用いて小麦粉を主原料とする可食容器を焼成する製造装置において、雌型の上部の面と接触する雄型のつば部の面に、金型内部に充填したバッターの加熱により発生する蒸気を外部へ排出するための溝を複数個設け、さらに雌雄両金型の接触する面の密着状態を維持するためのロック機構を設けたことを特徴とする可食容器の製造装置である。
【００１３】
本発明の製造装置の好ましい態様では、雌型にバッターを充填し、雄型が雌型に嵌合するときに、内部のバッターが雄型と雌型の空隙に均一に広がるように雄型を上下運動させる機構を設ける。これにより、バッターが空隙に均一に広がるのみならず、製品の各部が均質に膨潤・焼成される。
【００１４】
【発明の実施の形態】
本発明では、雌型の上部の面と接触する雄型のつば部の面に、金型内部に充填したバッターの加熱により発生する蒸気を外部へ排出するための複数の溝を設けるが、この排出溝の形状、大きさも重要な因子である。これらの因子は可食容器の大きさ、形状、バッターの固形分量、加水量、流動性等によって支配されるが、一般的な円錐状のコーンカップ（口径３０〜７０ｍｍ、長さ５０〜１７０ｍｍ、内容積６０〜１５０ｍｌ）では、雄型のつば部の面に設ける排出溝は深さを０．１〜２．０ｍｍ、好ましくは０．２〜１．０ｍｍ、幅を１．０〜５．０ｍｍ、好ましくは２．０〜３．０ｍｍとし、長さを雄型のつば部外周部から雄型の円錐部のつけ根の位置までとすることが好ましい。あるいは長さを雌型円錐部分内面と雄型円錐部分外面との間隙（コーン口径部の肉厚部の幅に相当する間隙）の少し手前の位置までで止めてもよい。参考までに図１（ａ）に雄型と雌型が密着嵌合した状態の断面図を、図１（ｂ）に雄型のつば部の排出溝を下から見た図を示す。
【００１５】
コーンカップの形状、大きさによっては、排出溝からの膨潤空気・蒸気の排気効果が充分でなくなるおそれがあるため排出溝の形状・大きさについて充分考慮しなければならない。排出溝は対称的な配置で複数個設けられるが、好ましくは４〜８個である。なお、雌雄両金型の接触する面を完全に密着しやすくするために、接触する面に傾斜又は段差を設けることもできる。従来法では用いた総原料固形分の約５〜８％がバリとなっていたが、このようにすることによってバリが約１／５に減少した。
なお、雄型の代りに雌型に又は両方に排出溝を設けることも試みたが、結果的には雄型のみに排出溝を設置した場合が最も好ましい状態が得られた。
【００１６】
雄型と雌型の金型を用いて可食容器を焼成する場合、バッター中の澱粉が膨潤・糊化して体積が増大し、金型内部の圧力が上昇すると、その力で雄型が押し上げられて、雄型と雌型との間隙が大きくなるが、本発明の装置では、これを防止するために雌雄両金型の接触する面を完全に密着できるようなロック機構が設けられる。ロック機構は従来公知のものが使用できるが、例えば雄型が雌型に密着したときに上から押さえて両金型を固定できるようなものが使用される。この場合、ロック機構が雄型を押さえる力はバッターの加熱で内部圧が上昇しても雄型がほとんど持ち上げられないような強さが必要である。従来の形式では、内部圧力が上昇してロック機構が破壊されたこともあったが、本発明では排出溝が形成されているためその心配はなくなった。
【００１７】
本発明の装置では、雌型にバッターを充填し、雄型が雌型に嵌合するときに、一度に雄型が降りてきて雌型と組合されるのではなく、例えば１〜５秒間隔で２〜１５回雄型を上下運動させ、内部のまだ加熱されていないバッターを雄型・雌型の空隙に均一に広がるようにする機構を設けることが好ましい。
【００１８】
【実施例】
本発明を以下の実施例によって具体的に説明するが、本発明はこれらに限定されるものではない。
【００１９】
円盤状の円周部分に４０個の焼成金型が配列し、約２分２０秒間で１回転するロータリー式の焼成装置を使用した。円周部分の約６０％はガスバーナーによる加熱部分である。この装置では、焼成が終わった金型は加熱部分から離れ、一定速度で円周部分を移動しながら、雌型は観音開き式に開放され、焼成された製品が脱離して落下し、雄型は自動的に上昇して雌型から離れ、続いて雌型は再び元の位置に戻り、そこへ新しいバッターが一定量充填されるようになっている。そのとき雌型の中へ雄型が降りてきて両金型が密着し、２〜３秒間隔で約１０〜２０ｍｍ上下動を１０回繰り返し、内部のバッターを雄型と雌型との間隙に均一に広げる。その後、雌雄両金型が嵌合し、次に押さえロック機構が降りてきて両金型の密着状態を保持する。金型は予め充分加熱されているため、バッターの澱粉はすぐに膨潤糊化を開始し、約５〜６秒後には金型内に満ちあふれ、排出溝からバッターが蒸気とともに一部排出される。続いてガス炎が直接金型に上下側面からあたる加熱部分に入り焼成される。
【００２０】
使用した円錐状の雌雄両金型の形状は図１に示すとおりであり、その各サイズは以下の通りである：

