CN110800943A - 高生物活性黑苹果干脆片及加工技术 - Google Patents
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Abstract
本发明涉及一种高生物活性黑苹果干脆片及加工技术，加工工艺流程如下：鲜果、分选、去皮、切片、发酵、干燥、包装、黑苹果干脆片，本发明采用高温枯草芽孢杆菌发酵液雾化喷射技术。60℃‑80℃条件下，雾化处理苹果切片，采用4kGy剂量，60Coy射线辐照切片后的苹果切片，加促羰氨反应，使苹果切片产生焦黑色。本发明喷施枯草芽孢杆菌抗菌肽溶液，利用其抑菌功能，避免货架期间病原菌侵染；枯草芽孢杆菌高产淀粉酶和蛋白酶的功能，充分利用其产酶类的特点，采用高产α‑淀粉酶枯草芽孢杆菌雾化发酵技术，加促苹果切片羰氨反应；另外枯草芽孢杆菌有利于保持防御酶系的活性。
Description
技术领域
本发明涉及苹果干脆片，尤其是一种高生物活性黑苹果干脆片及加工技术。
背景技术
新疆阿克苏糖心苹果甘甜味厚，汁多无渣，营养丰富。羰氨反应产生的类黑精能够抗氧化、抗自由基、抗病且与酶结合后能够提高活性。鲜切阿克苏糖心苹果通过羰氨反应产生独特的香味和色泽并具有抗氧化高活性的功效；目前，羰氨反应多是在高温高湿条件下自然进行，耗时长且上色不均匀。利用微生物产生酶类物质加促苹果羰氨反应的技术较少。利用生物制剂生产黑苹果干脆片的技术市场上很少见，目前制作黑苹果的技术有以下不足之处。
(1)羰氨反应过程中，蛋白质与糖，氨基酸与糖结合，结合产物不容易被酶利用，营养成分不容易被消化。
(2)黑脆片制作过程，因其温度、湿度的把控不稳定，制作过程耗时长，且会产生有害物质。
(3)市面上多是利用枯草芽孢杆菌抑菌抗病功能作用于作物上，利用其分泌酶类加促羰氨反应，同时抑制有害物质、抑制病原菌的产生研究还较少。
(4)加工中的冷冻干燥技术耗时长，且成本高，不适宜用于苹果这种大量干脆片加工；喷雾干燥技术，温度高，干燥过程中会影响产品成分的稳定性及成分物质，营养物质流失。
(5)糖心苹果含糖量高，切片在干燥过程中易结块粘连、吸湿，导致产品品质差。
经过检索，与本申请相关的专利如下：
1、一种非油炸膨化寒富苹果脆片的制作方法(CN 104872564A)，该专利缺点：①切片时，刀片直接切入，苹果内部细胞液外流，极易发生病原菌滋生；②糖煮阶段，在破坏易发生褐变的酶活性同时也破坏SOD等防御酶活性；③热风干燥耗时长且苹果片干燥过程中成分变化不好控制。
2、一种无膨化低糖度水果冻干脆片的快速制备方法(CN 101433300A)。该缺点：①切片时，刀片直接切入，苹果内部细胞液外流，极易发生病原菌滋生；
②选用的低糖度水果与氧接触易发生褐变；微波干燥阶段，膨化度不稳定，存在水果脆片膨化的可能性；③升华干燥阶段的冷冻干燥手段，能耗大，加大了干脆片成本；
3、一种冻干罗汉果的制备方法(CN 102224838A)。该缺点：①真空冷冻干燥，时间长，能耗大，虽保留了罗汉果整果干燥，但是，增加了罗汉果成本；②加热过程中，分段加热，过于频繁，增加了工艺的繁琐，不利于批量生产。③整果保存期间，因在果上打孔，易引入病菌且不易控制。
发明内容
本发明的目的在于克服现有技术的不足之处，提供一种制作过程简单、工艺效率高的一种高生物活性黑苹果干脆片及加工技术。
本发明实现目的的技术方案如下：
一种高生物活性黑苹果干脆片加工方法，具体工艺要求及参数为：
(1)分选：筛选无病虫侵害、无机械损伤、果实成熟程度大致相同的新鲜优质糖心苹果；
(2)清洗和去皮：在流动的自来水下洗去其表面上的泥土并擦干水滴，削去表皮；
(3)切片：采用超高压水射流切割技术对苹果切片，厚度2mm；
(4)发酵：采用高温枯草芽孢杆菌发酵液雾化喷射技术，60℃-80℃条件下，雾化处理苹果切片双面，采用4k Gy剂量，60Coy射线辐照切片后的苹果切片，加促羰氨反应，使苹果切片产生焦黑色；
