CN103876202B - 一种生鲜板栗包装产品的加工方法 - Google Patents
一种生鲜板栗包装产品的加工方法 Download PDFInfo
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- CN103876202B CN103876202B CN201410047402.7A CN201410047402A CN103876202B CN 103876202 B CN103876202 B CN 103876202B CN 201410047402 A CN201410047402 A CN 201410047402A CN 103876202 B CN103876202 B CN 103876202B
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Abstract
本发明提供了一种生鲜板栗包装产品的加工方法，所述方法包括：取生鲜去刺球板栗，用剪刀在板栗壳上剪出切口，40～50℃热风干燥30～60min后，手工去壳、去衣，用1～3ppm臭氧水浸泡30～45min，然后于80～90℃保鲜护色液中漂烫5～10s后，立即放入5～10℃的保鲜护色液中超声处理30～45min，再2～8℃冷藏10～16h后，-18～-48℃预冻10～16h，最后干燥48～72h至含水量为10～18%，于洁净环境下真空包装，即得所述生鲜板栗包装产品；所得产品色、香、味、形均保持良好，且可以较长时间（2个月）在室温下贮运和大众的农贸市场批发销售，不仅适合家庭和商业餐饮的烹调制作，也适合板栗食品厂的二次加工销售，经试销，深受各类消费者的青睐。
Description
（一）技术领域
本发明涉及一种生鲜板栗包装产品的加工方法。
（二）背景技术
板栗（Castanea mollissima Blume）又称栗子，属壳斗科（Fagaceae）栗属坚果类植物，原产于我国，分布区域广泛、品种丰富，不仅是我国传统的农副产品，也是世界上重要的干果之一。板栗是我国的主要经济树种之一，素有“木本粮食”、“铁杆庄稼”和“干果之王”之美称。
板栗不仅营养成分丰富，而且中医研究还认为板栗味甘平、性温、入脾、胃、肾、无毒，还有益气补血、补肾厚肠、调脾养肝、活血止血等食疗功效。此外，板栗果实肉质细腻、香甜可口、风味独特、男女老少皆宜，是深受广大消费者欢迎的大众健康食品。
但现有传统简单的食用方法、相对较难的保藏技术和采收后不能及时加工，导致优质的板栗资源没能得到科学、合理和充分利用。
板栗采后的含水量约在50%左右，呼吸强度比许多水果还高，因此极易腐烂，新陈代谢及呼吸作用还会消耗体内积累的物质，随着时间增长，其生理性状和化学成分也会发生变化。另外，板栗在生长时常遭到栗食象鼻虫、桃蛀螟等的侵害和繁殖而造成板栗腐烂、霉变。据统计，每年因霉烂、虫害、失水和发芽而造成的采后损失达总产量的35%～50%，损失巨大。现有的板栗贮藏保鲜技术研究主要包括：冷藏、辐照、气调保鲜和涂膜保鲜等。贮藏前后各品种的含水量、脂肪含量、可溶性蛋白质含量、淀粉含量、可溶性糖含量均呈显著性差异。其中冷藏是目前国内贮藏板栗广泛使用的方法，它虽能延长贮藏时间，但在贮藏后期品质下降明显，失水严重，不能达到高标准。
另外传统冷藏的板栗原料普遍的销售渠道为批发和农贸市场路线，产品类型绝大多数为仅仅剥去最外层的刺球的板栗，还残留有内层的褐色的硬壳和囊衣。客户买过去之后还得去除坚硬的外壳和板栗仁衣，不仅耗时耗力，十分麻烦，而且也产生了多余的闲散垃圾，另外这种直接销售的初级板栗产品无任何抑菌和灭菌处理，常温保质期很短，时间长了会脱水和褐变，长期保藏需冷藏冷冻。同样对于生产厂家和销售商来说运输过程最好需冷链，限制了远距离大范围销售，同样也照成多年来板栗销售不畅，储运过程损失巨大等现象，严重影响了板栗产业。
