RU2004969C1 - Method for processing corn and cereals and device for its realization - Google Patents

Abstract

Usage: feed production, namely the pre-processing of grain components of animal feed. SUMMARY OF THE INVENTION: the method comprises treating a feed with infrared radiation for three cycles; the first - a wavelength of 0.96 - 1 μm, a flux density of 28-3 kW / m; the second - a wavelength of 1.4-1.6 μm, a flux density of 28-3 kW / m2, the third - a wavelength of 3.4 - 3.46 microns, a flux density of 6-8 kW / m2. the interval of the first cycle is 10 - 15 s, the second - 30 - 40 s, the third - 50 - 60 s. The device contains a table with a vibrator, infrared radiation units and a control unit that allows you to change the distance from the radiation units to the vibratory conveyor table 2 sp.p. f-ly, 1 ill.

Description

The invention relates to feed production and can be used for pretreatment of grain components of animal feed, as well as the manufacture of food grain products.

A known method of processing grain products, including the preliminary cleaning and subsequent processing of infrared radiation (IR radiation) for 20 ... 30 s to obtain a product with a moisture content of 6 ... 8% (UK Application, No. 1311066 NKI A 2 Q , 1973). In the process of processing grain products according to the described method, it is exposed to infrared radiation with a flux density of 2 ... 6 kW / m2. Such processing leads to intensive drying of the product, increasing its fragility, which facilitates processing. However, the described process practically does not affect the taste and nutritional value of the product, which limits the application of this method.

Closest to the proposed method in terms of technical nature and the achieved result is a method of processing grain products, including processing by infrared radiation (USSR Author's Certificate No. 1443868, class A 23 K 1/10, 1987). Irradiation of the product according to the specified method is carried out by infrared radiation in the range of 0.8 .., 5.0 μm with a density of 18 ... 25 kW per 1 m2, which allows to reduce the infection, mainly of feed grain, by microorganisms, increases the digestibility of the product by agricultural animals .

As experiments show, in the implementation of this method, IR radiation only intensely affects the moisture in the grain, which heats up during irradiation, turns into steam and breaks the grain. This leads to the mechanical degradation of starch and, as a result, to a slight increase in the content of dextrins and reducing sugars.

A known apparatus for processing grain products, comprising a conveyor for receiving the processed product, and an infrared radiation source mounted thereon (USSR Author's Certificate No. 456966, class F 26 B 17/04, 1972). The described device allows only drying of the product, but does not ensure its disinfection, since only one-sided heating occurs during processing. An increase in heating intensity (ray flux density) can lead to one-sided burning

product. Therefore, the described apparatus is rarely used in the food industry.

Closest to the invention according to

the technical nature and the achieved result is a plant for heat treatment of grain products, containing a table for placing on it the processed product, over which the blocks are installed

infrared radiation sources (USSR Author's Certificate No. 1458666, class F 26 B 3/30, 1987). The table in the described solution is made in the form of a conveyor, and each infrared radiation unit contains a radiation source and a set of screens.

The described installation is more perfect than the above, however, it does not provide uniform heating.

each grain (grain) from all sides, as well as the ability to control (set) the wavelength of infrared radiation in the processing of grain products. So the existing level

The technique does not allow us to solve the problem of increasing the nutritional value of the product by increasing the content of dextrins and reducing sugars in it by comprehensively uniformly treating each grain with infrared radiation with optimized operating parameters.

The essence of the proposed method is as follows: in accordance with the known method of processing

grain products, including processing the feedstock with infrared radiation, according to the invention, irradiation is carried out for three cycles, the first of

which are carried out by radiation with a wavelength of AI 0.96 ... 1.0 μm and a beam flux density Pi 28 ... 30 kW per 1 m2 for 10-15 s, the second cycle - by radiation with a wavelength of λ2 1.4 .. .1.6 microns and beam flux density

p2 28-30 kW per 1 m2 for 30 ... 40 s, and the third - radiation wavelength Ls 3.40 ... 3.46 μm and a beam flux density Pz 6-8 kW per 1 m2 for 50. ..60 s.