【００２１】
可食容器を製造するために使用したバッターは小麦粉２５ｋｇ、コーンスターチ７ｋｇ、砂糖３ｋｇ、植物油１ｋｇに膨張剤、乳化剤、香料等を適量添加したものを水３３ｌと混合したものである。
【００２２】
上記のような条件で円錐型の可食容器を製造したところ、従来の方法では原料総固形分の約４重量％のバリが生じたが、本発明の方法では薄鱗片状の屑が約１〜１．５重量％生じたのみでバリ取りの必要性もなかった。また表面皮層の剥離や欠けもなく、外観形状に何ら問題がなかった。焼成された製品の良品率も９８％以上であった。
【００２３】
【発明の効果】
本発明によれば、バリ部分が実質的に生じない外観的に優れた可食容器を高収量で製造することができる。
【図面の簡単な説明】
【図１】図１の（ａ）は雄型と雌型が密着嵌合した状態の断面図であり、（ｂ）は（ａ）の雄型を下から見た図である。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an edible container manufacturing method and manufacturing apparatus, and more specifically, an edible container containing ice cream, sherbet, cream, or the like generally called a corn cup is manufactured in a high yield without impairing the appearance. The present invention relates to a method and an apparatus for doing so. Hereinafter, in the present specification, the edible container is mainly described as having a conical shape. However, the edible container of the present invention is not only a conical shape but also a pyramid shape, a truncated cone, a truncated cone shape, or a combination thereof. It also covers objects that have decorative patterns and steps on them.
[0002]
[Prior art]
From a fairly old age, flour is the main ingredient and batters (also called water species) are prepared and poured into a metal mold consisting of both male and female molds. Containers have been manufactured. Large-scale mass-produced types such as a rotary method that heats a disk-shaped circumferential part while moving it as a baking machine, or a method that heats the mold while moving horizontally and vertically by a caterpillar type Has been developed.
[0003]
In the production of an edible container, the temperature inside the mold rises with baking, steam is generated by the gelatinization and swelling of starch, and the pressure inside the mold increases. On the other hand, in the conventional manufacturing apparatus, the male mold is once lifted by the pressure inside the mold, and the internal steam is discharged from the gap between the male mold and the female mold.
[0004]
However, not only steam but also a batter filled inside was partially ejected from this gap, and the batter that was blown out was baked as it was, and burrs were generated in the product. This burr needs to be removed later, but at that time, the upper edge of the product was chipped or the surface layer was peeled off.
[0005]
The edible container is required to have a sufficient strength at the upper edge, be smooth and have a beautiful appearance. Many common cone cups have a caliber of 30 to 70 mm, a length of 60 to 150 mm, and a volume of 60 to 150 cm ³ , and it has been difficult to satisfy these requirements for all these products.
In recent years, the properties required of edible containers are not only required to be safe as food, but also to have a delicious appearance as well as an external shape, pattern, and beauty.
[0006]
[Problems to be solved by the invention]
The inventors of the present invention have been researching for a long time, particularly in the production method and the production apparatus of edible containers, in which a product having no defect at the upper edge of the product is produced with a high yield. As described above, the defect on the upper edge of the product is that the upper edge after removing the burrs after firing from the product lacks smoothness as described above, resulting in partial peeling and chipping of the surface skin layer. there were.
[0007]
Conventionally, in this type of manufacturing equipment, after the male collar is in close contact with the upper surface of the female mold, the presser lock comes down on the upper part of the male mold. The male mold is slightly lifted by the expanded air / steam generated from the inside of the female mold cavity, and the batter is uniformly ejected from the mold through the gap between the male collar and the female mold. At the same time, a part of the mold was raised and discharged from the mold, and the protruding portion was baked to become a burr at the top. This burr portion reached 5% or more of the solid content of the raw material, and had to be deburred before becoming the final product.
[0008]
The present invention was devised in view of the current state of the prior art, and an object thereof is to provide a method and an apparatus for producing an edible container excellent in appearance with substantially no burrs at a high yield. There is.
[0009]
[Means for Solving the Problems]
While the inventors have studied various firing conditions, batter composition, adjustment conditions, etc., as a means for expelling the expanded air / steam generated in the mold by heating, various shapes can be fired. Attempts were made to make a cut in the upper edge corner of the female mold as is done, but the conical mold did not solve the problem, the female upper edge surface was all smooth and the mold The internally generated air / steam is discharged, the internal batter rises upward, and the batter spreads evenly over the entire gap between the male mold and female mold, and a part of the batter overflows outside the mold together with the expanded air / steam. For example, a specific discharge groove for the male mold should be installed in the collar portion of the male mold that is in close contact with the upper surface of the female mold, and the contact surfaces of both the male and female molds other than the discharge groove section may be closely adhered and fitted. Structure and close contact between both molds The combination of the provision of the locking mechanism as condition can be maintained, found that the above object can be attained, thereby completing the present invention.
[0010]
That is, the present invention is a method for firing an edible container mainly made of flour using a male mold and a female mold, and on the surface of the male collar that comes into contact with the upper surface of the female mold, Using a mold provided with a plurality of grooves for discharging steam generated by heating of the batter filled inside the mold, the surfaces where both male and female molds are in contact are completely adhered and fired. It is the manufacturing method of the edible container characterized.
[0011]
In a preferred embodiment of the production method of the present invention, when the female mold is filled with batter and the male mold is fitted to the female mold, the male mold is so arranged that the internal batter spreads uniformly in the gap between the male mold and the female mold. Move up and down multiple times. In this way, the batter not only spreads uniformly in the voids, but also heat is transferred from the preheated mold, and starch gelatinization / swelling begins uniformly, and each part of the product is uniformly swelled and baked .