(5)干燥：射频-脉冲真空除湿板式干燥技术，抽真空联合射频频率为30MHz, 射频功率为5kW脉冲，通过除湿板式干燥技术上对黑苹果切片间歇式加热干燥处理，加热温度45℃，间歇交替时间为60s。
(6)包装：包装即得黑苹果干脆片。
而且，所述发酵的温度为85～89℃，蒸汽压力为0.3～0.4MPa时，瞬间减压至-0.08MPa，温度下降到75℃，维持1.5h。
而且，在所述干燥过程中喷洒麦芽糊精粉末。
本发明的优点和积极效果是：
1、本发明喷施枯草芽孢杆菌抗菌肽溶液，利用其抑菌功能，避免货架期间病原菌侵染；枯草芽孢杆菌高产淀粉酶和蛋白酶的功能，充分利用其产酶类的特点，采用高产α-淀粉酶枯草芽孢杆菌雾化发酵技术，加促苹果切片羰氨反应；另外枯草芽孢杆菌有利于保持防御酶系的活性。
2、本发明采用射频-脉冲真空除湿板式预干燥结合压差膨化技术。脉冲射频穿透能力大、加热均匀，同时添加麦芽糊精有效解决苹果切片因糖分含量高，导致干燥过程粘结问题,提高干燥产品营养成分保留量及均匀度,而且还可以显著地缩短干燥时间50％左右。
3、本发明采用压差膨化操作温度过低则膨化度低，苹果脆片外观和酥脆度差，操作温度过高时，易发生焦糊。两者有机结合，优势互补，克服单独使用射频-脉冲和压差膨化产生的“硬芯”“焦化”问题。
附图说明
图1为本发明制备过程中的苹果片。
图2为本发明制备的不带皮的黑苹果片。
图3本发明制备的带皮的黑苹果片。
图4本发明制备的带皮的黑苹果片。
图5为本发明制备的不带皮的黑苹果片(喷洒糊麦芽精粉末)。
具体实施方式
下面通过具体实施例对本发明作进一步详述，以下实施例只是描述性的，不是限定性的，不能以此限定本发明的保护范围。
一种高生物活性黑苹果干脆片及加工技术，加工工艺流程如下：鲜果、分选、去皮、切片、发酵、干燥、包装、黑苹果干脆片
具体工艺要求及参数为：
(1)分选：筛选无病虫侵害、无机械损伤、果实成熟程度大致相同的新鲜优质糖心苹果。
(2)清洗和去皮：在流动的自来水下洗去其表面上的泥土并擦干水滴，削去表皮，尽量保持削去的表皮厚度一致。
(3)切片：采用超高压水射流切割技术对苹果切片，厚度2mm。保持细胞完整性营养不流失，切割同时利用高压水对削面进行清洗和磨削。
(4)发酵：采用高温枯草芽孢杆菌发酵液雾化喷射技术。60℃-80℃条件下， 360°雾化处理苹果切片，采用4kGy剂量，60Coy射线辐照切片后的苹果切片，加促羰氨反应，使苹果切片产生焦黑色。
采用辐照的目的是：辐射释放的能量使糖心苹果中糖苷键断裂，释放羰基，进一步与氨基化合物发生反应，加速糖心苹果羰氨反应，减短苹果切片产生焦黑色的时间)
(6)干燥：射频-脉冲真空除湿板式干燥技术，抽真空联合射频频率为 30MHz,射频功率为5kW脉冲，通过除湿板式干燥技术上对黑苹果切片间歇式加热干燥处理。加热温度45℃，间歇交替时间为60s。
在干燥过程中优选加入麦芽糊精，可以采用喷洒的方式，将苹果片两侧喷洒麦芽糊精，防止苹果片直接的粘连。
(6)包装：包装即得黑苹果干脆片。
针对上述过程，本发明的相关说明如下：
1、接种枯草芽孢杆菌，高产酶系，有效加快羰氨反应
枯草芽孢杆菌(ATCC 6633)；功能及特性：产α-淀粉酶，纤维素酶，蛋白酶，分泌活性抗菌物质；安全性高，无毒害无残留，对不良环境，如热、紫外线、电离辐射有抗性，且高温稳定。发酵液过滤掉菌种后使用，主要利用其产生的产α-淀粉酶。
本发明经过60℃-80℃条件下，枯草芽孢杆菌发酵液360°雾化处理糖心苹果切片，渗入细胞内部，产生大量α-淀粉酶，水解淀粉链，淀粉链断裂，产生大量低聚糖和游离羰基，同时，枯草芽孢杆菌分泌蛋白酶，水解核苷酸，大量游离氨基生成，加促羰氨反应、类黑精的生成，缩短反应时间；采用4kGy剂量， 60Coy射线辐照苹果切片，进一步加促羰氨反应，使苹果切片表面产生焦黑色和特殊香味。效果及优点：温度相差10℃，羰氨反应速度相差3-5倍，温度越高，速度越快。枯草芽孢杆菌发酵雾化液，高产α-淀粉酶、蛋白酶，水解糖类化合物、蛋白质等物质，有效持续的供应羰基、氨基，且产生大量活性抑菌物质，同时辐射释放的能量使苹果切片糖苷键断裂，释放羰基，进一步与氨基化合物发生反应，加速羰氨反应，缩短黑苹果切片的生成时间。
