CN113142520A - Preparation method of akebia trifoliata fruit freeze-dried crisp - Google Patents
Preparation method of akebia trifoliata fruit freeze-dried crisp Download PDFInfo
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Classifications
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
- A23L19/09—Mashed or comminuted products, e.g. pulp, purée, sauce, or products made therefrom, e.g. snacks
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
- A23P30/10—Moulding
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
- A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Food Science & Technology (AREA)
- Polymers & Plastics (AREA)
- Manufacturing & Machinery (AREA)
- Health & Medical Sciences (AREA)
- Nutrition Science (AREA)
- Preparation Of Fruits And Vegetables (AREA)
Abstract
The invention discloses a preparation method of akebia trifoliata fruit freeze-dried crisp, which comprises the following steps: selecting raw materials; cleaning, screening, sterilizing and drying; separating; breaking cell wall and homogenizing; blending sugar degree; injection molding; pre-freezing; sublimation drying; resolving and drying; and (5) delivering out of the warehouse, packaging and storing. The invention respectively carries out obvious optimization and improvement on separation, wall-breaking homogenization, sugar degree and pre-freezing, can realize the low-sugar standard, slow freezing and quick-freezing alternative pre-freezing modes of high-efficiency separation, wall-breaking homogenization and nutrition maximization, naturalness without addition and melting in the mouth, and provides a healthy food suitable for both young and old.
Description
Technical Field
The invention relates to the technical field of fruit processing, in particular to a preparation method of akebia trifoliata fruit freeze-dried crisp.
Background
Akebia trifoliata (Akebia trifoliata) is a perennial woody vine of Akebia of the family Akebia. The fruit is commonly called as "August melon" or "August fried", ripened in the lunar calendar about August, and automatically cracked along the belly suture of the fruit after ripening, and is similar to banana in shape. Purplish red peel, white and snow pulp, fineness, juiciness, smooth taste and fragrant smell. The research of Liurenpei et al finds that the pulp of Liurenpei et al is rich in protein, sugar, vitamin C and amino acid, the content of aromatic amino acid is far higher than that of conventional fruits such as apples, pears and peaches, and the wild fruits are developed based on the content of free amino acid. Meanwhile, the akebia trifoliate also contains various bioactive substances which are beneficial to the human body, such as saponin, oleanolic acid, flavone and the like, and the pharmacological experiment of the alpha-glucosidase inhibitor extracted from akebia trifoliate shows that the activity of the akebia trifoliate is about 16 times stronger than that of acarbose which is a first-line diabetes drug, wherein the patent is 'CN 201310737187' -a novel 23-oleanolic acid compound, and the preparation method and the application thereof in preparing glycosidase inhibitors. The development and utilization prospect of akebia trifoliata as a third-generation fruit with abundant nutrition and food therapy health care function is very wide, but the problems of strong seasonality, difficult storage and low edibility become the primary problems restricting the development of akebia trifoliata, and how to solve the problems becomes urgent.
The traditional fruit processing modes such as pickling, vacuum frying dehydration, hot air drying and the like are not suitable for the akebia trifoliate, the product form, color and nutrient content of the akebia trifoliate are greatly lost, and the sensory evaluation is not ideal. The vacuum freeze drying technology is a technology which is simplified from medicine and applied to the field of food, not only can completely retain the color and the fragrance of food, but also can maximally lock the activity of nutrient substances and secondary metabolites. The problems of strong seasonality, difficult storage and low edibility of the akebia trifoliata are well solved by adopting pure pulp of akebia trifoliata for freeze drying. Drying under the complete frozen state, the product can not collapse, the whole appearance almost keeps unchanged, the shaping is convenient, the interior presents a loose and porous structure, on one hand, the palatability that the freeze-dried block is formed to be instantly melted in the mouth is facilitated, on the other hand, the weight of the freeze-dried block is greatly reduced, and the weight is about 1/5 before drying. In the aspect of preservation, the fresh fruit of akebia trifoliata can be stored for 2 months at most and will decay under the freezing condition, and process into the freeze-drying piece, product dehydration is thorough, adopt freezing evacuation or fill nitrogen gas packing and assist the light-resistant to preserve, can keep 3 years not rotten, very convenient to marketing, the storage cost is low, compare with fresh fruit, avoided the transportation and stored, the very high cold chain of consumption in the sales process, the convenient while that stores and transports reduces logistics cost and transportation loss, more can increase its nutrient substance's stability, improve the added value of product. At present, the patent related to akebia trifoliata fruit pulp freeze-drying only comprises 'CN 201911019317-a preparation method of akebia trifoliata fruit powder instant solid beverage', and the preparation method comprises the operation steps of fruit selection, cleaning, meat taking, freeze-drying, crushing, sterilization and packaging, and finally akebia trifoliata fruit powder is obtained. But the method has a plurality of defects that (1) freeze drying does not undergo homogenization pretreatment, and the freeze drying time can be prolonged; (2) the pre-freezing mode has no substitution with time length, vacuum degree range and temperature curve, and the conditions of product deformation, light fragrance, foaming, disintegration, color change and insufficient drying are easy to occur in the actual production; (3) too high a microwave heating temperature can result in a significant reduction in the active material of the product. Overall, the product is not ideal and the quality of the lyophilized product is not uniform.
The technology of the invention respectively makes obvious optimization and improvement on separation, wall breaking homogenization, sugar degree and pre-freezing, gives a vacuum degree and temperature curve system which is specially used for the product in the parameters of freeze-drying and the like, makes bold innovation and attempt in the aspects of injection molding and packaging, particularly gives a definite numerical value on the key parameter, and has higher probability of falling to the ground.