[0012]
Further, in the manufacturing apparatus for firing an edible container mainly made of flour using a male mold and a female mold, the present invention has a male collar surface in contact with the upper surface of the female mold. Provided with a plurality of grooves for discharging the steam generated by heating the batter filled in the mold to the outside, and further provided with a lock mechanism to maintain the contact state of the contact surfaces of both male and female molds It is the manufacturing apparatus of the edible container characterized.
[0013]
In a preferred embodiment of the manufacturing apparatus of the present invention, when the female mold is filled with batter and the male mold is fitted to the female mold, the male mold is so arranged that the internal batter spreads uniformly in the gap between the male mold and the female mold. A mechanism for moving up and down is provided. Thereby, not only the batter spreads uniformly in the gap, but each part of the product is uniformly swollen and fired.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, the surface of the male collar portion that contacts the upper surface of the female mold is provided with a plurality of grooves for discharging steam generated by heating the batter filled in the mold to the outside. The shape and size of the discharge groove are also important factors. These factors are governed by the size and shape of the edible container, the solid content of the batter, the amount of water added, the fluidity, etc., but the general conical corn cup (caliber 30 to 70 mm, length 50 to 170 mm, With an internal volume of 60 to 150 ml), the discharge groove provided on the surface of the male collar has a depth of 0.1 to 2.0 mm, preferably 0.2 to 1.0 mm, and a width of 1.0 to 5.0 mm. It is preferable that the length is 2.0 to 3.0 mm, and the length is from the outer periphery of the male collar to the base of the male cone. Alternatively, the length may be stopped to a position just before the gap between the inner surface of the female cone portion and the outer surface of the male cone portion (a gap corresponding to the width of the thick portion of the cone diameter portion). For reference, FIG. 1 (a) shows a cross-sectional view of a state in which a male mold and a female mold are closely fitted, and FIG. 1 (b) shows a view of the discharge groove of the male collar from the bottom.
[0015]
Depending on the shape and size of the cone cup, the exhaust effect of the swollen air / steam from the discharge groove may not be sufficient, so the shape and size of the discharge groove must be fully considered. A plurality of discharge grooves are provided in a symmetrical arrangement, and preferably 4 to 8 discharge grooves. In addition, in order to make it easy to completely contact the contact surfaces of both the male and female molds, an inclination or a step can be provided on the contact surfaces. In the conventional method, about 5 to 8% of the total raw material solids used were burrs. By doing so, the burrs were reduced to about 1/5.
In addition, although it tried also to provide a discharge groove | channel in a female type | mold or both instead of a male type | mold, the case where the discharge groove | channel was installed only in the male type | mold resulted in the most preferable state.
[0016]
When baking edible containers using male and female molds, the starch in the batter swells and gelatinizes to increase the volume, and when the pressure inside the mold rises, the male mold is pushed up by that force. As a result, the gap between the male mold and the female mold becomes large. In the apparatus of the present invention, in order to prevent this, a lock mechanism is provided so that the surfaces of the male and female molds that come into contact with each other can be completely adhered. As the lock mechanism, a conventionally known one can be used. For example, when the male mold is in close contact with the female mold, a mechanism capable of holding both molds by pressing from above is used. In this case, the force with which the lock mechanism holds the male mold needs to be strong enough that the male mold can hardly be lifted even if the internal pressure rises due to the heating of the batter. In the conventional type, the internal pressure increased and the lock mechanism was destroyed. However, in the present invention, since the discharge groove is formed, the worry is eliminated.
[0017]
In the apparatus of the present invention, when a female mold is filled with a batter and the male mold is fitted to the female mold, the male mold is not lowered and combined with the female mold at one time. It is preferable to provide a mechanism that causes the male mold to move up and down 2 to 15 times so that the batter that has not been heated yet spreads uniformly in the gap between the male mold and the female mold.
[0018]
【Example】
The present invention will be specifically described by the following examples, but the present invention is not limited thereto.
[0019]
A rotary-type baking apparatus was used in which 40 baking molds were arranged in a disk-shaped circumferential portion and rotated once in about 2 minutes and 20 seconds. About 60% of the circumference is heated by the gas burner. In this device, the mold after firing is separated from the heating part, moving the circumferential part at a constant speed, the female mold is opened in a double-spreading manner, the fired product is detached and dropped, and the male mold is It automatically lifts away from the female mold, and then the female mold returns to its original position and is filled with a new amount of batter. At that time, the male mold descends into the female mold, and both molds come into close contact, and the vertical movement is repeated 10 to 20 mm at intervals of 2 to 3 seconds, and the internal batter is placed in the gap between the male mold and female mold. Spread evenly. Thereafter, both the male and female molds are fitted, and then the press lock mechanism is lowered to maintain the close contact state of both molds. Since the mold is sufficiently heated in advance, the starch of the batter starts to swell and gelatinizes immediately, and after about 5 to 6 seconds, the mold overflows, and the batter is partially discharged from the discharge groove together with the steam. . Subsequently, the gas flame enters the heating part directly hitting the mold from the upper and lower sides and is fired.
[0020]
The shape of the conical male and female molds used is as shown in FIG. 1, and the sizes are as follows:

