CN103494285A - 一种活性乳酸菌果蔬饮料基料的生产方法及其发酵装置 - Google Patents
一种活性乳酸菌果蔬饮料基料的生产方法及其发酵装置 Download PDFInfo
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Abstract
本发明提供了一种活性乳酸菌果蔬饮料基料的生产方法及其发酵装置,用泡菜发酵液、果菜浆、冷开水按一定配比,经多级扩大发酵制得一定量的发酵液,再以此发酵液、活性乳酸菌冻干粉和由冷加工复配的多种果菜浆汁,经乳酸菌水封厌氧发酵,制成活性乳酸菌果蔬饮料基料。用此基料和糖水冲调出的饮料酸甜清爽,维生素和矿物质及各种酵素酶含量丰富,初期活性乳酸菌数≥5×107cfu/ml,基料可常温贮存,保质期一年。发酵装置由汁液罐、浆料罐、保温水箱、温度自动控制、T型管道过滤器、进排料阀、水封构件等组成,汁液罐与浆料罐通过管道过滤器连通。
Description
一.技术领域:本发明涉及食品与发酵领域,是一种活性乳酸菌果蔬饮料基料的生产方法及其发酵装置。
二.背景技术:
我国2012年水果产量1.5亿吨左右,蔬菜超过7亿吨,是世界第一大果蔬生产国,但是水果和蔬菜的加工转化能力分别只有6%和10%,果蔬采后损失率高达25%~30%,提高果蔬的加工转化能力和降低采后损失率具有重大的社会效益和经济效益。
乳酸菌活菌体及其代谢产物对人体有多方面显著的保健作用,我国活性乳酸菌制品基本都是以鲜乳或乳制品为原料经乳酸菌发酵制得,以水果和蔬菜为原料经乳酸菌发酵生产的饮料很少,一般都是要将水果和蔬菜加热熟化处理,混以乳制品,再经乳酸菌发酵制得,但要冷链贮存,保值期很短,一般20天到30天,加工品种基本上只有番茄、胡萝卜、黄瓜等少数蔬菜。单纯用水果和蔬菜为原料经乳酸菌发酵制成饮料的学术讨论和科研论文在许多期刊杂志上多有发表,但是真正用于生产实践的极少。活性乳酸菌果蔬饮料基料不需冷链贮存,保值期超过一年,如此保值期长的活性乳酸菌果蔬饮料产品还未见诸报道。
水果和蔬菜不仅营养价值高,而且还含有许多对人体非常有益的生物活性物质,特别是有些品种蔬菜,对维持人体正常生理功能、生长发育、防治疾病、延缓衰老等方面都具有特殊的作用,但往往这些品种蔬菜制成饮料口味很差,例如苦瓜、洋葱、大蒜、苦苦菜、菌类等,消费者难以接受。如何通过冷加工制备成果蔬浆汁饮料,最大程度地保留水果和蔬菜的营养和各种生物活性物质,充分利用各种蔬菜的药食价值,是值得开拓和研究的课题。
三.发明内容:
为了实现上述目标,本发明提供一种活性乳酸菌果蔬饮料基料的生产方法及其发酵装置,发酵装置见说明书附图。
附图说明:图1是发酵装置结构示意图。
图中标记:(1)电加热控制器、(2)温度传感器、(3)泄流阀、(4)固定横梁、(5)窥视透镜、(6)水封槽外沿、(7)水封槽内沿、(8)水封盖、(9)汁液罐、(10)汁液罐进料阀、(11)进水阀、(12)空气除菌过滤器、(13)浆料罐进料阀、(14)T型管道过滤器、(15)浆料罐、(16)罐体支架、(17)保温水箱、(18)水箱支架、(19)浆渣放料阀、(20)放水阀、(21)汁液放料阀。
汁液罐、浆料罐、水封盖、水封槽、T型管道过滤器、进水阀、汁液罐进料阀、浆料罐进料阀、浆渣放料阀、放水阀、汁液放料阀全部为不锈钢材质;汁液罐、浆料罐套在保温水箱中,通过固定横梁、罐体支架、浆渣放料阀、放水阀、汁液放料阀连接,保温水箱材质为碳钢;T型管道过滤器管道通径≥200mm,过滤网孔径≥80目;浆料罐进料阀、浆渣放料阀通径≥80mm,汁液罐进料阀、汁液放料阀通径≥50mm;空气除菌过滤器在放料时开启,其它状态时关闭;电加热控制器和温度传感器组成温度检测、电加热闭环控制系统,加热温度设定后,系统自动控制保温水箱水温。
