CN112971035A - 一种长货架期豆腐干的生产方法 - Google Patents
一种长货架期豆腐干的生产方法 Download PDFInfo
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Abstract
本发明公开一种长货架期豆腐干的生产方法,大豆经筛选、泡豆、磨浆、去渣、煮浆、点浆、蹲脑、上板压榨、切块、碱液浸泡、卤制、涂膜、包装、高功率微波杀菌后获得长货架期豆腐干产品。本豆腐干生产方法在传统豆腐干加工方法中融入了涂膜保鲜和高功率脉冲微波杀菌技术,产品的弹性和韧性好,保质期长,拥有广阔的应用前景。
Description
技术领域
本发明涉及一种长货架期豆腐干的生产方法,属于豆制品深加工领域。
背景技术
豆制品是我国主要的植物蛋白食品,以大豆为主要原料,经过浸泡、清洗、磨浆、煮浆、滤浆、点浆、上箱、成型、压制等工序加工制作而成,主要包括豆腐、豆腐干、茶干、豆腐皮、千张、腐竹、素鸡等,在我国已有两千年的食用历史,在城乡居民“菜篮子”中占有较重份额。豆腐干,又名豆腐干、白干、干豆腐,豆腐干是豆腐的再加工制品,咸香爽口,硬中带韧,久放不坏。豆腐干营养丰富,含有大量蛋白质、脂肪、碳水化合物,还含有钙、磷、铁等多种人体所需的矿物质。豆腐干突出的营养益处是高钙。豆腐干的最大特点是营养均衡。据测定,每100克的豆腐干含有336千卡的热量,含731毫克的钙,而脂肪含量不足16克,多吃也不会发胖。豆腐干在制作过程中会添加食盐、茴香、花椒、大料、干姜等调料,既香又鲜,久吃不厌,被誉为“素火腿”。还可加工成卤干、熏干、酱油干等,是拌凉菜、炒热菜的上乘原料。豆腐干是佐酒下饭的最佳食品之一,也便于旅途携带和食用。可以说,豆腐干就是“浓缩”了的豆腐。
然而,由于蛋白营养丰富,水分含量高,豆腐干容易滋生微生物而腐败变质,保质期短,夏季尤为严重,不仅严重阻碍了豆腐干产业的发展,也直接影响到豆腐干的质量与安全。为了延长豆腐干的保质期,豆腐干生产商们一般通过高温灭菌或添加化学防腐剂的方式抑制或杀灭豆腐干中的微生物。然而,高温灭菌手段会严重破坏豆腐干的质构和风味。随着人们对绿色、健康消费理念的追求成为主流,化学防腐剂潜在的健康隐患使得添加化学防腐剂的食品越来越不被人们接受。因此,如何开发一种不添加化学防腐剂即可实现长货架期的豆腐干生产技术显得十分必要。
发明内容
发明目的:本发明针对豆腐干保质期短,高温灭菌会改变豆腐干质构和风味,添加化学防腐剂不适应现在消费者绿色健康消费理念的情况,在豆腐干生产过程中利用天然防腐剂联合涂膜保鲜技术和高功率脉冲微波杀菌技术,实现对豆腐干中微生物的联合杀灭,使豆腐干产品在不经过高温灭菌、不添加防腐剂的情况下大大延长产品保质期。