The essence of the proposed installation is that in the installation for processing grain products, containing a table for placing on it the processed grain product, over which blocks of infrared radiation sources are mounted, according to the invention, the table is equipped with a vibrator. The blocks are mounted with the possibility of changing the distance between the table and the blocks. The table and blocks are equipped with a single mechanism for changing the angle of inclination

horizontal, and each block of infrared sources has a fixed radiation wavelength and a control circuit independent of other blocks.

It was experimentally established that when IR irradiation of grain products with a wavelength of At 0.96 ... 1.0 μm and a flux density of Pi 28 ... 30 kW per 1 m2 for a short time, intense heating of only the surface layers occurs, accompanied by a transition of moisture into the center of each seed (caryopsis), by the destruction of capillaries and pores of the surface layer. The optimum duration of this processing cycle is P 10 ... 15 s.

With an Ah wavelength of 0.96 µm, a flux density of PI 28 kW per 1 m2, and a Ti 10 s cycle duration, the effect of this PC irradiation cycle is almost not felt. At Ach 1.0 µm, a PI density of 30 kW per 1 m2, and a duration of Ti 15 s, the grain product is degraded and unsuitable for further use.

The second cycle of IR irradiation of grain products, as shown by experiments, leads to an increase in vaporization within each grain (caryopsis). Steam, having no outlet, since the surface capillaries and pores, due to the high temperature of the surface of the caryopsis are deformed and clogged, creates a high internal pressure, which opens the caryopsis. In this case, mechanical destruction of the starch contained in the grain occurs with the formation of dextrins and reducing sugars. The optimal regimes of the second IR irradiation cycle were Aa 1.4 ... 1.6 μm, Pa 28 ... 30 kW per 1 m2, and T2 3 ... 40 s. At Aa 1.4 and A2 1.6 µm, the cycle effect is not realized. With A2 1.4 ... 1.6 μm, P2 28 kW per 1 m2, the cycle duration significantly increases, which is not economically justified. A flux density of P2 of 30 kW leads to the destruction of the product. At T2 40 s, a decrease in the content of reducing sugars in the product was noted.

The third cycle is aimed at thermal decomposition of the remaining intact starch grains, which leads to an increase in the content of dextrins and reducing sugars in the product, i.e. to an increase in nutritional value compared to known solutions. The optimal modes of the third cycle: Az 3.40 ... 3.46 μm, Рз 6 ... 8 kW per 1 m2. TK 5, ... 60s. With Az 3.40 and Az 3.46, the effect of the method is felt

weak, since such PC radiation is practically not absorbed by starch molecules. At Pg 6 kW per 1 m2, the duration of the process is extremely extended, which 5 increases the cost of the process. At Tk 50 s, the cycle does not provide a solution to the problem of increasing the nutritional value of the product. An increase in Tg over 60 s is meaningless, since for 60 s everything is earlier (for I and II

0 cycles) non-degradable starch molecules are destroyed.

Thus, each cycle of IR processing solves its own task and all together, performed sequentially,

5 make it possible, for example, for feed grain by an average of 15%, to increase the content of dextrins in comparison with the prototype.

The design of the proposed installation

0 provides, due to table vibration, the rotation of each grain in the process of irradiation, which allows to achieve high uniformity of heating; By setting the tilt of the table, the grain is transported into the hopper, which ensures the continuity of the processing process; the placement of various infrared sources (blocks) makes it easy to optimize the parameters of the irradiation cycles.

0 as a result of the search, technical solutions containing features distinguishing the proposed method from the prototype were not detected. However, technical solutions have been identified that contain features similar to

5 features that distinguish the proposed device from the prototype. Known vibration devices for transporting bulk materials, such as Auth. St. USSR No. 587055. cl. At 65 C 27/00, published.

05.01.78 g. The presence of a vibrator and an inclined table in the specified device is aimed at increasing productivity. In the proposed device, the presence of a vibrator provides each caryopsis rotation,

5 which contributes to its uniform comprehensive heating.

In this case, the frequency and amplitude of table vibration are selected experimentally for each type of product, for example, for

0 barley with 13% humidity, the optimal values of amplitude A and frequency G were A 0.8 ... 1.2 mm, G 4, ... 60 Hz.

Other technical solutions having features that distinguish the offer from

5 prototypes not detected. Therefore, the proposed technical solutions can be recognized as meeting the criteria of inventive step.