Disclosure of Invention
Aiming at the technical defects, the invention aims to provide a preparation method of akebia trifoliata fruit freeze-dried crisp to solve the problems in the background technology.
In order to solve the technical problems, the invention adopts the following technical scheme:
the invention provides a preparation method of akebia trifoliata fruit freeze-dried crisp, which comprises the following steps:
(1) selection of raw materials
Selecting fresh akebia trifoliate fruits which have higher maturity, are not rotten and deteriorate, wherein the raw material selection standard is that the fruits are softened, the fruits are kneaded to feel like well-cooked peaches, and abdominal stitches are obviously whitened but are not cracked;
(2) cleaning, screening, sterilizing, and drying
Firstly, a stainless steel bubble cleaning machine is adopted to clean silt, dust, hair, weeds and other attachments on the surfaces of fruits, and then, the fruits which do not meet the requirements such as immature fruits, cracked fruits, rotten fruits, deteriorated fruits and the like are removed by manually screening fresh fruits. Sterilizing fruits meeting the requirements by using hydrogen peroxide, putting the sterilized fruits on a lifting machine, conveying the fruits into an air dryer by using a conveying belt, and enabling the dried fresh fruits to meet the sanitary requirements on production;
(3) separation of
Peeling and removing seeds of the air-dried fresh fruits;
(4) homogenizing for breaking cell wall
And pouring the separated pulp turbid liquid into a wall breaking machine, rotating at a low speed, and preliminarily homogenizing the pulp turbid liquid. When no macroscopic obvious large tissue exists in the pulp suspension, ultra-high-speed wall breaking is started until the whole pulp suspension is in a water solution state, which is similar to a sand ice state;
(5) blending of sugar degree
And (4) adopting a brix meter to mix the brix of the homogenized pulp aqueous solution, wherein the brix is controlled to be 6-12%.
(6) Injection molding: and (3) introducing the pulp aqueous solution with the adjusted sugar degree into a special injection molding device, wherein a squeeze bottle is adopted for small-batch production, and a specially customized gun arranging device is adopted for quantitative injection for large-batch production. And the injection molding mode comprises two modes, namely a fixed ultra-large production mold and a personalized plastic suction mold.
(7) Prefreezing
Pre-freezing by combining a staged slow-speed and rapid pre-freezing mode, firstly reducing the temperature of a pre-freezing bin to-12 to-8 ℃, putting materials into the pre-freezing bin, maintaining for 40 to 90min, promoting the production of products with large-particle ice crystals, keeping the fragrance of the products to a certain degree, then regulating the temperature of the pre-freezing bin to-50 to-45 ℃, rapidly producing a large amount of small ice crystals, freezing the raw materials to be solid, and pre-freezing for 4 to 6 hours;
(8) sublimation drying
The adopted vacuum pressure is stabilized between 40Pa and 80 Pa. The cold trap temperature was-45 ℃. The temperature gradient of the stage is set to-20 ℃/1h, -15 ℃/1h, -10 ℃/1h, -5 ℃/1h, 0 ℃/1h and room temperature/2 h, and the total is 7 h;
(9) drying by desorption
In order to improve the freeze-drying efficiency, a rapid heating mode is adopted, the temperature of the stage is increased from room temperature to 30 ℃, then is increased to 65 ℃ in a gradient manner and is kept until the difference between the material temperature and the temperature of the partition plate is not more than 10 ℃;
(10) and (5) delivering out of the warehouse, packaging and storing.
Preferably, in the step (2), the concentration of the hydrogen peroxide is 1 to 3 weight percent, and the sterilization time is 30 to 180 seconds.
Preferably, in the step (3), the specific steps of peeling and removing seeds are as follows:
(1) peeling: the peel and the flesh are separated manually, the peel can be broken off by lightly pinching along the abdominal suture line with hands, and then the flesh is dug out by a stainless steel tool and placed in a material barrel, so that the pollution caused by contacting the flesh with hands can be avoided;
(2) removing seeds: the ripe august flesh is crystal clear, the average sugar content reaches more than 10g/100g, the august is viscous, the direct centrifugal efficiency is low, and the separation is not thorough. In order to realize high-efficiency separation, the separation gradient experiment shows that the mass ratio of the seed-containing pulp: mixing and stirring water according to the ratio of 9:1 for 10min at the rotation speed of 1000r/min, standing for 10min, and centrifuging the stirred seed-containing pulp, so that the seed-pulp separation efficiency can be greatly improved.
Preferably, the accessory product of the holboellia latifolia peel separated in the step (3) enters a dicing machine to be used as a raw material of the holboellia latifolia fruit tea.
Preferably, the accessory product of the holboellia latifolia seed separated in the step (3) enters a drying and stir-frying workshop to be used as a raw material of the holboellia latifolia seed oil.
In the step (4), the rotating speed of the low-speed rotation is 20000r/min, and the rotating speed of the instant wall breaking is 40000 r/min.
Preferably, in the step (6), the plastic suction mold is customized individually, and the thickness of the product is controlled to be 1.5 cm-2.5 cm.
In step (9), the temperature gradient at this stage is set as: 30 ℃/1h, 45 ℃/1h, 65 ℃/hold.
Preferably, in the step (10), the ex-warehouse packaging is divided into two types, namely a manufacturer fixed mold and a plastic-uptake customized mold;
(1) and (3) ex-warehouse packaging of a manufacturer fixing mold:
taking the freeze-dried material out of the drying bin, cutting the overflowing part along the bottom of the mold by a blade, pushing the product out of the mold by a clean wood stick, then respectively screening the shape and the color difference, removing the serious damage and the color difference, putting the product into a food grade high-barrier plastic bag, rotating the bag opening, then fastening the bag opening by a sealing rope, placing the bag opening on a clean platform which is 20cm away from the ground and away from the wall, and then subpackaging according to the requirements of customers.