生物保鲜是近年来发展起来的减少食品腐败变质的新技术。其原理是通过隔离食品与空气的接触以减少产品的氧化,或是通过生物保鲜物质本身具有的良好抑菌作用来延长食品的保质期,其最大的特点就是安全。国内外相关科技人员对生物保鲜技术进行了多方探索,从来源于生物体本身的组成成分或其代谢产物中寻找无毒无味、有效抑菌的生物保鲜物质,如大蒜素、茶多酚、黄蒿酚等植物提取物、昆虫抗菌肽、溶菌酶、乳酸链球菌素等。涂膜保鲜技术就是在食品表面涂上一层高分子的液态膜,干燥后成为一层很均匀的膜,可以隔离果实与空气进行气体交换,可减少病原菌的侵染而造成的腐败,同时有些涂抹保鲜剂本身具有一定的杀菌或抑菌效果。因此联合具有防腐保鲜效果的天然提取物和涂膜保鲜技术将进一步增强其防腐保鲜效果。高功率脉冲微波技术,将微秒级宽度的高压脉冲加到脉冲磁控管上,使其产生脉冲功率达到数百千瓦至几兆瓦(而平均功率只有几百瓦至几千瓦)的高功率、周期性的脉冲微波能量,通过微波传输系统以及谐振腔体作用到被处理的物料上,使物料在极短时间内受到高能量的微波照射,而又不会使物料温度得到明显升高,从而实现了利用周期性瞬时高功率脉冲微波能量而平均功率很低的脉冲微波处理技术。这一技术可在不使物料温度明显升高的情况下杀灭物料中的微生物,是一种高效的非热杀菌技术。
本发明提出了一种长货架期豆腐干的生产方法,包括如下步骤:
(1)将大豆经浸泡磨浆、煮浆、点浆、蹲脑、破脑、上板、压榨、切块后得到豆腐干白胚,将豆腐干白胚冷却至室温后用白碱水浸泡,优选地,浸泡5-10分钟,期间不断搅拌;
(2)将步骤(1)获得的豆腐干白胚经摊晾后得到白豆腐干;
(3)将白豆腐干经卤制后摊晾得到卤制豆腐干;
(4)向多糖溶液中加入天然抑菌性提取物,获得复合涂膜剂;
(5)向步骤(2)得到的白豆腐干或步骤(3)得到的卤制豆腐干中加入复合涂膜剂中浸泡0.5-3分钟后取出、摊晾至豆腐干表面无水,得到涂膜白豆腐干或涂膜卤制豆腐干;
(6)将涂膜白豆腐干或涂膜卤制豆腐干包装后利用高功率脉冲微波设备进行杀菌,得到长货架期豆腐干产品。
其中,步骤(1)中,将大豆按照豆水比1:4-8的比例加水浸泡,大豆豆瓣吸水涨裂后磨浆、除去豆渣获得豆浆;浸泡大豆用的水中含有0.2-0.5%(w/w)的白碱,采用碱性介质浸泡大豆达到吸水率所需时间可以缩短16%~20%。
优选地,在煮浆步骤中,豆浆煮沸并维持5-15分钟并进一步除去残留豆渣,调整豆浆浓度为7-11°Brix。
优选地,在豆浆温度80℃以上时进行点浆,点浆结束后蹲脑5-15分钟。
其中,采用过滤或离心出去豆渣。若采用过滤的方法,需采用100目以上滤布过滤;若采用离心过滤的方法,则离心机转速为3000-5000转/分钟,离心3-5分钟。
优选地,用盐卤、石膏、葡萄糖酸内酯、酸浆或果蔬中的任意一种进行点浆。其中酸浆和果蔬都可作为豆腐的凝固剂,酸浆指的是利用微生物对黄浆水进行发酵形成酸浆,果蔬指的是以新鲜果蔬为原料经乳酸菌发酵后制得的发酵液。
优选地,在破脑步骤中,将豆腐脑破碎至2-5mm;压榨时首先利用时间间隔0.3-0.5s的连续点压至滴水,再用时间间隔为1-2s的点压3-8次,之后用时间间隔为5-10分钟的加压2-5次。
步骤(1)中白碱水中含0.1-0.5%(w/w)白碱,水温为60℃以上。
优选地,步骤(3)和步骤(5)中的摊晾采用自然晾干、吹干或烘干。
优选地,步骤(5)中,卤制采用的卤汁的基本配方为:每1000g水包含如下组分:八角1.5-2.0g,桂皮0.8-1.5g,陈皮0.2-0.4g,干姜1.0-1.5g,小茴香1.2-1.6g,酱油6-15g,盐15-25g。