The drawing schematically shows the proposed installation.

It contains a table 1 for placing a grain product on it (not shown in the drawing). Blocks of infrared radiation sources 2-4 are installed above table 1, each of which includes an infrared radiation generator 5, a reflector 6 located above the block and designed to increase the uniform distribution of the radiant flux throughout table 1. The entire thermo-radiation part of the installation is covered by a protective cover 7, under which a vapor-air mixture is accumulated during the processing of grain products, which is discharged from the processing zone through the opening 8 by means of an exhaust fan 9. Blocks 2-4 are arranged to vary the distance from table 1 to the corresponding block. For this, each block 2-4 is provided with a screw mechanism with an elastic element (spring). Table 1 and blocks 2-4 are rigidly interconnected using a common frame 10. The frame 10 is connected to the base of the installation using a screw mechanism 11. The mechanism 11 is designed to change the angle of inclination of the frame 10 together with the table 1 and the blocks with respect to the plane of the base. Block 2 is equipped with an infrared generator of the type KGT-220-1000, the maximum emissivity of which falls on the wavelength AI 0.98 μm, block 3-PC-generator type KGT 220-1000, the maximum emissivity of which falls on the wavelength Az 1, 5 microns. Block 4 is equipped with tubular electric heaters (TENs) with a total power of 6 kW, the maximum PC radiation of which falls on a wavelength of Az 3.42 microns. Each unit 2-4 has an independent electrical control circuit. The installation is equipped with a vibrator 12, which is mounted on the base 10 and kinematically connected to the table 1. The installation has a loading hopper 13, from which the grain product through the dispenser (not shown) is fed to table 1, the receiving hopper 14, which after heat treatment enters product, and then through the lock gate 15 to the cooling conveyor 16.

When carrying out a number of technological operations, for example, heat treatment at high temperatures, a loss in mass and moisture content of the product is possible. In order to obtain a product of the required humidity, a mixing device 17 and humidifier are provided in the installation, equipped with nozzles 18, which are fixed in the receiving hopper 14. The cooling conveyor 16 is enclosed in a casing 19, from which warm air is pumped out of the conveyor 16 from the exhaust fan 20. The finished product through the inlet 21 enters the packaging area (not shown).

Installation works as follows.

The initial product (grain, groats, etc.) enters the feed hopper 13 and through the dispenser, ensuring uniform

the product is fed onto table 1. The dispenser is configured so that it can smoothly increase or decrease the amount of product fed for heat treatment. Grain product in a uniform layer of 2, .. 4 grains

distributed over table 1. The emitter unit 2 is turned on. Using the vibrator 12, the optimal values of the frequency and amplitude of vibration of the table 1 are set.

In the range of the block 2 emitters

the grain product is subjected to heat treatment by a radiant flux from high-temperature quartz halogen emitters of the type KTT-220-1000, the maximum emissivity of which is shifted to the region

AI 0.98 µm (first spectral absorption region of water). During the passage of block 2, the product is heated to 100-110 ° C in the surface layers, followed by a decrease in temperature to the center of the grain. At

the moisture present in the product is directed towards the center of the grains, and the surface layers are sintered, i.e. the system of existing pores and capillaries is abruptly disrupted.

After the product is processed by the emitter unit 2, it falls into the zone of operation of the emitter unit 3, in which KGT-220-1000 type generators are also installed, but the maximum emissivity of which is shifted to the AZ region of 1.5 μm (the second spectral region of water absorption), heating of grains over the entire volume and maximum evaporation of moisture in the inner layers. Excessive internal pressure of the vapor-gas medium breaks the grain from the inside. In this case, many large and small cracks appear. The grain swells and increases in volume.

In the block 4 of emitters, tubular electric heaters of the 5HT422381 brand are installed, the maximum emissivity of which falls on Az 3.4 microns (the absorption band of the CH2 group contained in starch molecules). In the third heat treatment cycle, the starch undergoes intensive thermal decomposition and its decomposition into easily digestible dextrins and reducing sugars, i.e. a sharp increase in its nutritional value. The processed product in the process of vibration of the table 1 is poured into the receiving hopper 14, where it can be subjected to artificial humidification through the nozzles 18. In the nozzles 18, air or other aqueous solution is sprayed with compressed air, which enters the processed product, mixed in the receiving hopper by the device 17. Heat-treated the product entering the hopper 14 is hygroscopic and readily absorbs moisture deposited on its surface. In this case, partial cooling of the product and restoration of its moisture content to the initial level occurs. The humidified product passes through the lock gate 15 for further cooling to the cooling conveyor 16 and, when the required temperature is reached, is used in accordance with the current process.