(2) Plastic uptake customized mould ex-warehouse package
The products customized by plastic suction all have the matched packaging storage system, and the products are packaged according to the designed packaging mode. After packaging, the product is also placed on a clean platform at a distance of 20cm from the wall, above the ground.
The invention has the beneficial effects that:
1. efficient separation system: the invention discloses a method for separating skin and meat of a backthern melon, which comprises the steps of injecting water, stirring, standing and centrifuging, wherein the patents of CN 201910653671-an automatic skin and meat separator of the backthern melon and CN 201911089786-an automatic skin and meat separator of the backthern melon are invented at present, but the skin and the meat are separated, juice of the skin is mixed into the pulp, and the bitter taste of a freeze-dried meat product is obvious. The previous centrifugation starts directly with pure pulp, so that extremely high rotation speed is required to completely separate the pulp from the seeds, and occasionally, the pulp is polluted due to broken seeds. For this case, prior to centrifugation as materials: stirring for 15min, standing for 10min, centrifuging the middle and upper layers, greatly improving the efficiency of separating seeds from meat, reducing the damage of seeds and preventing the flesh from becoming yellow and bitter.
2. Wall-breaking homogenizing nutrition maximization: generally, homogenization can be performed by adopting a high-speed stirring mode, but the effect is not ideal, some fibrous tissues cannot be well treated, so that the density is uniform, the mouthfeel is inconsistent, or the drying degree of products is different during freeze-drying, and a 40-mesh sieve is used according to the operation of other patents such as 'CN 201310414578-a preparation method of actinidia arguta freeze-dried fruit powder'. In CN 201710423917A preparation method of fructus Sorbi Pohuashanensis lyophilized powder-application publication, 60 mesh sieve is adopted, and then 200 mesh sieve is adopted. In the invention patent CN201911019317, namely a method for preparing the akebia trifoliata fruit powder instant solid beverage, which is similar to the former patent, homogenization is not mentioned. For the august fruit pulp, the problem of non-uniform density is solved by filtration, but the pulp is inevitably wasted, so that the loss of nutrient components is caused, and the cost is increased. And adopt hypervelocity broken wall machine homogeneity, except can the density of homogeneous jam, avoid appearing freezing inhomogeneous, still can not cause waste and nutrition to run off.
3. The natural additive-free: as a dietetic health-care fruit, the best freeze-drying is not mixed with additives. The difference between the mouthfeel and the taste of different fruits before and after freeze-drying is very obvious, and in order to enable the product to meet the requirements of the consumer market, additives are generally needed to be formulated, so that the main body of the frozen kiwi fruit powder is diluted and sold secretly, for example, in CN201310414578, a preparation method of frozen kiwi fruit powder with actinidia arguta, 25% of maltodextrin is added for maintaining the shape and the mouthfeel; in CN 201110355310-Mori fructus pulp lyophilized tablet and process, various additives are added for sweet and sour blending; the akebia trifoliata fruit freeze-dried crisp does not need to be doped with other additives, has completely pure natural taste, and can be prepared by only controlling the proportion of raw materials and water to achieve the purpose of regulating and controlling the sugar degree.
4. Low sugar standard for just-in-the-mouth: the sugar degree is different, and the time, the taste and the color of the freeze-dried product are greatly different. In similar invention patents, "CN 201310414578-a preparation method of actinidia arguta freeze-dried fruit powder" and "CN 201911019317-a preparation method of clematis trifoliate instant solid beverage" do not refer to sugar degree of the product, while in "CN 201110355310-mulberry pulp freeze-dried tablet and process", "CN 201210090402-vacuum freeze-dried lemon juice powder and preparation method thereof" and "CN 201710423917-a preparation method of freeze-dried powder of actinidia arguta" refer to sugar degree ranges, which are "100-: the sugar content of the product is at least 3 times lower than that of the product, so that the product can well maintain the form, the requirement of melting in the mouth is met, and the product meets the current trend of low-sugar healthy life.
5. Slow freezing and quick freezing alternate pre-freezing mode: the pre-freezing modes are generally two, namely slow freezing and quick freezing respectively, and early experiments show that ice crystals generated by the slow pre-freezing are large and irregular; the diffusion resistance to water vapor is small during drying, which is beneficial to sublimation. But can cause serious mechanical damage to cell tissues and influence the shape and the rehydration of a finished product, thereby causing easy deformation and poor rehydration. The ice crystals generated by quick pre-freezing are smaller, the more the number of formed crystal nuclei is, the smaller the porosity is and the larger the resistance is. The water vapor only penetrates through the dried solid film layer by permeation, the drying time is greatly prolonged, the sublimation is not facilitated, and the rehydration performance after drying is good. For food with fragrance, solid matter part between ice crystals is large during slow freezing, loss of fragrance by diffusion during sublimation is reduced, and fragrance is maintained. In order to enable the shape, the taste and the quality of the product to reach a better state, the technology adopts a staged slow and rapid pre-freezing mode to perform pre-freezing, and a more ideal pre-freezing mode is obtained in the aspects of the fragrance, the taste, the shape and the energy consumption of the product. In many similar freeze-drying patents such as "CN 201410088430-vacuum freeze-drying fruit juice white fungus quinoa soup and production method", "CN 201911019317-preparation method of caulis akebiae trifoliate powder instant solid beverage" and "CN 201210090402-vacuum freeze-drying lemon fruit juice powder and preparation method" are direct pre-freezing time, no further discussion and research is made on the pre-freezing time,
6. the vacuum degree range of the special product is clarified: the efficiency is highest through gradient experiments, the range of vacuum freeze drying vacuum degree which meets the standard is 40-60 Mpa, and in the range, the product cannot foam and deform or collapse.