具体地,所述多糖溶液中的多糖为壳聚糖、可溶性大豆多糖、普鲁兰多糖、槐豆胶、卡拉胶、魔芋胶或黄原胶中的任一种或几种的组合,多糖添加量为0.3-0.5%(w/w)。
所述天然抑菌性提取物为大蒜素和茶多酚中的任意一种或两者的混合物,添加量为0.2-0.5%(w/w)。若混合加入,大蒜素与茶多酚最适配比为1:3。
优选地,步骤(6)中,高功率脉冲微波设备处理时,瞬时输出功率为360~400kw,输出脉冲宽度为3~5μs,占空比1:1200~1500,整个过程持续3-5min。
有益效果:本发明在豆腐干生产过程中利用天然防腐剂联合涂膜保鲜技术和高功率脉冲微波杀菌技术,实现对豆腐干中微生物的联合杀灭,使豆腐干产品在不经过高温灭菌、不添加防腐剂的情况下大大延长了产品保质期,同时制备的产品弹性和韧性好。
附图说明
图1长货架期豆腐干生产技术路线图;
图2不同加工技术获得的豆腐干4℃保存下细菌变化趋势。
具体实施方式
图1为本发明提出的长货架期豆腐干生产技术路线图,下面结合具体实施例对本发明做进一步详细说明,下述实施例将有助于理解本发明,但是本发明的保护范围不限于下述的实施例。
实施例1
(1)挑出大豆中霉变、发黑、蛀虫的大豆,用清水清洗,然后按照豆水比1:6的比例加含有0.3%(w/w)白碱的水浸泡,大豆豆瓣吸水涨裂后磨浆,3000转/分钟离心5分钟除去豆渣获得豆浆;
(2)豆浆煮沸并维持10分钟,用120目滤布进一步除去残留豆渣,调整豆浆浓度为10°Brix;
(3)在豆浆温度85℃时用盐卤进行点浆,点浆结束后蹲脑15分钟;
(4)对蹲脑后的豆腐脑破脑后倒入框模中进行压榨,首先利用时间间隔0.3s的连续点压至滴水,再用时间间隔为2s的点压5次,之后用时间间隔为5分钟的加压3次,压榨结束后切割获得豆腐干白胚;
(5)豆腐干白胚冷却至室温后用0.3%(w/w)白碱水浸泡5分钟,期间需不断搅拌;
(6)步骤(5)获得的豆腐干白胚经吹干表面水分后进行卤制得到卤制豆腐干,卤汁成分为(g/1000g水):八角2.0g,桂皮1g,陈皮0.3g,干姜1.2g,小茴香1.5g,酱油10g,盐20g。
(7)将壳聚糖溶于水中获得0.3%(w/w)壳聚糖溶液,加入质量分数为0.3%的大蒜素,获得复合涂膜剂;
(8)将步骤(6)获得的卤制豆腐干加入步骤(7)中的复合涂膜剂中浸泡2分钟后取出、摊晾至豆腐干表面无水,得到涂膜卤制豆腐干;
(9)将涂膜卤制豆腐干包装后利用高功率脉冲微波设备进行杀菌,瞬时输出功率为380kw,输出脉冲宽度为4μs,占空比1:1400,整个过程持续4min,得到长货架期卤制豆腐干产品。
本申请进一步考察了不同生产方式豆腐干的保存情况,如图2所示,对不同生产方式获得的豆腐干4℃保存条件下微生物数量变化情况进行统计,结果表明,对照(未经过涂膜或高功率脉冲微波杀菌)豆腐干在保存过程中微生物数量增加迅速,微生物数量在第4天超过6log10 CFU/g。豆腐干分别经过涂膜保鲜和高压脉冲微波处理后细菌数量极少,前两天细菌数量几乎为0,在保存过程中细菌数量虽然有所增加,但是在第14天时仍然低于5log10 CFU/g,说明涂膜保鲜和高压脉冲微波杀菌可很好的抑制豆腐干中细菌的生长,当涂膜保鲜和脉冲微波杀菌联用时,豆腐干中的细菌数量在整个保存期内都极低,在第14天时细菌数量任然低于3log10 CFU/g,说明联合使用涂膜保鲜和高压脉冲微波杀菌可最大限度的杀灭豆腐干中的细菌,大大延长豆腐干保质期。
