CN111000169B - 柿子薄片三维微波空气射流干燥技术 - Google Patents

柿子薄片三维微波空气射流干燥技术 Download PDF

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CN111000169B
CN111000169B CN201910682451.0A CN201910682451A CN111000169B CN 111000169 B CN111000169 B CN 111000169B CN 201910682451 A CN201910682451 A CN 201910682451A CN 111000169 B CN111000169 B CN 111000169B
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drying
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CN111000169A (zh
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邵重晓
杜美军
李喜宏
贾晓昱
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Tianjin Gasin Dh Fresh Technology Co ltd
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Abstract

本发明涉及一种柿子薄片三维微波空气射流干燥方法，分级与清洗、切片、微波升温、蒸汽脱涩、热空气反向一次干燥、负压间歇式二次干燥、冷却与包装。本发明采用高温(60‑70℃)高压环装喷射柠檬酸和40％酒精蒸汽(360°旋转)进行柿子脱涩，高温致使液体分子布朗运动更加剧烈，高压提高脱涩液在柿子薄片中的渗透扩散速度，柠檬酸对柿子细胞膜起到破膜作用，使40％的酒精蒸汽快速扩散进入细胞内，将单宁由可溶状态聚合变成不可溶性凝胶，从而达到均匀快速脱涩效果。