7. The vacuum drying temperature curve of the special product is clarified: experiments show that the disintegration temperature of the product is about 85 ℃, so a special drying curve is set, the cold-trap temperature is-45 ℃, and the temperature in the sublimation drying stage is-30 ℃/1h, -20 ℃/1h, -5 ℃/1h, 10 ℃/1h, 25/2h, 50 ℃/1h, 65 ℃/6h and 40 ℃/maintenance. The difference between the product before and after warehousing is not obvious through the detection of a color difference meter, the browning condition is not generated, and the shrinkage phenomenon does not occur in the whole shape.
8. Compared with the production of the traditional freeze-drying mold, the plastic suction freeze-drying mold adopted in the method has the following advantages:
(1) mould packing integration: the plastic is not required to be demoulded after being frozen and dried, and the plastic can be used as internal package, so that the operation steps are reduced, the labor is saved, and the product loss is reduced;
(2) the shape is more diversified: the customization of the product shape can be carried out according to the requirements of consumers, and the individual requirements of the consumers are met;
(3) protecting a product: the plastic suction mould has good supporting capacity, and can greatly reduce the loss of products in the aspects of stacking, storage and transportation;
(4) value-added effect: the plastic suction mould can be well integrated with the product in shape and can be matched with the product in color, and the plastic suction mould can be combined with external packaging in color, shape and packaging modes, so that the product is more easily colored;
(5) publicity effect: the plastic sucking mould can print the information to be transmitted in a blank place and can also play a more obvious propaganda effect. Overall, the plastic suction mould and the freeze-drying product are more matched in value and are more in line with the positioning of the high-end market.
Detailed Description
One example
The invention provides a preparation method of akebia trifoliata fruit freeze-dried crisp, which comprises the following steps:
1. selection of raw materials
The raw material for freeze-drying processing is to select fresh akebia trifoliata fruits with higher maturity, no decay and no deterioration. Because the ripeness degree is low, the taste of the fruit is poor, and the seeds and the meat are difficult to separate; the ripeness degree is too high, and the natural cracking of the fruits is difficult to avoid and the fruits are polluted. Therefore, the raw materials are selected according to the standard that the fruits are softened, the kneaded fruits feel like well-done peaches, and the abdominal stitches are obviously whitened but not cracked.
2. Cleaning, screening, sterilizing, and drying
Firstly, a stainless steel bubble cleaning machine is adopted to clean silt, dust, hair, weeds and other attachments on the surfaces of fruits. Subsequently, the fruits which are not ripe, cracked, rotten, deteriorated and the like are rejected by manually screening the fresh fruits. The fruits meeting the requirements enter a hydrogen peroxide disinfection and sterilization link, the concentration of the hydrogen peroxide is 1 to 3 percent, and the sterilization time is 1 min. After sterilization, the raw materials are put in a lifter and enter an air dryer through a conveyor belt, and the fresh fruits after air drying meet the sanitary requirements on production.
3. Separation of
The separation is mainly divided into two steps, namely peeling and removing seeds;
(1) skin and meat separation (peeling): although patents "CN 201911089786-an august peel and meat automatic separation device" and "CN 201910653671-an august peel and meat automatic separator" exist, the separation effect is not ideal, because the separation principle is extrusion type, which causes the juice in the peel to flow into the jam, and further causes the jam to be bitter and astringent, and cannot be used. Therefore, in order to avoid the juice of the peel from flowing into the pulp, and in combination with the actual situation of production, manual separation of the peel and the pulp is the most suitable and efficient method. Because the maturity of the raw materials is high, the fruits are softened, the fruit peels can be broken off by lightly pinching along the abdominal suture line with hands, then the pulp is dug out by adopting a stainless steel tool and is placed in a material barrel, the pollution caused by the contact of the pulp with the hands can be avoided, and the separated accessory product of the holboellia latifolia peel enters a dicing machine to be used as the raw material of the holboellia latifolia fruit tea.
(2) Separating seed from meat (removing seeds): the ripe august flesh is crystal clear, the average sugar content reaches more than 10g/100g, the august is viscous, the direct centrifugal efficiency is low, and the separation is not thorough. In order to realize high-efficiency separation, the separation gradient experiment shows that the mass ratio of the seed-containing pulp: mixing and stirring water according to the ratio of 9:1 for 10min, wherein the rotation speed of a stirrer is 1000r/min, standing for 10min, centrifuging the stirred pulp containing the seeds, greatly improving the separation efficiency of the seeds and the pulp, and feeding the separated accessory product of the holboellia latifolia seeds into a drying and stir-frying workshop to serve as a raw material of the holboellia latifolia seed oil.
4. Homogenizing for breaking cell wall
Pouring the separated pulp turbid liquid into a wall breaking machine, and firstly inching at a low speed of 20000r/min to carry out the most preliminary homogenization on the pulp turbid liquid. And starting ultra-high-speed wall breaking when no macroscopic obvious large tissue exists in the pulp suspension, wherein the instantaneous rotating speed of the wall breaking is 40000r/min until the whole pulp suspension is in a water solution state, which is similar to that of sand ice.
5. Blending of sugar degree
The thickness of the material mainly influences the freeze-drying time, and the sugar degree of the material is a quantitative index of the consistency of the product, so that the freeze-drying time of the product is influenced, and the palatability of the product is influenced more obviously. In order to realize the standardization of products, the effects of one product and one standard and standardizing the market are achieved, and the sugar degree of the materials is subjected to gradient experiments to carry out product subdivision screening.
