, Vol. 11, No. 1, pp. 13-18, Mar. 2010 1, 2 3 1 2 3 Development the Ready-to-Heat Foods with Cooked Rice Aseptically Packed (KAGOME DELI) Tetsuya FUKAYA 1,, Kinya SAKUMA 2, and Ryuichi TSUTSUMI 3 1 KAGOME CO., LTD., Research Institute, 17 Nishitomiyama, Nasushiobara, Tochigi 329-2762, Japan 2 Nitto Aliment Corporation, 1578-4 Okada, Shibata, Niigata 957-0356, Japan 3 HISAKA WORKS, LTD., 2-1-48 Higashikounoike, HigashiOsaka, Osaka 578-0973, Japan Sales of the ready-to-heat foods with cooked rice aseptically packed have increased manyfold in Japan over the past 10 years. Cooked rice aseptically packed is better taste and higher quality, as compared with retort-pouch cooked rice. KAGOME DELI that was started to sale from 1999 by KAGOME Co., Ltd., was very unique in microwave oven cooking foods. It was made up of the cooked rice aseptically packed and the retort-pouch cooking sauce (eg. for Risotto, Chicken Rice, and Doria). Consumer could cook these using a microwave oven during two minutes only, and take in the low-calorie (lower 300 kcal/menu). In this report, two technical considerations were suggested on the development process of KAGOME DELI. These were microorganism control, package development, for cooked rice aseptically packed. To improve safety of the cooked rice aseptically packed, it is preferable that cooked rice is adjusted ph 4.9 or below and 5.0% or more oxygen concentration of head space. And higher usability package for cooked rice was able to be developed by understanding the relation between the strength of sealing and peeling. Keywords: KAGOME DELI, ready-to-heat, cooked rice, aseptic, risotto, microorganism control, package, Clostridium botulinum, Bacillus subtilis, usability 1 NASA 1999 54,000 2008 98,000 1.8 [i] 1999 2010 1 12 2010 2 20 1 329-276217 2 957-03561578-4 3 578-09732 1 48 Fax: 0287-39-1038, E-mail: Tetsuya_Fukaya@kagome.co.jp 96.5 [ii] 2 1 300 kcal 100
14 2 Fig. 1 Fig. 2 120 20 RIC 130 20 100NASA 0.5 m ft 3 ph 1 1 105 100 RIC Fig. 3 3 100 2 3.1 3.1.1 Clostridium botulinum Bacillus subtilis 2 Fig. 1 Manufacturing process of cooked rice. Fig. 2 Components of production process for cooked rice aseptically packed. Fig. 3 Historical heat on model process of cooked rice.
15 3.1.2 3.1.2.1 C. botulinum C. botulinum 15 6 A 5 56A 62A, 97A, Hall, Renkon-1B 5 9B, 213B, 407-1, Fukuyama, Okra 10 C. botulinum 10 4 CFU/ml8010 100l 10 30 ph Figs. 45 18 0.5 ph ph4.76.2 9 C. botulinum 5 10 153020 C. botulinum 0.1 1 ph 5.2 7 C. botulinum ph 4.74.9 2 20 C. botulinum ph C. botulinum B. subtilis ph 6.5 Figs. 67 4 0.5 5.19.815 B. subtilis 1 4 Fig. 6 Effect of oxygen concentrations on B. subtilis growth. Fig. 4 Effect of ph on the growth of C.botulinum in cooked rice under around 0.5% oxygen. Fig. 5 Effect of ph on the growth of C.botulinum in cooked rice under around 0.1% oxygen using deoxydant. Fig. 7 Effect of oxygen concentrations on C. botulunum growth and toxin type.
16 5.1 3 1 C. botulinum 1 1 0.55.1 2 5.1 1 0.5 C. botulinum B. subtilis 5 C. botulinum 5 3.1.2.2 B. subtilis B. subtilis 2 B801 B802 1/15N ph Tables 1, 2, 3 ph 4.65.0 7.0 B801 B802 ph B802 B801 1.010-5 CFU/g 100 g 1.010-3 CFU 1.010-5 CFU F2D i i ph 5.0 B801 D 98 15.4 2D 98 30.8 981520 B801 B801 ph ph7.0 10620.8 ph5.0 9830.8 1048.2 ph4.6 984.8 ph 7.0 10620 Table 1 Heat resistance of B.subtilis B801 and B802 strain in 1/15M phosphate buffer (ph 4.6). ph4.6 Temperature () strain B801 B802 94 7.7 3.5 D value 96 4.9 3.0 (min) 98 2.4 2.0 100 1.6 0.9 Z value () 8.5 10.3 Table 2 Heat resistance of B.subtilis B801 and B802 strain in 1/15M phosphate buffer (ph 5.0). ph7.0 Temperature () strain B801 B802 106 10.4 8.8 D value 108 6.3 5.8 (min) 110 4.4 4.2 112 2.6 2.3 114 1.6 1.2 Z value () 10.0 9.5 Table 2 Heat resistance of B.subtilis B801 and B802 strain in 1/15M phosphate buffer (ph 7.0). ph5.0 Temperature () strain B801 B802 96-15.4 D value 98 15.4 11.8 (min) 100 11.2 8.2 102 6.6 4.8 104 4.1 2.9 106 2.6 - Z value () 10.1 10.6 ph 5.0 B. subtilis 105 ph 4.6 981520 3.1.3 100 ph 4.6 105
17 5 3.2 3.2.1 3.2.2 15 mm 300 mm/min 180 200 mm/ min 90 1530N 5 13N/15 mm Fig. 8 4 Fig. 9 4 4 513N/15 mm 6 1 4 22 1G5 1G5 Fig. 8 Relation between strength of sealing and peeling. 1 80 cm 1 3 6 3.2.3 10010 25 4 100 1.2 0.9 0.3 4 Fig. 9 Change of strength each sealing head in long-run test.
18 5 1) K. SakuTna, H. Katoda, T. Fukaya, T. Joh, A. Ito, A. Watanabe; A study on commercial sterility of cooked rice packed under semi-aseptic condition from the view point of cooking condition (in Japanese). Japan J. Food. Eng., 8, 295-304 (2007). 2) K. Sakuma, H. Katoda, T. Fukaya, T. Job, A. Ito, A. Watanabe; Effect of cooking water ph on commercial sterility in the production of cooked rice packed under semi-aseptic condition (in Japanese). Japan J. Food, Eng., 9, 157-165 (2008). 3) Y. Kasai, B. Kimura, S. Kawasaki, T. Fukaya, K. Sakuma, T. Fujii; Growth and Toxin Production by Clostridium botulinum in Steamed Rice Aseptically Packed under Modified Atmosphere, J. Food Protection, 68, 1005-1011 (2005). 4) B. Kimura, R. Kimura, T. Fukaya, K. Sakuma, S. Miya, T. Fujii; Growth and Toxin Production of Proteolytic Clostridium Botulinum in Aseptically Steamed Rice Products at ph 4.6 to 6.8, Packed under Modified Atmosphere, Using a Deoxidant Pack, J. Food Protection, 71, 468-472 (2008). U R L i) www.syokuryo.maff.go.jp/kasyoku/tyousa/newkekka/02. pdf (Feb.19.2010). ii) www.esri.cao.go.jp/jp/stat/shouhi/quarter/0403fukyuritsu. xls (Feb.15.2010). ready-to-heat 10 1999 2 1 300 kcal C. botulinum ph 4.9 5 C. botulinum 5 ph 5.0 B. subtilis 105 15 30N 513 N/15 mm 10010 1.2