实施例2
(1)挑出大豆中霉变、发黑、蛀虫的大豆,用清水清洗,然后按照豆水比1:4的比例加含有0.2%(w/w)白碱的水浸泡,大豆豆瓣吸水涨裂后磨浆,5000转/分钟离心3分钟除去豆渣获得豆浆;
(2)豆浆煮沸并维持5分钟,用100目滤布进一步除去残留豆渣,调整豆浆浓度为11°Brix;
(3)在豆浆温度90℃时用石膏进行点浆,点浆结束后蹲脑10分钟;
(4)对蹲脑后的豆腐脑破脑后倒入框模中进行压榨,首先利用时间间隔0.5s的连续点压至滴水,再用时间间隔为1s的点压8次,之后用时间间隔为10分钟的加压2次,压榨结束后切割获得豆腐干白胚;
(5)豆腐干白胚冷却至室温后用0.5%(w/w)白碱水浸泡5分钟,期间需不断搅拌;
(6)步骤(5)获得的豆腐干白胚经吹干表面水分后进行卤制得到卤制豆腐干,卤汁成分为(g/1000g水):八角1.5g,桂皮0.8g,陈皮0.4g,干姜1.5g,小茴香1.2g,酱油15g,盐15g;
(7)将可溶性大豆多糖溶于水中获得0.5%(w/w)可溶性大豆多糖溶液,加入质量分数为0.5%的茶多酚,获得复合涂膜剂;
(8)将步骤(6)获得的卤制豆腐干加入步骤(7)中的复合涂膜剂中浸泡3分钟后取出、摊晾至豆腐干表面无水,得到涂膜卤制豆腐干;
(9)将涂膜卤制豆腐干包装后利用高功率脉冲微波设备进行杀菌,瞬时输出功率为400kw,输出脉冲宽度为3μs,占空比1:1200,整个过程持续3min。
制备得到的卤制豆腐干在第14天时细菌数量任然低于3log10 CFU/g,说明联合使用涂膜保鲜和高压脉冲微波杀菌可最大限度的杀灭豆腐干中的细菌,大大延长豆腐干保质期。
实施例3
(1)挑出大豆中霉变、发黑、蛀虫的大豆,用清水清洗,然后按照豆水比1:8的比例加含有0.5%(w/w)白碱的水浸泡,大豆豆瓣吸水涨裂后磨浆,120目滤布除去豆渣获得豆浆;
(2)豆浆煮沸并维持15分钟,用140目滤布进一步除去残留豆渣,调整豆浆浓度为7°Brix;
(3)在豆浆温度80℃时用酸浆进行点浆,点浆结束后蹲脑10分钟;
(4)对蹲脑后的豆腐脑破脑后倒入框模中进行压榨,首先利用时间间隔0.5s的连续点压至滴水,再用时间间隔为2s的点压3次,之后用时间间隔为10分钟的加压2次,压榨结束后切割获得白豆腐干;
(5)豆腐干白胚冷却至室温后用0.1%(w/w)白碱水浸泡10分钟,期间需不断搅拌;
(6)将壳聚糖和槐豆胶溶于水中获得质量分数分别为0.2%(w/w)壳聚糖和0.3%(w/w)槐豆胶的溶液,加入质量分数为0.1%(w/w)的大蒜素和0.3%(w/w)的茶多酚,获得复合涂膜剂;
(7)将步骤(5)获得的豆腐干白胚加入步骤(6)中的复合涂膜剂中浸泡2分钟后取出、摊晾至豆腐干表面无水,得到涂膜白豆腐干;
(8)将涂膜白豆腐干包装后利用高功率脉冲微波设备进行杀菌,瞬时输出功率为360kw,输出脉冲宽度为3μs,占空比1:1500,整个过程持续3min。