And (3) blending the sugar degree of the homogenized pulp aqueous solution by adopting a Japan Etotuo PAL-1 sugar degree instrument (unit brix). The variable is controlled to be the sugar degree by controlling the variable method, and the sensory evaluation difference of the freeze-dried products with different sugar degrees is very obvious. As shown in Table 1, the sugar content is between 6% and 10%, the freeze-dried product has stable shape, tastes like cotton candy, has elegant sweetness and strong fruity flavor, and has the characteristic of melting in the mouth; the sugar content is between 11 and 15 percent, the product has stable shape, has the characteristics of looseness and porosity, tastes like waffles, has full sweetness, is easy to melt in mouth and has strong fruit flavor; the sugar content is 16-20%, the product has a part of atrophied shape, the taste is similar to a tough biscuit, the melting is slow in the mouth, the sticky teeth are formed, the sweet smell is snored, and the fruit fragrance is rich.
Therefore, from the above sensory evaluation and acceptance, the sugar degree of the meat aqueous solution with the homogenization result is controlled to be between 6% and 12%, and the shape, sweetness and palatability of the product reach a more coordinated state.
6. Injection molding: and (3) introducing the pulp aqueous solution with the adjusted sugar degree into a special injection molding device, wherein a squeeze bottle is adopted for small-batch production, and a specially customized gun arranging device is adopted for quantitative injection for large-batch production. In order to be able to adapt to the needs of different consumers and to have a higher market share, two injection molding methods can be provided.
The first method comprises the following steps: fixed type ultra-large production mould: generally, the mold is a few polygonal bodies with regular shapes, such as cuboids, cubes, cylinders and the like, the selectivity is low, the mold opening cost is high, the replacement is difficult, but the mold can be recycled, and the mold is suitable for ultra-large-batch conventional production after specification determination.
And the second method comprises the following steps: personalized customization plastic suction mould: compared with the conventional stainless steel, the plastic suction mold has the advantages of extremely low mold opening cost, reusability, more flexibility, and capability of perfectly matching the updating requirement of the product and the unique requirement of a consumer on packaging.
The thickness requirement is as follows: generally, the thickness of the product is not more than 3cm, the pre-freezing and freeze-drying time can be greatly prolonged after the thickness exceeds 2cm, the probability of foaming of the product is increased, and the thickness is generally controlled to be 1.5 cm-2.5 cm.
7. Prefreezing
The pre-freezing modes are generally two, namely slow freezing and quick freezing, and early experiments show that ice crystals generated by the slow pre-freezing are large and irregular; the diffusion resistance to water vapor is small during drying, which is beneficial to sublimation. But can cause serious mechanical damage to cell tissues and influence the shape and the rehydration of a finished product, thereby causing easy deformation and poor rehydration. The ice crystals generated by quick pre-freezing are smaller, the more the number of formed crystal nuclei is, the smaller the porosity is and the larger the resistance is. The water vapor only penetrates through the dried solid film layer by permeation, the drying time is greatly prolonged, the sublimation is not facilitated, and the rehydration performance after drying is good. For food with fragrance, solid matter part between ice crystals is large during slow freezing, loss of fragrance by diffusion during sublimation is reduced, and fragrance is maintained. In order to enable the shape, taste and quality of a product to reach a better state, the technology adopts a staged slow-speed and rapid pre-freezing mode to pre-freeze, firstly, the temperature of a pre-freezing bin is reduced to-10 ℃, a tray filled with materials is pushed into a low-temperature pre-freezing bin through a cart and is maintained for 1 hour, products with large-particle ice crystals are promoted, the fragrance of the products can be kept to a certain degree, then, the temperature of the pre-freezing bin is reduced to-45 ℃, a large number of small ice crystals are rapidly generated, the raw materials are frozen to be solid, and the pre-freezing time is 5 hours.
8. Sublimation drying
The pre-frozen raw materials are sent into a freeze-drying workshop for drying, and the early vacuum degree gradient experiment shows that the product reaches a frozen state when the sugar degree is 6% -12%, the vacuum degree is above 40Pa, the product does not generate bubbles, the product can generate fine small bubbles when the vacuum degree is between 10Pa and 40Pa, irregular bubbles can occur when the vacuum degree is below 10Pa, and the deformation of the product is very obvious. In order to take the freeze-drying efficiency and the product performance into consideration, the adopted vacuum pressure is generally stabilized between 40Pa and 60 Pa. The cold trap temperature was-45 ℃. The temperature gradient of the stage is set to-20 ℃/1h, -15 ℃/1h, -10 ℃/1h, -5 ℃/1h, 0 ℃/1h and 20 ℃/2h, and the total is 7 h. .
9. Drying by desorption
When the temperature of the product reaches 20 ℃, more than 90% of water in the product is sublimated, so that the storage life and the quality guarantee period of the product are further prolonged. Continuing to perform the resolution drying, experiments show that the disintegration browning temperature of the product is about 85 ℃, so that the highest resolution temperature of 65 ℃ is generally adopted, in the process of the stage, in order to improve the freeze-drying efficiency, a rapid heating mode is used, the temperature of the stage is started from the room temperature, generally, the room temperature of a workshop is ensured to be generally 15 ℃ by an air conditioner of a factory building, and therefore the temperature gradient of the stage is set as follows: 30 ℃/1h, 45 ℃/1h and 65 ℃/maintenance until the difference between the material temperature and the clapboard temperature is not more than 10 ℃.