随着我国城镇化发展，生活节奏加快，消费者更加喜欢干净、方便、快捷、美观、安全和营养的食品。原有的板栗初级农产品很难满足消费者的高要求。
目前有关板栗加工的研究有罐头、糖炒板栗、栗脯、栗酱（栗糊，栗泥）、栗粉、栗糕、板栗饮料、板栗酒和速冻板栗仁等。随着生产的发展和技术的引进，目前市场上也出现了少量真空包装和充氮包装的软包装栗仁，其方便安全，风味隽美的特点受到了城乡居民的喜爱。但是，目前板栗包装产品绝大多数为高温杀菌后的熟制产品，不仅普遍存在严重的“褐变”问题，失去了板栗原有的鲜黄的色泽，影响了外观和销售品质，而且不适合进行再次更多类型的如各种菜肴烹饪等加工，限制了使用范围。另外虽然目前市场上有包装鲜品板栗销售，但有些是含保鲜液的包装产品，给人感觉有额外添加物，视觉上也不清爽，使用时候还得倒去液体，不是很方便。另外有些在生产中应用了甲基托布津、甲醛等工业用防腐杀菌剂和亚硫酸钠、高锰酸钾、次氯酸钠、苯甲酸钠、山梨酸钾等食品消毒剂和添加剂，虽然能延长保质期，但是在一定程度上给消费者带来了潜在食用危害。随着人们生活水平的提高和健康消费意识的增强，采用无污染、无危害的绿色添加剂生产板栗小包装生鲜品符合现代消费和社会潮流。
但是鲜品板栗的包装还是一个比较刺手的事。在生产加工阶段，褐变是最突出的问题，也是影响板栗成品质量的主要因素。鲜品板栗仁在空气中暴露，由于与氧接触酶促褐变很快就会引起褐变，酶促褐变是由多酚氧化酶（PPO）和过氧化物酶（POD）引起栗果中的酚类与单宁等成分氧化而产生的颜色变化。另外板栗本身和与环境接触还含有菌落，新鲜板栗本身还有呼吸作用，如果直接包装还会由微生物或呼吸作用产生涨袋，严重影响销售。但通过常规的高温漂烫等杀菌和灭酶工艺，也会立即产生非酶促褐变，非酶促褐变主要是由Maillard反应生成。目前一些常用的如次氯酸钠和亚硫酸盐漂白护色剂，虽然效果显著，但具有潜在食用安全风险，有些国家已禁止使用该类化学物品处理食品。另外在高温加热过程中板栗果肉会产生破碎和淀粉老化现象，影响了产品品质。因此，保持天然鲜黄色彩、不涨袋且保质期过关的板栗鲜品包装产品在市场上还十分少见。
在板栗抑制褐变和保鲜研究方面，虽然目前的文献和专利已有不少，但均存在差异性或品质有待改进问题：
（1）其中有些文献添加了对人体有潜在副作用的EDTA和NaHSO3（是一种不良的含硫护色方法）等化学制品或不良的辐照手段，食用安全性有待提高。
（2）在专利方面，有些护色时添加了不良的化学合成的EDTA、NaHSO3、焦亚硫酸钠、钾明矾、树脂或化学类食品防腐剂（如山梨酸钾等），以及物料的清洗和漂烫过程中使用了食用不安全的二氧化氯，或不良的辐照手段灭菌灭酶等。
（3）有些文献或专利是板栗原料的仓储式方法，不涉及终端的包装产品。如2005年浙江的陈建明对板栗在冷藏条件下的保鲜效果开展了试验，结果表明：板栗低温冷库（-2～2℃）贮藏15周，采用薄膜袋包装比采用编织袋包装可降低失水率约10个百分点；采用生物保鲜剂浸果处理（浸果3ｄ，在冷库内晾4ｄ）的失水率依次低于生物保鲜剂拌果、水洗与对照；所有处理的霉变率均在5%以下，以生物保鲜剂拌果、薄膜袋包装处理的最低。但文中为涉及具体的生物保鲜剂配方及比例，未涉及漂烫处理，薄膜袋包装也未涉及真空封口包装。
（4）有些文献或专利是板栗的涂膜保鲜，相对浸泡等方法，添加的外源物质较多，可能会对板栗的口感照成影响。如2010年河北农业大学的李亚新等人通过正交实验确定板栗仁涂膜液最佳配方为：壳聚糖1.5%，乙酸1.0%，明胶0.3%，甘油0.4%，单甘酯0.06%。2010年信阳农业高等专科学校的桑大席等人对板栗粉的护色研究发现，以0.25%柠檬酸、0.20%Vc、0.20%壳聚糖、0.35%NaCl处理的护色效果最好，得到的板栗粉为淡黄色。
