RU2531903C2 - Production of dry soybean concentrate - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to production of dry soybean concentrate and can be used in milk industry, confectionary, meat industry at production of sausages and semi-finished products. Proposed process comprises fine grinding of dried, cleaned and washed soybeans. note here that ferments are inactivated in cooker chamber at steam feed at medium temperature 92-95°C.Ground soybean suspension is filtered out to extract water extract wherefrom vegetable cream is mechanical separated at 88-90°C to get fat-free aqueous extract of soybeans with fat content not over 0.7% and acidity of 10-11°T.Said extract is sterilized at 135-137°C for 3 minutes and cooled to not over 7°C. Degreased aqueous extract of soybeans are thickened in vacuum evaporation unit, pasteurized at 75-78°C for 15-20 s and dried in hot airflow. Inlet air temperature makes 170-195°C while outlet air temperature equals 75-90°C. Dry powder is cooled down and packed.

EFFECT: improved odour, longer shelf life.

2 cl, 2 dwg, 3 tbl

Description

The proposed technical solution relates to methods for producing a food product from plant materials, namely, from soybeans that do not contain genetically modified organisms, and can be used in the dairy industry, confectionery industry, and in the meat industry in the manufacture of sausages and semi-finished products.

A known method of producing protein-fat concentrate from seeds of legumes and oilseeds (Application for invention No. 93051275, publ. 10.06.1996), in which the feedstock (soybeans, fodder beans, lupins, peas) are peeled, dry cleaned, crushed thermal modification of the native protein is carried out with the simultaneous inactivation of trypsin inhibitors, hemaggluteins, lipoxygenase, part of the oligosaccharides is separated by soaking, then fine grinding in an aqueous medium is carried out, extraction and emulsification in an aqueous medium or with the addition of vegetable oil or skim milk, the insoluble residue is separated, the emulsion is precipitated with dispersion medium globulins, the concentrated emulsion is separated, neutralization and homogenization are carried out, and a protein-fat concentrate containing 69-83% of the original protein and 72-85% of the original fat, which has a low content of anti-nutrition components, a light smell of nuts, a high balance in amino acid composition, which has a high emulsifying capacity and dispersibility at pH 6-9.

The disadvantages of this method include the following:

 1) the use of vegetable fats;

2) the use of fodder beans and oilseeds, which gives the final product a pronounced astringent bean or oil flavor;

3) this protein-fat concentrate from seeds of legumes and oilseeds is used only as compound feed for farm animals.

A known method of processing soybeans or meal into soybean suspension (Application for invention No. 94035231, publ. 06/27/1996), which consists in grinding beans or meal in water at the same time as extraction, moreover, the beans or meal placed in water are affected by high-frequency pulsed discharges voltage with an energy gradient in the interelectrode gap of at least 40 J / mm

The disadvantages of this method are the lack of a process for removing fat from the product, which leads to a pronounced bean smack and astringent consistency, as well as the shelf life of this product is reduced due to the high amount of fat.

A known method for the production of soy products (Application for invention No.2000107505, publ. 01/27/2002), including soaking the soybeans, grinding them and cooking in water by means of steam supplied to the cooking plant under atmospheric pressure, separation of the cooking slurry into liquid and solid phases by mechanical separation, coagulation of the liquid phase to obtain soybean and obrata destruction, obtained after coagulation, the back is mixed with oil by ultrasonic emulsification to obtain a finished emulsion - "artificial milk ”, enrichment of soya destructate with a biologically active additive and subsequent packaging for sale. Ultrasonic emulsification is carried out by pumping the sample from the lower part of the vessel of a vessel of a certain volume to its upper part through the vessel of an ultrasonic reactor, to which a metered amount of oil is added.

The disadvantages of this method, you can specify the following:

1) when using vegetable oil in the production, the finished product is fatty with a pronounced soy flavor;

2) coagulation of the protein, which translates it into an insoluble state.