(10) Delivery, packaging and storage
The packaging of the warehouse-out is divided into two types, namely a manufacturer fixed mold and a plastic uptake customized mold;
(1) and (3) ex-warehouse packaging of a manufacturer fixing mold:
taking the freeze-dried material out of the drying bin, cutting the overflowing part along the bottom of the mold by a blade, pushing the product out of the mold by a clean wood stick, then respectively screening the shape and the color difference, removing the serious damage and the color difference, putting the product into a food grade high-barrier plastic bag, rotating the bag opening, then fastening the bag opening by a sealing rope, placing the bag opening on a clean platform which is 20cm away from the ground and away from the wall, and then subpackaging according to the requirements of customers.
(2) Plastic uptake customized mould ex-warehouse package
The products customized by plastic suction all have the matched packaging storage system, and the products are packaged according to the designed packaging mode. After packaging, the product is also placed on a clean platform which is away from the ground and is 20cm away from the wall;
the packaging and storage of the two products are in accordance with the relevant requirements of the standard August melon of DBS 51/005-;
11. food safety detection
The indexes of sanitation, physicochemical property and the like accord with the relevant standards (GB/T7100-2015 biscuit, GB 2762-2017 food pollutant limit GB 2761-2017 food mycotoxin limit DBS51/005-2018 food safety local standard August melon)
Second, test and detection
2.1 Single factor experiment
In the experiment, referring to the kiwi fruit low-sugar compound jam processing technology [ J ] of Chenshiqing and the like, rural new technology, 2020(01) and 56 research method, and response surface analysis of vacuum freeze drying technology of Xixia apples of Zhao Fengming and the like [ J ] Chinese university of agriculture, 2015,20(05) 241) 248, screening of factors, and selecting 4 factors which influence the quality of the Bayue melon freeze-dried crisp: the August melon and fruit jam has sugar degree, pre-freezing time, vacuum degree and sublimation temperature. And (4) judging the optimum dosage of each single factor by sensory evaluation, and analyzing the influence of each factor on the sensory quality of the freeze-dried crisp.
(1) Prefreezing scheme
Scheme 1: directly reducing the temperature to-45 ℃ for pre-freezing for 6 h;
scheme 2: pre-freezing at-15 deg.C for 2 hr, and pre-freezing at-45 deg.C for 4 hr;
scheme 3: pre-freezing at-25 deg.C for 2 hr, and pre-freezing at-45 deg.C for 4 hr;
(2) heating curve scheme
Scheme 1: -30 ℃/1h, -20 ℃/1h, -5 ℃/1h, 10 ℃/1h, 20/2h, 50 ℃/1h, 60 ℃/6h, 40 ℃/hold.
Scheme 2: -30 ℃/1h, -20 ℃/1h, -5 ℃/1h, 10 ℃/1h, 20/2h, 50 ℃/1h, 70 ℃/6h, 50 ℃/hold.
Scheme 3: -30 ℃/1h, -20 ℃/1h, -5 ℃/1h, 10 ℃/1h, 20/2h, 50 ℃/1h, 80 ℃/6h, 65 ℃/hold.
2.1.1 sugar degree
Single factor experiment of the sugar degree of the holboellia latifolia jam: mixing the holboellia latifolia jam with different sugar content of the holboellia latifolia jam, setting the vacuum degree of a freeze dryer to adopt a scheme 2, setting the sublimation temperature to adopt a scheme 2, and determining the optimum selection of the holboellia latifolia jam sugar content by comparing the sensory score difference of the holboellia latifolia freeze-dried crisp with different sugar content of the holboellia latifolia jam.
TABLE 1 single-factor experiment design factor for sugar degree of August melon and fruit
2.1.2 prefreezing time period
One-factor experiment of prefreezing duration: the most suitable August melon and fruit jam sugar degree quantized by the last experiment is 10 Brix%, the vacuum degree of a freeze dryer is set to be 60pa, the sublimation temperature adopts a scheme 2, and the most suitable choice of the pre-freezing time length is determined by comparing the sensory score difference of freeze-dried crisps caused by different pre-freezing time lengths.
TABLE 2 prefreezing mode Single factor Experimental design
| Level of factor | Sugar degree | Length of prefreezing | Degree of vacuum | Temperature rising curve |
| 1 | 10Brix％ | Scheme 1 | 60Pa | Scheme 2 |
| 2 | 10Brix％ | Scheme 2 | 60Pa | Scheme 2 |
| 3 | 10Brix％ | Scheme 3 | 60Pa | Scheme 2 |
2.1.3 degree of vacuum
Taking the determined jam with the most suitable August melon and fruit jam sugar content and the pre-freezing time, setting different vacuum degrees, adopting a scheme 2 for a heating curve, and determining the most suitable vacuum degree by comparing the sensory evaluation differences of the freeze-dried crisp caused by different vacuum degrees.
TABLE 3 vacuum degree Single factor Experimental design
| Level of factor | Sugar degree | Length of prefreezing | Degree of vacuum | Temperature rising curve |
| 1 | 10Brix％ | Scheme 2 | 5Pa | Scheme 2 |
| 2 | 10Brix％ | Scheme 2 | 15Pa | Scheme 2 |
| 3 | 10Brix％ | Scheme 2 | 45Pa | Scheme 2 |
2.1.4 drying temperature Curve
Selecting the determined most suitable August melon and fruit jam sugar degree, pre-freezing time length and vacuum degree, selecting different sublimation temperatures, and determining the most suitable sublimation temperature by comparing the sensory score difference of the freeze-dried crisp of different sublimation temperature schemes.