[0021]
The batter used to produce the edible container is a mixture of 25 kg of wheat flour, 7 kg of corn starch, 3 kg of sugar, 1 kg of vegetable oil and an appropriate amount of a swelling agent, an emulsifier, a fragrance and the like mixed with 33 l of water.
[0022]
When a conical edible container was produced under the above conditions, a burr having a total solid content of about 4% by weight was produced in the conventional method. However, in the method of the present invention, thin scaly waste was about 1%. Only ˜1.5% by weight was produced, and there was no need for deburring. Moreover, there was no peeling or chipping of the surface skin layer, and there was no problem in the appearance shape. The non-defective product rate of the baked product was 98% or more.
[0023]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the edible container excellent in the external appearance which does not produce a burr | flash part substantially can be manufactured with a high yield.
[Brief description of the drawings]
1A is a cross-sectional view of a state in which a male mold and a female mold are in close contact with each other, and FIG. 1B is a view of the male mold of FIG.

Claims

In the manufacturing method of baking edible containers made mainly of flour using male and female molds, the mold is filled into the surface of the male collar that contacts the upper surface of the female mold. A plurality of grooves for discharging the steam generated by heating the batter to the outside, from the outer periphery of the male collar, to the male cone in the gap between the inner surface of the female cone and the outer surface of the male cone A method for producing an edible container, characterized in that, using a mold provided to a position slightly before the root of the base, the surfaces of both the male and female molds in contact are completely brought into close contact and fired.

The female mold is filled with batter, and when the male mold is fitted to the female mold, the male mold is moved up and down several times so that the internal batter spreads uniformly in the gap between the male mold and the female mold. The manufacturing method of the edible container of Claim 1.

Filling the inside of the mold on the surface of the collar part of the male mold that comes into contact with the upper surface of the female mold, in a manufacturing device that uses a male mold and a female mold to bake edible containers made mainly from flour. A plurality of grooves for discharging the steam generated by heating the batter to the outside, from the outer periphery of the male collar, to the male cone in the gap between the inner surface of the female cone and the outer surface of the male cone An apparatus for producing an edible container, characterized in that a lock mechanism is provided to a position slightly before the base of the base and further to maintain a close contact state between the surfaces of both the male and female molds in contact with each other.

Features a mechanism that moves the male mold up and down so that the batter inside the female mold fills the gap between the male mold and female mold when the female mold is filled with the batter and the male mold fits into the female mold. The edible container manufacturing apparatus according to claim 3.