活性乳酸菌果蔬饮料基料的生产方法包括以下步骤:
1.果菜饮料汁基料:
a.水果和蔬菜前处理
选用无霉烂变质的新鲜水果,或蔬菜,或多种水果,或多种蔬菜,或水果加蔬菜,或其它可食药用的植物,先用水冲洗掉表面污物,在1%~2%碱水中浸泡15分钟,漂洗干净后沥干表面水分,打成果菜浆,即时使用。
b.发酵液扩培
引入沒有杂菌污染的农家泡菜发酵液5~6份,糖分多的果菜浆汁1份,冷开水4~3份,加入发酵液、果菜浆、冷开水总重量0.01%的商品活性乳酸菌冻干粉,在发酵罐中水封厌氧发酵,发酵温度设定在30℃~33℃,时间24小时,通过多次扩培,制得一定量的发酵液,其PH值≤3.2,总酸量(以乳酸计)≥0.8%,活性乳酸菌数≥5×107cfu/ml,冻干粉中的主要菌种为植物乳杆菌、嗜酸乳杆菌、干酪乳杆菌、乳酸链球菌。
c.果菜浆汁乳酸菌发酵
浆料罐装入其总容量5%~10%的发酵液,将果菜浆汁流加到浆料罐中,用12小时将浆料罐装滿,并分4~6次将果菜浆汁总重量0.01%的商品活性乳酸菌冻干粉均量投入浆料罐中,继续发酵12~18小时后将汁液罐中的果菜发酵汁输入成品罐中再进入商品灌装。
d.压榨过滤发酵果菜浆回收发酵汁液
将浆料罐中的发酵果菜浆压榨过滤,过滤的发酵汁液输入中转罐中,待浆料罐中的发酵果菜浆排放完后再回放到浆料罐中,至装入总容量5%~10%的发酵汁液后,多余部分输入成品罐。压榨过的果菜渣经低温流化床干燥,是替代抗生素的饲料添加物。
2.果菜饮料浓浆基料:
水果和蔬菜前处理和发酵液扩培与前款相同,浆料罐与汁液罐用管道堵头隔断。
果菜浆汁用4~6小时流加到浆料罐中发酵,发酵6小时后用胶体磨将果菜浆汁发酵液进行研磨,边研磨边泵入汁液罐,留存5%~10%的果菜浆汁发酵液作后续生产用,分多次均量装入果菜浆汁总重量0.01%的活性乳酸菌冻干粉到汁液罐中,继续发酵8~12小时后,从汁液罐中排出成品果菜饮料浓浆基料。
本发明提供的活性乳酸菌果蔬饮料基料有如下优点:
1.活性乳酸菌含量高
我国酸奶国家标准GB19302-2010规定乳酸菌数≥1×106cfu/ml,市售酸奶常温贮存30天后,乳酸菌数将逐日大幅下降,很快少于1×106cfu/ml,活性乳酸菌果蔬饮料基料常温贮存30天内乳酸菌数≥1×107cfu/ml,常温贮存一年内乳酸菌数≥1×106cfu/ml。与动物性乳酸菌相比,植物性乳酸菌耐酸、耐胆盐及定植人体肠道能力更强,在改善肠道环境、提高人体免疫力方面更有优势。
2.无需冷链贮存,保质期长
目前市售活性乳酸菌饮料需要冷链贮存,保质期一般在20天~30天,活性乳酸菌果蔬饮料基料无需冷链贮存,也无需添加任何防腐剂、增稠剂、稳定剂、食用色素和香精,保质期长达一年以上。
3.口感纯正,风味好,营养丰富
生蔬菜汁有青草味或者辛辣味,很难入口,加温杀菌后有一股腐败味、蒸煮味,也难入口,本发明用冷加工打碎果蔬制浆、上千倍的增大果蔬组织发酵接触面、浆料置入较大容量低PH值发酵液环境、及果蔬浆汁流加的乳酸菌发酵生产工艺,基本消除了青草味或土腥味,辛辣味残留较少,与特征香味较浓的水果复配发酵后,比较容易掩饰一些残留不好的异味。乳酸菌发酵过程中产生的乳酸和醋酸等有机酸酸味爽口柔和,产生的微量双乙酰使之有奶香味,乳酸与醇结合生成的酯具有花果香味。本发明全工序加工温度不超过40℃,维生素和矿物质保留更多更全面,如维生素C不仅沒流失,在乳酸菌作用下含量还会成倍增加,特别是保留了果蔬中许多对人体非常有益的生物活性物质,如各种酵素酶。
4.资源利用度高