TABLE 4 temperature rise Curve Single factor Experimental design
2.2 orthogonal optimization experiments
Separating fresh August melon, homogenizing, sterilizing, pretreating to obtain pulp with different sugar degree, pre-freezing time and vacuum degreeAnd performing single-factor experiment in the temperature rise curve, selecting 3 levels of sugar degree, temperature rise curve and vacuum degree as 3 factors to perform orthogonal experiment on the basis of completing the single-factor experiment, and adopting L9(34) Orthogonal table, the levels of each test factor are set up in table 5.
TABLE 5 Quadrature experimental design table for lyophilized powder of holboellia latifolia
1.3 sensory evaluation
TABLE 6 sensory evaluation criteria for lyophilized powder of August melon
1.4 data processing
The data processing adopts Excel2010 software, SPSS20.0 for statistical analysis,
2. results and analysis
2.1 Freeze-dried powder proportioning Single factor experiment
2.1.1 sugar degree Single factor experiment
With the continuous increase of sugar degree, the product form of the akebia fruit protein freeze-dried powder begins to shrink, the taste becomes crisp and hard, the sweetness is increased, the fragrance is excessive, the pleasure is reduced, the palatability is weakened, the toughness is enhanced, and the overall effect is deteriorated. Therefore, according to the evaluation of groups, under the conditions that the vacuum degree is 60Pa, the prefreezing time length selection scheme 2 and the heating curve selection scheme 2 are adopted, the sugar degree of the raw material of the holboellia latifolia freeze-dried powder is controlled to be 4 brix% -13 brix%, wherein 4 brix% -8 brix% of the product has elegant sweetness and is suitable for low-sweetness people, and 9 brix% -13 brix% of the product has sufficient sweetness and is suitable for people with partial sweetness.
TABLE 7 sugar content single-factor experimental results of the lyophilized powder of holboellia latifolia
2.1.2 prefreezing time Single factor experiment
In general, the pre-freezing modes in the single factor are generally three, namely slow freezing, quick freezing and mixed freezing, and experiments show that ice crystals generated by the slow pre-freezing are large and irregular; the diffusion resistance to water vapor is small during drying, which is beneficial to sublimation. But can cause serious mechanical damage to cell tissues and influence the shape and the rehydration of a finished product, thereby causing easy deformation and poor rehydration. The ice crystals generated by quick pre-freezing are smaller, the more the number of formed crystal nuclei is, the smaller the porosity is and the larger the resistance is. The escape of water vapor only depends on the permeation of a dried solid film layer, the drying time is greatly prolonged, the sublimation is not facilitated, and the rehydration performance after drying is good. For food with fragrance, solid matter part between ice crystals is large during slow freezing, loss of fragrance by diffusion during sublimation is reduced, and fragrance is maintained.
TABLE 8 duration single-factor experimental results of the lyophilized August melon powder
2.1.3 vacuum Single factor experiment
The foaming condition of the holboellia latifolia protein freeze-dried powder is gradually reduced along with the increase of the vacuum degree, and when the vacuum degree is 3-10 Pa, the product has obvious foaming phenomenon and can not maintain the stability of the form. The foaming phenomenon of 10 Pa-30 Pa is reduced, although the product can maintain the shape, the foaming trace is obvious, and dissipation holes are left. Between 30Pa and 50Pa, the product can maintain its form and the foaming phenomenon is further reduced, but the foaming phenomenon is very slight even though it is close to about 50Pa, and the overall appearance of the product is affected. In a vacuum after 50Pa, the product was still foamed but not visible to the naked eye, but the drying time was prolonged. Therefore, in general, the product of scheme 3 has the best sense and the product of scheme 2 has a slightly inferior sense on the premise that the product meets the requirements, but the scheme 2 is more scientific in drying time and energy consumption.
TABLE 9 Single-factor experimental results on vacuum degree of August melon freeze-dried powder
2.1.4 temperature rise Curve Single factor experiment
Vacuum freeze drying is divided into 2 stages, sublimation drying and desorption drying respectively, and sublimation drying is mainly used for removing free water in materials, and desorption drying is used for removing combined water in tissues. As can be seen from the table, with the increase of the maximum resolution temperature and the maintenance, the color difference of the product is gradually obvious, the milky white color of the jam begins to be changed into dark yellow, and meanwhile, the shape of the product cannot be well maintained, and the phenomenon of shrinkage is started to appear. On the contrary, the water content of the product is inversely proportional to the keeping temperature, which is beneficial to the storage of the product.
TABLE 10 Single-factor experimental results of temperature rise curve of August melon freeze-dried powder
2.1.5 orthogonal optimization of experimental results
From the results of the range analysis in table 11, the primary and secondary sequences affecting sensory quality factors of the akebia japonica freeze-dried powder are sequentially temperature rise curve > vacuum degree > pre-freezing time > sugar degree, and the range R in the table shows that the temperature rise curve is used for comparing sensory scores of the freeze-dried powder, the next is the vacuum degree, and then the pre-freezing time is tried, and the sugar degree is the first time. The A1B2C2D2 is the optimal combination from the visual point of view.