Description

柿子薄片三维微波空气射流干燥技术
技术领域
本发明属于柿子片生产领域,尤其是一种柿子薄片三维微波空气射流干燥技术。
背景技术
柿子隶属柿科(Ebenaceae)柿属(Diospyros L.f. )多年生落叶果树,原产我国，栽培已有一千多年的历史。柿子是人们比较喜欢食用的果品，甜腻可口，营养丰富，不少人还喜欢在冬季吃冻柿子，别有味道。柿子营养价值很高，含有丰富的胡萝卜素、核黄素、维生素等微量元素。所含维生素和糖分比一般水果高1-2倍左右。假如一个人一天吃1个柿子，所摄取的维生素C基本上就能满足一天需要量的一半。所以，吃些柿子对人体健康是很有益的。
柿子干薄片是一道以柿子为主要原料通过切片干燥而制成的一种甜点，近年来深受普通大众的喜欢。随着柿子产量的逐年增加，鲜柿和柿饼的市场价格不断降低，而柿子含水率高，季节性明显，成熟后很容易腐烂变质，而柿子以鲜食和加工成柿饼为主，品种单一。这就亟待进行柿子精深加工，增加柿子产品种类，同时延长柿子产品的供应期，提高产品附加值。
现有的技术生产柿子薄片时，存在以下不足之处
1. 容易发生褐变。主要是因为切片时切面受到机械损伤以及多酚氧化酶在有氧条件下催化氧化，使得柿子切面色泽变暗，加工出的产品质量较差。
2. 柿子脱涩不均匀，不彻底，效率低。主要是因为传统浸泡式脱涩技术局限性较大，由于柿子细胞的栅栏作用，脱涩液从外部渗透入内部的速度和浓度依次递减，故内部脱涩效果不明显，完全脱涩时间偏长。
3.柿子的表观质量较差。传统的干燥技术，温度均匀性控制不到位，致使柿子片表面汽化速度与内部水分迁移速度不统一：表面汽化速度大于内部水分迁移速度，柿子表面硬化较快，外表干硬而内部湿软；表面汽化速度小于内部水分迁移速度，干燥时间过长。
4.柿子薄片复水性较差，口感较差。传统干燥处理的不均匀，致使柿子细胞失水程度不同，细胞间孔隙大小不均匀，所以复水性较差。
5.柿子干燥时间较长，生产效率较低。常用的柿子干燥方式为高温烘焙或低温冻干，这样的干燥方式均需要耗费大量的时间，生产效率较低，难以实现大规模连续化生产
据检索，发现以下与本申请相关的专利文献，具体公开内容如下：
1.柿子脆片制备方法及采用该方法制备的柿子脆片（发明专利号：ZLZL20121004148.1，授权日期：2013年9月11日）公开了一种柿子脆片的制备方法，采用先去皮、再切片、再脱涩的工艺设计，优点是简化了操作工艺，缩短了加工时间，提高了脱涩效果，脱涩后速冻和冷藏处理，既保留了鲜果本身营养，又不添加任何添加剂，消除了对人体存在危害的化学物质的使用。缺点是通过热水浸泡和喷淋处理的方式去涩，内外层去涩不均匀，处理时间偏长，效率低；干燥均匀性难以控制，外观质量差异性大；干燥时间较长，难以实现大批量连续生产。
2.一种柿子干的制备方法（发明专利号：ZL20171044132.1公开日期：2017年9月22日）发明了一种柿子干的制备方法包括:预处理、一次干燥、发酵、烘制、二次干燥、调味、三次干燥、包装；优点是方法简单,可进行批量操作,得到的柿子干果香浓郁,酥脆爽口,增加市场上柿子的深加工产品,使经济收入提高8.9%。柿子切瓣后置于低温抗坏血酸溶液中进行浸泡,促进柿子中的单宁转变为水不溶性单宁,淡化涩味,防止柿子褐变,增加柿子的营养含量：浸泡后将柿子进行冷冻干燥,低温减少水分,淡化涩味,避免软烂,便于后续加工。缺点是采用三次间歇式干燥处理，干燥时间较长；低温抗坏血酸浸泡脱涩处理，脱涩效果不显著；对浸泡后的柿子行冷冻干燥，干燥时间较长，且对设备要求较高。
3.一种真空微波加工柿子脆片的方法(发明专利号：ZL20171095947.9公开日期：2018年3月2日)发明了一种真空微波加工柿子脆片的方法。优点是能有效减少柿子的营养损失、生产效率高、成本低、营养丰富、口感佳等。所述的加工方法为：柿子薄片在真空度-0.09～-0.06Mpa下进行分段微波膨化干燥。缺点是没有解决切片时柿子薄片褐变的问题；该加工工艺未能实现柿子的脱涩，对柿子原料的求较高；虽然干燥时间大幅缩短，但仍存在薄片干燥均匀性差异大，表观质量差异性显著的技术问题；该加工方式需要实现对真空度和分段膨化的精准控制，实现起来复杂且困难。
发明内容
本发明的目的在于克服现有技术的不足之处，提供一种干燥效果好、效率高的柿子薄片三维微波空气射流干燥技术。
本发明解决其技术问题是采取以下技术方案实现的：
一种柿子薄片三维微波空气射流干燥方法，步骤如下：
（1）分级与清洗：选择新鲜、完整、无虫害的柿子硬果清洗干净；
（2）去皮：采用人工去皮法，削去柿子硬果柿皮，并去掉果蒂；
（3）切片：先将去皮后的柿子硬果竖切成两半，再用水刀射流切片，柿子薄片切分至4-5mm，切割采用防褐变水溶液，包括0.5%NaCl+1%维生素C+0.5%柠檬酸配制的水溶液，通过高压微枪头形成水刀进行柿子果块的切割；
（4）微波升温：将柿子薄片平铺在网状托盘上置于带有超声波的装置中，超声波功率为1500 W，处理3 min；
（5）蒸汽脱涩：脱涩液为10%柠檬酸和40%乙醇，温度60-70℃，压力0.3～0.4 MPa，360°环绕柿子片环装喷射脱涩液蒸汽，转速为2-3 rad/min，脱涩操作时间为8-10 min；
（6）热空气反向一次干燥：热空气反向360°旋转干燥35-40 min，转速为2-3 rad/min。热风温度为70-80 ℃。
（7）负压间歇式二次干燥：再次放置到超声波的装置，将装置中抽真空，真空度为-0.10Mpa，在超声波功率1000 W下，间歇干燥15 min，干燥至含水率10％以下；