制备得到的卤制豆腐干在第14天时细菌数量任然低于3log10 CFU/g,说明联合使用涂膜保鲜和高压脉冲微波杀菌可最大限度的杀灭豆腐干中的细菌,大大延长豆腐干保质期。
本发明提供了一种长货架期豆腐干的生产方法,具体实现该技术方案的方法和途径很多,以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。本实施例中未明确的各组成部分均可用现有技术加以实现。
Claims (10)
1.一种长货架期豆腐干的生产方法,其特征在于,包括如下步骤:
(1)将大豆经浸泡磨浆、煮浆、点浆、蹲脑、破脑、上板、压榨、切块后得到豆腐干白胚,将豆腐干白胚冷却至室温后用白碱水浸泡,期间不断搅拌;
(2)将步骤(1)获得的豆腐干白胚经摊晾后得到白豆腐干;
(3)将白豆腐干经卤制后摊晾得到卤制豆腐干;
(4)向多糖溶液中加入天然抑菌性提取物,获得复合涂膜剂;
(5)向步骤(2)得到的白豆腐干或步骤(3)得到的卤制豆腐干中加入复合涂膜剂中浸泡0.5-3分钟后取出、摊晾至豆腐干表面无水,得到涂膜白豆腐干或涂膜卤制豆腐干;
(6)将涂膜白豆腐干或涂膜卤制豆腐干包装后利用高功率脉冲微波设备进行杀菌,得到长货架期豆腐干产品。
2.根据权利要求1所述的方法,其特征在于,步骤(1)中,将大豆按照豆水比1:4-8的比例加水浸泡,大豆豆瓣吸水涨裂后磨浆、除去豆渣获得豆浆;浸泡大豆用的水中含有0.2-0.5%(w/w)的白碱。
3.根据权利要求2所述的方法,其特征在于,采用过滤或离心出去豆渣。
4.根据权利要求2所述的方法,其特征在于,用盐卤、石膏、葡萄糖酸内酯、酸浆或果蔬中的任意一种进行点浆。
5.根据权利要1所述的方法,其特征在于,在破脑步骤中,将豆腐脑破碎至2-5mm;压榨时首先利用时间间隔0.3-0.5s的连续点压至滴水,再用时间间隔为1-2s的点压3-8次,之后用时间间隔为5-10分钟的加压2-5次。
6.根据权利要1所述的方法,其特征在于,步骤(1)中白碱水中含0.1-0.5%(w/w)白碱,水温为60℃以上。
7.根据权利要1所述的方法,其特征在于,步骤(5)中,卤制采用的卤汁的基本配方为:每1000 g水包含如下组分:八角1.5-2.0 g,桂皮0.8-1.5g,陈皮0.2-0.4 g,干姜1.0-1.5g,小茴香1.2-1.6 g,酱油6-15g,盐15-25g。
8.根据权利要1所述的方法,其特征在于,所述多糖溶液中的多糖为壳聚糖、可溶性大豆多糖、普鲁兰多糖、槐豆胶、卡拉胶、魔芋胶或黄原胶中的任一种或几种的组合,多糖添加量为0.3-0.5%(w/w)。
9.根据权利要1所述的方法,其特征在于,所述天然抑菌性提取物为大蒜素和茶多酚中的任意一种或两者的混合物,添加量为0.2-0.5%(w/w)。
10.根据权利要1所述的方法,其特征在于,步骤(6)中,高功率脉冲微波设备处理时,瞬时输出功率为360~400kw,输出脉冲宽度为3~5μs,占空比1:1200~1500,整个过程持续3-5min。
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