The method was carried out as follows.

Grain was placed in a single layer on a vibrating table, which was subsequently subjected to IR radiation. First, for processing on 1 cycle, the product was irradiated with an infrared radiation generator (type KGT-220-1000) with a wavelength of AI 0.8 ... 1.2 μm and a beam flux density of PI 20 ... 32 kW per 1 m2, then in the second cycle, an infrared radiation generator (type KGT-200-1000) with an Ar wavelength of 1.0-2.0 μm and a beam flux density of Ra 20 ... 32 kW per 1 m, and the third cycle was carried out in an area provided with tubular electric heaters (heating elements) with a temperature of 450, .. 600 ° C, installed at a distance of 70 ... 75 mm from the pallet. TENs provided irradiation of grain with a wavelength of Az 3.0 ... 4.0 μm and a beam flux density of Pz 5 .., 10 kW per 1 m In the process, the flow rate was controlled by changing the distance from the emitter to the grain product.

During processing, the regimes A, P, T were varied in order to optimize them.

Example 1. The method was carried out for treating feed grain (barley) with a moisture content of 13%. The grain contains in the surface microflora bacteria Pseudomonas herbicola up to 160 thousand cells per 1 kg of grain.

The processing results and operating parameters are given in table. 1.

Example 2. The method was carried out for processing rye with a moisture content of 14%. Grain contamination with Aspergillus fungi (various species) of 9 thousand cells was noted. per 1 kg of grain, while 100% infection within the microflora was registered, the composition of which is dominated by Altenaria fungi and in small quantities Aspergillus and Fusarium.

The processing results and operational parameters are given in table. 2.

Processing grain products by the proposed method allows to increase the content of dextrins in the product compared to the prototype for barley on average 15%, for rye 10%. Thus, the processing of grain products by the proposed method allows to increase the nutritional value of the product.

The optimal processing conditions for the proposed method are as follows:

AI 0.96 ... 1.0 μm; Pi 28 ... 30 kW per 1 M2; Ti 10-15 s;

A2 1.4 ... 1.6 microns; Р2 28 ... 30 kW per 1 m2; T2 30 ... 40 s;

Az 3.40 ... 3.46 μm; Rz 6 ... 8 kW per 1 m2; Tz 50 ... 60s.

Using the proposed method allows almost completely destroying both the external and internal microflora, as well as reducing the destructive force during grinding from 37 according to the (prototype) to 6N.

(56) N.P. Chern Chern. Feed production. M .: Agropromizdat, 1989, p. 183-187.

u o o

L

with

U (O

Claims (2)

1. A method of treating grain and cereals, including exposure to them by a flux of electromagnetic radiation in the infrared range, characterized in that the exposure is carried out in three successive stages, the first of which is carried out with a wavelength of 0.96 - 1 μm, a flux density of 28-30 kW / m2 and an exposure of 10-15 s, a second with a wavelength of 1.4 -1.6 μm, a flux density of 28-30 kW / m2 and an exposure of 30-40 s, a third with a wavelength of 3 , 40 - 3.46 μm, a flux density of 6-8 kW / M2 and an exposure of 50 - 60 s. 2. Device for processing grain and cereals, containing a base on which 0 5 a vibratory conveyor is fixed with a mechanism for changing its angle of inclination, while above the vibratory conveyor are installed blocks of infrared radiation sources connected to a control unit, characterized in that the blocks of infrared radiation sources are installed with the possibility of changing the distance between the vibratory conveyor and each block while maintaining their position relative to the carrier the surface of the vibratory conveyor, with the first block of infrared sources having a wavelength of 0.96 - 1 μm, the second -1.4-1.6 μm, and the third - 3.40 - 3 .46 microns, and the control unit is configured to separately control each unit of the infrared source. J C 5