（8）冷却与包装：将干燥后的柿子薄片取出冷却至室温，然后进行充氮包装，得到柿子干片。
而且，所述切割速度为230～350 mm/min，水喷嘴直径0.46 mm，磨料喷嘴直径1.6mm，射流压力210 MPa。
本发明的优点和积极效果是：
1. 本发明采用水刀切割过程主要是法向力大于柿子细胞间的拉应力，造成断裂，同时射流切割还具有渗入作用。刀切直接破坏细胞壁造成细胞液流出，导致微生物腐败生长及褐变；而水射流由于其渗入能力和柔性，能切入细胞与细胞之间，通过破坏细胞之间的拉应力使其断裂，有效抑制褐变，保持细胞完整性，营养物质零流失。另外用天然防褐变水溶液代替清水通过高压微枪头形成水刀，切割完成后会在果块切面形成一层水膜，具有隔氧护色的作用，有效抑制表面褐变。
2.本发明的 微波隧道干燥方式可以同时干燥大批量柿子薄片，柿子原料与微波直接作用，柿子细胞间与细胞内的极性分子（水分子等）吸收微波，并在微波的作用下改变原有分子结构，呈现方向性排列；极性分子随外电磁场的变化进行极性运动，并以与微波频率相同的速度（915MHz的微波下极性分子运动速度为9.15亿次/秒）进行摩擦碰撞产生热能，使柿子薄片内部在短时间内温度迅速升高达到加热效果，干燥均匀性好且节能效率高。
3. 本发明采用高温（60-70℃）高压环装喷射柠檬酸和40%酒精蒸汽（360°旋转）进行柿子脱涩，高温致使液体分子布朗运动更加剧烈，高压提高脱涩液在柿子薄片中的渗透扩散速度，柠檬酸对柿子细胞膜起到破膜作用，使40%的酒精蒸汽快速扩散进入细胞内，将单宁由可溶状态聚合变成不可溶性凝胶，从而达到均匀快速脱涩效果。
4. 本发明采用微波隧道方式加热干燥，热空气与高温柠檬酸和40%酒精混合蒸汽相向360°运行，形成对流漩涡，加快水分散失速度，三种相耦合的干燥作用方式，使柿子表面汽化速度与内部水分迁移速度大幅提高且相对一致，极大地提高干燥效率，缩短干燥时间，复水性和皱缩均匀性较好，表观质量相应提高。
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。
随着我国柿子种植面积的不断扩大，柿子的产量不断增加，但是柿子含水量较高，不易贮藏，市场上柿子以鲜食和加工成柿饼为主，品种单一，不能满足消费者口感和需求，亟待进行柿子的精深加工。柿子薄片营养丰富，口感极佳，贮藏期长等优势特点受到广大消费者的喜爱和追捧。但是柿子干燥片的制作大多局限于家庭厨房小制作，工业化生产起步较晚，本发明的目的在于提供一整套无褐变的皱缩均匀性较好的柿子薄片批量快速干燥方法，并解决其中的关键技术难题。
一种柿子薄片三维微波空气射流干燥方法，步骤如下：
（1）分级与清洗：选择新鲜、完整、无虫害的柿子硬果清洗干净；
（2）去皮：采用人工去皮法，削去柿子硬果柿皮，并去掉果蒂；
（3）切片：先将去皮后的柿子硬果竖切成两半，再用水刀射流切片，柿子薄片切分至4-5mm厚为宜。为防止果实与空气接触发生氧化褐变，切片工序要采取护色措施。所以采用超高压水射流切割技术切分柿子硬果，配置广谱天然防褐变水溶液，包括0.5%NaCl+1%维生素C+0.5%柠檬酸配制的水溶液，通过高压微枪头形成水刀进行柿子果块的切割，溶液可以循环使用，切割厚度5～6 mm，切割速度为230～350 mm/min，水喷嘴直径0.46 mm，磨料喷嘴直径1.6 mm，射流压力210 MPa。切割完成后会在柿子果块切面形成一层水膜，具有隔氧护色的作用，有效抑制表面褐变。
利用超高压水刀射流切割技术，采用超高压水刀射流切割技术对柿子切片，抑制褐变，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；另外用天然防褐变水溶液代替清水通过高压微枪头形成水刀，切割完成后会在果块切面形成一层水膜，具有隔氧护色的作用，有效抑制表面褐变。
（4）微波升温：将柿子薄片平铺在网状托盘上置于微波隧道中，在微波功率为1500W条件下柿子内外温度快速升温3 min。
（5）蒸汽脱涩：脱涩液为10%柠檬酸和40%乙醇，高温（60-70℃）高压（0.3～0.4MPa）环装喷射脱涩液蒸汽（360°旋转，转速为2-3 rad/min）。脱涩操作时间为8-10 min。
使用高温高压柠檬酸和40%酒精混合蒸汽360°旋转喷射脱涩技术（气体熏蒸），提高脱涩液的扩散渗透效果，脱涩均匀性大幅提高，缩短了脱涩操作时间。
（7）热空气反向一次干燥：热空气反向360°旋转干燥35-40 min，转速为2-3 rad/min。热风温度为70-80 ℃。
采用微波隧道干燥方式提高柿子内部温度，加快内部水分迁移速度，外加热空气（60-60℃）反向360°旋转干燥，提高外表水分汽化速度，内外水分散失相对统一，柿子皱缩均匀性较好，表观质量较好。
（7）负压间歇式二次干燥：再次放置到超声波的装置，将装置中抽真空，真空度为-0.10Mpa，在微波功率1000 W下间歇干燥15 min，干燥至含水率10％以下 。
采用微波隧道方式加热干燥，热空气与高温柠檬酸和40%酒精混合蒸汽相向360°运行，形成对流漩涡，加快水分散失速度，三种相耦合的干燥作用方式，极大地提高干燥效率，大幅缩短干燥时间。
采用微波隧道干燥外加热空气反向360°旋转干燥，提高柿子干燥的均匀性，复水性相应提高。
（8）冷却与包装：将干燥后的柿子薄片取出冷却至室温，然后进行充氮包装，得到柿子干片。