2、射频-脉冲真空除湿板式预干燥结合压差膨化技术
抽真空联合射频频率为30MHz,功率为5kW脉冲，通过除湿板式干燥技术上对苹果切片间歇式加热干燥处理。加热板加热温度45℃,间歇交替时间为2min。
经真空脉冲预干燥后压差膨化，基于“爆米花”原理。膨化时，真空密闭环境下将预处理的苹果切片通过蒸气加热使内部水分不断蒸发，产生水蒸汽，压力不断上升，温度达到85～89℃，蒸汽压力达到0.3～0.4MPa时，瞬间减压至-0.08 MPa，温度下降到75℃，维持1.5h。苹果切片内部水分突然汽化、闪蒸，产生强大的蒸汽压差，能够保持苹果营养成分、生鲜风味、脱水彻底、口感酥脆、形态饱满、膨化均匀。
效果及优点：真空环境降低酶活性，产品质量不受影响。脉冲射频穿透能力大、加热均匀。同时添加麦芽糊精有效解决苹果切片因糖分含量高，导致干燥过程粘结问题,提高干燥产品营养成分保留量及均匀度,而且还可以显著地缩短干燥时间50％左右。压差膨化操作温度过低则膨化度低，苹果脆片外观和酥脆度差，操作温度过高时，易发生焦糊。两者有机结合，优势互补，克服单独使用射频- 脉冲和压差膨化产生的“硬芯”“焦化”问题。
3、枯草芽孢杆菌抗菌肽抑菌防腐
枯草芽孢杆菌(BNCC 189983)发酵获得枯草芽孢杆菌抗菌肽，作为一种新型的食品防腐剂，具有无毒、无残留、无耐药性的优点，其抑菌效果显著，生产周期短，成本低，并可减少食品冷链运输过程中的能量消耗。
苹果脆片均匀喷湿1.2g/L枯草芽孢杆菌抗菌肽溶液，晾5min，40℃热风干燥0.5h。优点和效果：天然微生物防腐剂抗菌谱广，生产周期短无毒，有效抑菌防腐。
七、指标测定
(1)发酵时间及
| 处理 | 发酵时间 |
| 接种枯草芽孢杆菌 | 3d |
| 对照组 | 5d |
接种枯草芽孢杆菌，有效缩短发酵时间。
(2)苹果脆片保存3个月后的菌落总数
| 处理 | 细菌菌落总数(CFU/ml) |
| 枯草芽孢杆菌抗菌肽 | 2.89×10<sup>2</sup> |
| 对照组 | 8.16×10<sup>4</sup> |
接种枯草芽孢杆菌抗菌肽，明显抑制细菌数目的增长。
(3)保存3个月后产品感官品质
注：每项指标满分10分
保存3个月后，产品感官品质良好。
Claims (3)
1.一种高生物活性黑苹果干脆片加工方法，其特征在于：具体工艺要求及参数为：
(1)分选：筛选无病虫侵害、无机械损伤、果实成熟程度大致相同的新鲜优质糖心苹果；
(2)清洗和去皮：在流动的自来水下洗去其表面上的泥土并擦干水滴，削去表皮；
(3)切片：采用超高压水射流切割技术对苹果切片，厚度2mm；
(4)发酵：采用高温枯草芽孢杆菌发酵液雾化喷射技术，60℃-80℃条件下，雾化处理苹果切片双面，采用4k Gy剂量，60Coy射线辐照切片后的苹果切片，加促羰氨反应，使苹果切片产生焦黑色；
(5)干燥：射频-脉冲真空除湿板式干燥技术，抽真空联合射频频率为30MHz,射频功率为5kW脉冲，通过除湿板式干燥技术上对黑苹果切片间歇式加热干燥处理，加热温度45℃，间歇交替时间为60s。
(6)包装：包装即得黑苹果干脆片。
2.根据权利要求1所述的高生物活性黑苹果干脆片加工方法，其特征在于：所述发酵的温度为85～89℃，蒸汽压力为0.3～0.4MPa时，瞬间减压至-0.08MPa，温度下降到75℃，维持1.5h。
3.根据权利要求1所述的高生物活性黑苹果干脆片加工方法，其特征在于：在所述干燥过程中喷洒麦芽糊精粉末。
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