（5）有些文献或专利是板栗的速冻产品，其后续储运和销售需要冷冻过程，增加了设备和成本，不利于生鲜板栗产品的农贸市场等大规模销售渠道推广。
（6）有些文献和专利不是以包装后的终端产品为导向，而且也没有相关的保质期数据。
（7）虽然有些文献或专利是板栗包装食品，但不是相关的生鲜板栗产品，而是熟制品（即食休闲产品）。一般有长时间炒制、水煮或后续长时间高温杀菌，或有些是带液体的玻璃罐头食品或粉碎后质地变化的板栗蓉制品。该类熟制品不仅普遍因高温过程的褐变现象。在产品的用途上与本专利也存在差异。
与本发明较接近的是2005年浙江徐康明的“一种板栗保鲜工艺”专利（CN1754435A）。该发明涉及一种板栗保鲜工艺，采用初选、分类、冷藏脱水、剥壳、精选、浸渍保鲜、真空包装、冷藏等步骤。发明解决了目前板栗难以长时间储藏的问题。其中冷藏、脱水：将分选均匀的板栗在进行冷藏，冷藏时间1～3个月，温度控制在-4℃到3℃，让板栗在冷藏室内自然脱水至板栗重量减轻1%～5%。浸渍、保鲜时采用的无菌水中添加有1/1000～3/1000的维生素E。但该专利中的前处理冷藏脱水时间较长，需要1～3个月，影响了规模生产的效率。另外保鲜液为仅含有1/1000～3/1000维生素E的无菌水，产品后续仍需冷藏（-4～3℃），未见易于流通环节的室温贮藏的描述。
（三）发明内容
本发明目的是提供一种食用安全、充分保持原有生板栗色香味形、保质期内包装良好的生鲜板栗包装产品的加工方法，以解决现有生鲜板栗保鲜过程中普遍添加有害化学添加剂、没有商品化包装、无法常温贮运等问题。
本发明采用的技术方案是：
一种生鲜板栗包装产品的加工方法，所述方法包括：取生鲜去刺球板栗，用剪刀在板栗壳上剪出切口，40～50℃热风干燥30～60min后，手工去壳、去衣，用1～3ppm臭氧水浸泡30～45min，然后于80～90℃保鲜护色液中漂烫5～10s后，立即放入5～10℃的保鲜护色液中超声处理30～45min，再2～8℃冷藏10～16h后，-18～-48℃预冻10～16h，最后干燥48～72h至含水量为10～18%，于洁净环境下真空包装，即得所述生鲜板栗包装产品；所述保鲜护色液组成如下：柠檬酸（食品级）0.4%～0.8%，Vc（食品级）0.4%～0.8%，食盐2%～3%，食醋0.1%～0.3%，乳酸链球菌素0.1%～0.3%，食用酒精2%～4%，胡萝卜素0.2%～0.4%，溶剂为水。
本发明专利采用臭氧水浸泡、保鲜护色液短时漂烫、冷冻干燥和真空包装等方法达到减菌、抑菌、抑酶、抑制褐变和抑制生鲜板栗呼吸作用，所生产的生鲜板栗真空包装产品具有食用安全、充分保持原有生板栗色香味、保质期内包装良好的等特点。有效解决了现有生鲜板栗保鲜过程中普遍添加有害化学添加剂、没有商品化包装、无法常温贮运等问题。可以较长时间（2个月）在室温下贮运和普通的农贸市场批发销售，不仅适合家庭和商业化餐饮的后续烹调制作，也适合板栗加工食品厂的二次加工销售。
步骤说明：
1.原料选择：一般板栗收购的时候基本是去刺球后的带壳板栗，选择果实饱满，外壳无虫孔、无病斑、无霉斑、无破损、无异味的新鲜带壳板栗为好。
2.带壳板栗小切口：用剪刀或刀片切板栗壳小口，以利于后续去壳。注意切口时不得损害板栗的果仁组织。
3.热风干燥：40～50℃热风干燥，30～60min，以利于板栗壳和衣的分离，便于后续的去衣。
4.手工去壳、去衣：以切口为开始位置，手工快速剥去板栗的壳和衣。注意去衣要完全，否则在后续的漂烫时会导致褐变。
5.去除劣质板栗：去除板栗果仁中有虫斑、霉斑、腐烂、裂开等的劣质板栗。