本发明所用的水果和蔬菜品种很多,特别是蔬菜,除了不经加热有毒性和淀粉含量很高的部分薯类外,基本所有蔬菜,包括食用菌、水生蔬菜、各种野菜、可食用花卉和其它可食用植物都可以用来加工。
5.绿色环保
本发明生产过程产生的洗涤废水较容易处理重复使用,污水、废渣很少,不产生废气、噪声,无腐蚀和辐射,清洁环保。
6.能耗低
本发明生产用水用电很少,每吨饮料耗水不到3吨,耗电低于3kw,不用蒸汽,综合能耗≤7kgce/t,目前各饮料厂家碳酸饮料的综合能耗在15kgce/t左右,果蔬饮料在30kgce/t左右。
7.生产工艺简单,生产人员少,设备投资少,生产成本低
本发明生产工序环节少,控制因素少,控制精度要求低,同等生产量果蔬饮料,本发明生产人员少1/4~1/3,设备、厂房等投资少50%~70%,生产成本低40%左右。
四.具体实施方式:
1.菠萝四瓜汁乳酸菌饮料基料
a.选用无霉烂变质的整体苦瓜、东瓜、南瓜、哈密瓜、菠萝各20%,先用水冲洗掉表面污物,在1%~2%碱水中浸泡15分钟,漂洗干净后沥干表面水分,打成果菜浆,即时使用。
b.乳酸菌发酵液6份,菠萝四瓜浆汁1份,冷开水3份,加入发酵液、果瓜浆汁、冷开水总重量0.01%的商品活性乳酸菌冻干粉,在发酵罐中水封厌氧发酵,发酵温度设定在30℃~33℃,时间24小时,通过多次扩培,制得一定量的果瓜浆汁发酵液,
c.浆料罐装入其总容量5%的果瓜浆汁发酵液,将上述果瓜浆汁流加到浆料罐中,用12小时将浆料罐装滿,并分4~6次将果瓜浆总重量0.01%的商品活性乳酸菌冻干粉均量投入浆料罐中,继续发酵12~18小时后将汁液罐中的果瓜发酵汁输入成品罐中再进入商品灌装。
d.将浆料罐中的发酵果瓜浆压榨过滤,回收的果瓜发酵汁液输入中转罐中,待浆料罐中的发酵果瓜浆排放完后,再将果瓜发酵汁液回放到浆料罐中,至装入总容量5%~的果瓜发酵液后,多余部分输入成品罐。原料与发酵汁液产出平均收得率在88%以上。
该饮料基料一份,用13%白糖水三份冲调后,是一款酸甜清爽,维生素和矿物质及各种酵素酶含量丰富,保健作用很好的乳酸菌果蔬汁饮料,后味带点清凉爽口的微苦。
2.黑木耳、洋葱、茄子、花菜、甜橙浓浆乳酸菌饮料基料
a.黑木耳4%份量,浸泡5小时,选用无霉烂变质的整体洋葱24%份量、茄子24%份量、芹菜24%份量菜、甜橙24%份量,先用水冲洗掉表面污物,在1%~2%碱水中浸泡15分钟,连同黑木耳漂洗干净后沥干表面水分,打成果菜浆,即时使用。
b.乳酸菌发酵液6份,黑木耳、洋葱、茄子、芹菜、甜橙浆汁1份,冷开水3份,加入发酵液、果菜浆汁、冷开水总重量0.01%的商品活性乳酸菌冻干粉,在发酵罐中水封厌氧发酵,发酵温度设定在30℃~33℃,时间24小时,通过多次扩培,制得一定量的果菜浆汁发酵液,
c.去掉浆料罐与汁液罐连通的T型管道过滤器中的过滤网,換上管道堵头,装入浆料罐总容量5%的果菜浆汁发酵液,将前述果菜浆汁流加到浆料罐中,用6小时将浆料罐装滿,继续发酵6小时后用胶体磨将发酵果菜浓浆进行研磨,边研磨边泵入汁液罐,留存5%的发酵果菜浓浆在浆料罐备用,研磨细度≥200目。并分4次将果菜浆总重量0.01%的商品活性乳酸菌冻干粉均量投入汁液罐中,继续发酵8~12小时后将汁液罐中的发酵果菜浓浆输入成品罐中再进入商品灌装。因黑木耳水发后重量增大了10倍,原料与发酵果菜浓浆产出平均收得率在130%以上。
该饮料基料一份,用15%白糖水三份冲调后,是一款酸甜绵稠,维生素和矿物质及各种酵素酶含量丰富,保健作用很好的乳酸菌果蔬浆高膳食纤维饮料,蔬菜中的异味基本除掉,少数味觉特别敏感的人群会有察觉,甜橙特征香气浓郁。
Claims (10)
1.一种活性乳酸菌果蔬饮料基料的生产方法,该方法包括以下步骤:
a)选用无霉烂变质的新鲜果蔬用水冲洗掉表面污物,在1%~2%碱水中浸泡15分钟,漂洗干净后沥干表面水分,打成果菜浆。按泡菜水发酵液、果菜浆、冷开水5~6∶1∶4~3的比例和三种原料总重量0.01%的活性乳酸菌冻干粉,在浆料罐中发酵,通过多次扩培,制得一定量的果菜浆发酵液。
b)浆料罐与汁液罐用T型管道过滤器连通,浆料罐中装入5%~10%的果菜浆发酵液,用8~12小时将果菜浆流加到浆料罐中,并分多次均量装入果菜浆总重量0.01%的活性乳酸菌冻干粉,继续发酵12~18小时后,从汁液罐中排出成品果菜饮料汁基料输到成品罐。浆料罐中的发酵果蔬浆留5%~10%作后续生产用发酵液,其余经压榨后的果菜饮料汁基料输到成品罐。
c)果菜饮料浓浆基料与果菜饮料汁基料生产方法不同处是:浆料罐与汁液罐隔断,果菜浆用4~6小时流加到浆料罐中发酵,发酵6小时后用胶体磨将果菜浆发酵液进行研磨,边研磨边泵入汁液罐,留存5%~10%的果菜浆发酵液作后续生产用,分多次均量装入果菜浆总重量0.01%的活性乳酸菌冻干粉到汁液罐中,继续发酵8~12小时后,从汁液罐中排出成品果菜饮料浓浆基料。
2.根据权利要求1所述的活性乳酸菌果蔬饮料基料的生产方法,其特征是:所述的发酵为乳酸菌水封厌氧发酵,发酵温度设定在30℃~33℃。
3.根据权利要求1所述的活性乳酸菌果蔬饮料基料的生产方法,其特征是:活性乳酸菌冻干粉是商用的植物乳杆菌、嗜酸乳杆菌、干酪乳杆菌、乳酸链球菌的多菌种组合。
4.根据权利要求1所述的活性乳酸菌果蔬饮料基料的生产方法,其特征是:所指果蔬为一种水果、或多种水果、或一种蔬菜、或多种蔬菜、或水果和蔬菜,蔬菜中还包括食用菌、水生蔬菜、各种野菜、可食用花卉及其它可食用植物;各种果蔬加工处理时温度均不超过40℃。
5.根据权利要求1所述的活性乳酸菌果蔬饮料基料的生产方法,其特征是:饮料基料为饮料汁基料和饮料浓浆基料。
6.根据权利要求1所述的活性乳酸菌果蔬饮料基料的生产方法,其特征是:胶体磨研磨细度≥200目。
7.一种活性乳酸菌果蔬饮料基料的发酵装置,其特征是:汁液罐与浆料罐置于保温水箱中,通过固定横梁、罐体支架、浆渣放料阀、放水阀、汁液放料阀固定连接,并用T型管道过滤器相互连通,窥视透镜设在两罐上沿;发酵原料通过汁液罐进料阀、浆料罐进料阀输入;水封槽外沿高度低于水封槽内沿,水封盖用于隔离罐外空气进入、外排罐内二氧化碳气体,并兼作检修用,泄流阀用于泄流水封槽内脏水;空气除菌过滤器在排料时打开,其它工序时关闭;进水阀的出水口置于保温水箱的上方,保温水箱的底部用多个水箱支架支撑,电加热控制器的电加热部分在保温水箱内,控制部分在保温水箱外壁上,温度传感器检测保温水箱内水的温度。
8.根据权利要求7所述的一种活性乳酸菌果蔬饮料基料的发酵装置,其特征在于:T型管道过滤器的过滤孔径80~150目,过滤器按工艺需要可封堵。
9.根据权利要求7所述的一种活性乳酸菌果蔬饮料基料的发酵装置,其特征在于:电加热控制器和温度传感器组成温度检测、电加热闭环控制系统,加热温度设定后,系统自动控制水箱内水温。
10.根据权利要求7所述的一种活性乳酸菌果蔬饮料基料的发酵装置,其特征在于:所有与发酵原料和成品接触的构件为不绣钢材质或符合食品卫生安全的塑胶材质。
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CN108244429A (zh) * | 2018-01-09 | 2018-07-06 | 安徽妙奇树生物科技有限公司 | 一种哈密瓜复合酵素饮品的制备方法 |
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