Claims (2)

1.一种柿子薄片三维微波空气射流干燥方法，其特征在于：步骤如下：
（1）分级与清洗：选择新鲜、完整、无虫害的柿子硬果清洗干净；
（2）去皮：采用人工去皮法，削去柿子硬果柿皮，并去掉果蒂；
（3）切片：先将去皮后的柿子硬果竖切成两半，再用水刀射流切片，柿子薄片切分至4-5mm，切割采用防褐变水溶液，包括0.5%NaCl+1%维生素C+0.5%柠檬酸配制的水溶液，通过高压微枪头形成水刀进行柿子果块的切割；
（4）微波升温：将柿子薄片平铺在网状托盘上置于带有超声波的装置中，超声波功率为1500 W，处理3 min；
（5）蒸汽脱涩：脱涩液为10%柠檬酸和40%乙醇，温度60-70℃，压力0.3～0.4 MPa，360°环绕柿子片环装喷射脱涩液蒸汽，转速为2-3 rad/min，脱涩操作时间为8-10 min；
（6）热空气反向一次干燥：热空气反向360°旋转干燥35-40 min，转速为2-3 rad/min，热风温度为70-80 ℃；
（7）负压间歇式二次干燥：再次放置到超声波的装置，将装置中抽真空，真空度为-0.10Mpa，在超声波功率1000 W下，间歇干燥15 min，干燥至含水率10％以下；
（8）冷却与包装：将干燥后的柿子薄片取出冷却至室温，然后进行充氮包装，得到柿子干片。
2.根据权利要求1所述的柿子薄片三维微波空气射流干燥方法，其特征在于：所述切割速度为230～350 mm/min，水喷嘴直径0.46 mm，磨料喷嘴直径1.6 mm，射流压力210 MPa。
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PE01 Entry into force of the registration of the contract for pledge of patent right

Denomination of invention: Three dimensional microwave air jet drying technology for persimmon slices

Effective date of registration: 20230425

Granted publication date: 20220923

Pledgee: Tianjin Rural Commercial Bank Co.,Ltd. Dongli center sub branch

Pledgor: TIANJIN GASIN-DH FRESH TECHNOLOGY CO.,LTD.

Registration number: Y2023120000019