6.臭氧水浸泡：手工去壳和衣后立即放入1～3ppm的臭氧水中浸泡30～45min（DJ-W3030臭氧水机，金华市广源仪器厂），进行初步的减菌、抑菌、抑酶、抑制褐变和抑制生鲜板栗呼吸作用。臭氧是一种通过空气放电产生的具有强氧化作用的物质，对细菌、霉菌、病毒都有杀灭作用，近十余年来，在食品工业中，臭氧被用来提高食品货架寿命和安全性，被开发作为新的食品消毒剂。臭氧与化学合成品不同，其处理食品后快速分解为氧气，不残留任何有害物质，对人体健康无不良影响。即使在安全性要求很高的美国也被批准符合GRAS（通用安全标准）。EPRI（美国电力研究）专家委员会在1997就得出科学结论：明确公告臭氧应用于食品加工符合GRAS，臭氧在食品杀菌方面的应用有原料的清洗杀菌处理，制造过程中制品和支撑品的杀菌，水果蔬菜的清洗等。
7.保鲜液漂烫：臭氧水浸泡后立即在80～90℃的保鲜液中（水浴锅保温）漂烫5～10s，要严格控制温度和时间，过高的温度和过长的时间会造成板栗果仁的不可逆褐变。保鲜液的作用是减菌、抑菌、抑酶、抑制褐变（护色）和抑制生鲜板栗呼吸作用。
8.保鲜液冷藏：漂烫后的板栗仁需要迅速放入到10℃以下的保鲜液中，冰浴超声10～20min（探头式超声波处理器FS-1200，上海生析超声仪器有限公司），然后含板栗仁的保鲜液在4～8℃冷藏10～16h，超声和冷藏长时放置有利于板栗仁充分吸收保鲜剂，利于板栗仁的减菌、抑菌、抑酶、抑制褐变（护色）和抑制生鲜板栗呼吸作用。注意漂烫后要迅速放入低温的保鲜液中，否则漂烫后自然冷却的长时间高温会导致板栗仁褐变，冷藏时的保鲜液与漂烫时的保鲜液组成与比例一致。
9.预冻：在冻干前，-18～-48℃预冻10～16h。
10.冻干：冷冻干燥24～72h（德国Christ公司，Alpha2-4LD Plus），控制水分含量为10～18%（w/w），冻干后水分和水分活度减少，有利于抑制微生物的生长繁殖，同时也有利于生鲜板栗的呼吸作用，延长真空包装后的保质期。另外水分含量也不可太低，如果≤10%，则板栗仁不仅容易裂开，而且也不利于后续的复水加工使用。
11.包装：在洁净环境下，迅速对冻干后的板栗仁（1h以内）进行真空包装。包装材料预先经过紫外或臭氧水浸泡杀菌，包装时接触的手和容器也经过清洗消毒。其中包装袋的材料为复合透明蒸煮袋。
包装后的产品可采取的贮藏方式：-18℃冷冻贮藏、0～8℃冷藏和15～25℃常温贮藏，对产品进行色、香、味、形等感官和微生物指标检测之后，即可流通销售。
整个操作过程要轻柔，务使板栗仁不产生组织破碎导致的褐变。水分测定采用GB/T5009.3-2010，菌落总数测定采用GB4789.2-2010。感官测定部分采用中华人民共和国国内贸易行业标准《熟制板栗和仁SB/T10557-2009》，在光亮度为300lx～500lx条件下，将板栗仁置于清洁、干燥的白瓷盘中，用目测检查色泽、颗粒形态和杂质，嗅其气味，尝其滋味与口感，做出评价。
本发明的有益效果主要体现在：采用本发明生产方法，所得生鲜板栗包装产品的保质期可以达到冷冻（-12～-18℃，12个月）冷藏（0～4℃，5个月）和室温（15～25℃，2个月）三种要求，保质期内与生板栗相比色、香、味、形均保持良好，且不发生微生物或呼吸作用产生的涨袋现象，产品各方面品质良好。可以较长时间（2个月）在室温下贮运和大众的农贸市场批发销售，不仅适合家庭和商业餐饮的烹调制作，也适合板栗产品食品厂的二次加工销售，经试销，深受各类消费者的青睐。
（四）具体实施方式
下面结合具体实施例对本发明进行进一步描述，但本发明的保护范围并不仅限于此：
实施例1：
生鲜带壳板栗→剪刀人工剪小切口→40℃热风干燥30min→手工去壳、去衣→去除劣质板栗→3ppm臭氧水浸泡30min→80℃保鲜护色液（食品级柠檬酸0.5%，食品级Vc0.5%，食盐2.0%，食用醋酸0.2%，乳酸链球菌素0.2%，食用酒精2%，胡萝卜素0.2%，溶剂为水）漂烫5s→立即放入10℃以下的保鲜护色液，超声40min→6℃冷藏12h→-18℃预冻12h→冷冻干燥24h（至含水量为17.5%）→洁净环境下真空包装→生鲜板栗真空包装产品。