TABLE 11 Quadrature experimental results of August melon lyophilized powder
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (9)
1. A preparation method of akebia trifoliata fruit freeze-dried crisp is characterized by comprising the following steps:
(1) selection of raw materials
Selecting fresh akebia trifoliate fruits with higher maturity, no rot and no deterioration, wherein the raw material selection standard is that the fruits are softened, the fruits are kneaded to feel like well-cooked peaches, and abdominal stitches are obviously whitened but are not cracked;
(2) cleaning, screening, sterilizing, and drying
Firstly, cleaning silt, dust, hair, weeds and other attachments on the surfaces of fruits by using a stainless steel bubble cleaning machine, then manually screening fresh fruits, removing the fruits which do not meet the requirements such as immature, cracked, rotten and deteriorated fruits, sterilizing the fruits which meet the requirements by using hydrogen peroxide, putting raw materials into a lifter after sterilization, and feeding the sterilized fruits into an air dryer by using a conveyor belt, wherein the fresh fruits after air drying meet the sanitary requirements on production;
(3) separation of
Peeling and removing seeds of the air-dried fresh fruits;
(4) homogenizing for breaking cell wall
Pouring the separated pulp suspension into a wall breaking machine, firstly rotating at a low speed, preliminarily homogenizing the pulp suspension, and starting ultra-high-speed wall breaking when no macroscopic obvious large tissue exists in the pulp suspension until the whole pulp suspension is in a water solution state, which is similar to a sand ice state;
(5) blending of sugar degree
Adopting a brix meter to mix the brix of the homogenized pulp aqueous solution, wherein the brix is controlled to be 6-12%;
(6) injection molding: introducing the pulp aqueous solution with the adjusted sugar degree into special injection molding equipment, wherein a squeeze bottle is adopted for small-batch production, and a specially customized gun arranging equipment is adopted for quantitative injection for large-batch production, and the injection molding mode is two modes, namely a fixed ultra-large production mold and a personalized customized plastic suction mold;
(7) prefreezing
Pre-freezing by combining a staged slow-speed and rapid pre-freezing mode, firstly reducing the temperature of a pre-freezing bin to-12 to-8 ℃, putting materials into the pre-freezing bin, maintaining for 40 to 90min, promoting the production of products with large-particle ice crystals, keeping the fragrance of the products to a certain degree, then regulating the temperature of the pre-freezing bin to-50 to-45 ℃, rapidly producing a large amount of small ice crystals, freezing the raw materials to be solid, and pre-freezing for 4 to 6 hours;
(8) sublimation drying
The adopted vacuum pressure is stabilized between 40Pa and 80Pa, and the cold trap temperature is-45 ℃; the temperature gradient of the stage is set to-20 ℃/1h, -15 ℃/1h, -10 ℃/1h, -5 ℃/1h, 0 ℃/1h and room temperature/2 h, and the total is 7 h;
(9) drying by desorption
In order to improve the freeze-drying efficiency, a rapid heating mode is adopted, the temperature of the stage is increased from room temperature to 30 ℃, then is increased to 65 ℃ in a gradient manner and is kept until the difference between the material temperature and the temperature of the partition plate is not more than 10 ℃;
(10) and (5) delivering out of the warehouse, packaging and storing.
2. The preparation method of the akebia trifoliata fruit meat freeze-dried shortbread as claimed in claim 1, wherein in the step (2), the concentration of hydrogen peroxide is 1 wt% -3 wt%, and the sterilization time is 30 s-180 s.
3. The preparation method of akebia trifoliata fruit freeze-dried shortbread as claimed in claim 1, wherein in the step (3), the specific steps of peeling and removing seeds are as follows:
(1) peeling: the peel and the flesh are separated manually, the peel can be broken off by lightly pinching along the abdominal suture line with hands, and then the flesh is dug out by a stainless steel tool and placed in a material barrel, so that the pollution caused by contacting the flesh with hands can be avoided;
(2) removing seeds: the pulp containing seeds according to the mass ratio: mixing and stirring the mixture with water in a ratio of 9:1 for 10min at a rotation speed of 1000r/min, standing for 10min, and centrifuging the stirred seed-containing pulp.
4. The method for preparing akebia trifoliata fruit meat freeze-dried shortbread as claimed in claim 1, wherein the accessory product akebia trifoliata fruit skin separated in step (3) enters a dicer to be used as a raw material of akebia trifoliata fruit tea.
5. The method for preparing akebia trifoliata fruit freeze-dried crisps as claimed in claim 1, wherein the accessory product akebia trifoliata seeds separated in step (3) enter a drying and stir-frying workshop to be used as a raw material of akebia trifoliata seed oil.
6. The preparation method of akebia trifoliata fruit freeze-dried shortbread as claimed in claim 1, wherein in the step (4), the rotation speed of the low-speed rotation is 20000r/min, and the instantaneous rotation speed of the wall breaking is 40000 r/min.
7. The method for preparing akebia trifoliata fruit meat freeze-dried shortbread as claimed in claim 1, wherein in the step (6), the plastic suction mold is customized individually, and the thickness of the product is controlled to be 1.5 cm-2.5 cm.
8. The method for preparing akebia trifoliata fruit freeze-dried shortcake as claimed in claim 1, wherein in the step (9), the temperature gradient in the stage is set as follows: 30 ℃/1h, 45 ℃/1h, 65 ℃/hold.
9. The method for preparing akebia trifoliata fruit freeze-dried shortbread as claimed in claim 1, wherein in the step (10), the packaging for ex-warehouse is divided into two types, namely a factory fixed mold and a plastic uptake customized mold;
(1) and (3) ex-warehouse packaging of a manufacturer fixing mold:
taking the freeze-dried material out of a drying bin, cutting the overflowing part along the bottom of a mold by using a blade, pushing the product out of the mold by using a clean wood stick, then respectively screening the shape and the color difference, removing the damage and the serious color difference, putting the product into a food-grade high-barrier plastic bag, fastening a bag opening by using a sealing rope after rotating, placing the bag opening on a clean platform which is 20cm away from the ground and away from the wall, and then subpackaging according to the requirements of customers;
(2) plastic uptake customized mould ex-warehouse package
The products customized by plastic suction all have the matched packaging storage system, and the products are packaged according to the designed packaging mode, and after being packaged, the products are also placed on a clean platform which is away from the ground and is 20cm away from the wall.
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