实施例2：
生鲜带壳板栗→剪刀人工剪小切口→50℃热风干燥60min→手工去壳、去衣→去除劣质板栗→1ppm臭氧水浸泡30min→85℃保鲜护色液（食品级柠檬酸0.6%，食品级Vc0.5%，食盐2%，食用醋酸0.1%，乳酸链球菌素0.2%，食用酒精2%，胡萝卜素0.3%，溶剂为水）漂烫8s→立即放入10℃以下的保鲜护色液，超声30min→4℃冷藏10h→-18℃预冻14h→冷冻干燥72h（至含水量为10.8%）→洁净环境下真空包装→生鲜板栗真空包装产品。
实施例3：
生鲜带壳板栗→剪刀人工剪小切口→45℃热风干燥40min→手工去壳、去衣→去除劣质板栗→2ppm臭氧水浸泡45min→90℃保鲜护色液（食品级柠檬酸0.6%，食品级Vc0.6%，食盐3%，食用醋酸0.3%，乳酸链球菌素0.3%，食用酒精3%，胡萝卜素0.4%，溶剂为水）漂烫10s→立即放入10℃以下的保鲜护色液，超声30min→4℃冷藏12h→-48℃预冻12h→冷冻干燥48h（至含水量为12.6%）→洁净环境下真空包装→生鲜板栗真空包装产品。
所得生鲜板栗包装产品保质期都可达冷冻12个月（-12～-18℃）冷藏5个月（0～4℃）和室温2个月（15～25℃）的要求，保质期内菌落总数≤10000cfu/g，与生板栗相比色、香、味、形均保持良好，且不发生微生物或呼吸作用产生的涨袋现象，产品各方面品质良好。
Claims (1)
1.一种生鲜板栗包装产品的加工方法，所述方法包括：取生鲜去刺球板栗，用剪刀在板栗壳上剪出切口，40～50℃热风干燥30～60min后，手工去壳、去衣，其特征在于：去衣后的板栗用1～3ppm臭氧水浸泡30～45min，然后于80～90℃保鲜护色液中漂烫5～10s后，立即放入5～10℃的保鲜护色液中超声处理30～45min，再2～8℃冷藏10～16h后，-18～-48℃预冻10～16h，最后干燥48～72h至含水量为10～18％，于洁净环境下真空包装，即得所述生鲜板栗包装产品；所述保鲜护色液组成如下：柠檬酸0.4％～0.8％，Vc 0.4％～0.8％，食盐2％～3％，食醋0.1％～0.3％，乳酸链球菌素0.1％～0.3％，食用酒精2％～4％，胡萝卜素0.2％～0.4％，溶剂为水。
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| CN105410821A (zh) * | 2015-11-18 | 2016-03-23 | 河北科技师范学院 | 牛奶风味即食型板栗冻干切片及其加工方法 |
| CN105532868A (zh) * | 2015-12-24 | 2016-05-04 | 承德神栗食品有限公司 | 一种去壳生鲜板栗仁的保鲜方法 |
| CN105995859A (zh) * | 2016-06-14 | 2016-10-12 | 安徽真心食品有限公司 | 牛奶补虚益肺胃的涂膜板栗仁及其制备方法 |
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| CN106974145B (zh) * | 2017-03-22 | 2019-12-31 | 大兴安岭中北农业科技股份有限公司 | 抗辐射蓝莓饮料及其制备方法 |
| CN109588679A (zh) * | 2018-12-31 | 2019-04-09 | 昆明源水农产品开发有限公司 | 一种板栗加工方法 |
| CN110754526A (zh) * | 2019-11-06 | 2020-02-07 | 广西壮族自治区亚热带作物研究所（广西亚热带农产品加工研究所） | 一种板栗果仁储存防霉变的方法 |
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