There is also known a method for producing soy milk and a method for producing finely ground soybeans suitable for producing soy milk (RF Patent No. 2101979, publ. 20.01.1998), selected as a prototype. The known method involves the fine grinding of washed and dried soybeans, preparing a suspension of the obtained crushed material, heating the suspension with subsequent cooling. At the same time, the beans are dried to a moisture content of 5-7%, before grinding, the bean peel is removed, fine grinding is carried out by dry grinding of beans without a peel. The suspension is prepared by mixing the crushed material with water heated to 60-90 ° C. After mixing the finely ground beans with water, the suspension obtained is ground, the suspension is heat treated at 85-90 ° С, the suspension is cooled to 10-15 ° С, then milk is introduced into the suspension to obtain soy milk, after which the resulting product is homogenized, and subjected to final heat treatment to sterilize it and fill the appropriate packaging with a sterilized product, which is either sterilized or sterilized after filling. Trisodium citrate and tripotassium phosphate are added to the water before mixing with the finely divided material, and calcium lactate is added to this mixture.

The disadvantages of the above method are:

1) the lack of separation okara, as a result of which the finished product is obtained with a pronounced bean and astringent taste;

2) the use of salt - stabilizer (trisodium citrate);

3) the product has a bulk consistency.

Thus, the known methods do not provide a high quality product and are not products used in the food industry. Soy itself is quite stable during storage, but as long as the integrity of the bean peel is maintained. As soon as the beans are chopped, soybeans lose their stability. In addition, soybeans contain substances that, when processed, give the final product an unpleasant odor (hydrogen sulfide, herbal, which is removed by a deaerator).

There are various ways to eliminate unpleasant odors, however, they require significant costs and complicate the process. Thus, there is a social need to create a rational industrial method for producing soybean concentrate, which does not have the disadvantages inherent in the known methods.

The objective of the present invention is to satisfy the above needs and to create a simple way to obtain a product with high biological value and good functional properties.

The technical result consists in obtaining a dry soybean concentrate having an improved odor and a long shelf life.

This is achieved by the fact that the method of obtaining dry soybean concentrate is characterized in that it involves fine grinding of dried and husked, washed soybeans, while the enzyme inactivation process is carried out in a cooker cooking chamber by supplying steam at a temperature of 92-95 ° C, from the resulting crushed soybean suspension, which is filtered to clean from impurities and fibers, emit an aqueous extract from which vegetable cream is removed by mechanical separation at a temperature of 88-90 ° C and get a non-fat aqueous extract of soybeans with a fat content of not more than 0.7% and an acidity of 10-11 ° T, sterilize it at a temperature of 135-137 ° C for 3 minutes and cool to a temperature of not more than 7 ° C, a non-fat aqueous extract of soy the beans are concentrated in a vacuum evaporator, pasteurized at a temperature of 75-78 ° C for 15-20 seconds and dried in a stream of hot air, the temperature of the incoming air being 170-195 ° C, and the leaving air being 75-90 ° C, then dry the powder is cooled and packaged.

Vegetable creams isolated by separation have a fat content of at least 19% and an acidity of not more than 10 ° T.

Figure 1 presents a brief flow chart of the production of dry soybean concentrate; figure 2 is a flow chart of the production of soybean skim milk.

The proposed method is implemented as follows.

The technological process for the production of dry soybean concentrate consists of the following stages (figure 1):

- Reception of whole grains of soybeans;

- Cleaning and decortication - the husk from the grains is removed mechanically to rid the soybean of the astringent effect and avoid any contamination of the product;

- Grinding with water (extraction) - allows you to naturally dissolve all the useful substances of soy;

- Decanting (filtration) - allows you to eliminate all the fibers and get a clean aqueous extract of soybeans;

- Separation (degreasing) - removal of vegetable fat under the action of centrifugal force;

- Heat treatment (sterilization) at a very high temperature of 135 ° C ± 2 ° C in a very short period of time (3 min) - allows you to save all useful substances, remove antitrypsin and ensure high nutritional value of the product;

- Obtaining a protein suspension - an aqueous extract of soybeans;

- Reservation of non-fat water extract of soybeans;

- Thickening in a vacuum evaporator;

- pasteurization of the mixture;

- Drying the product on a disk spray installation;

- Packing and packaging of dry product;

- Storage.

1. Acceptance and preparation of soybeans

Soybeans are taken in weight and quality established by the laboratory of the enterprise, based on the requirements specified in the "Instructions for the input control of soybean seeds."

Soybeans after confirmation of compliance with regulatory documents are taken to the balance of production. As necessary, beans - raw materials through the feed system (pipeline with compressed air passing inside) are sent to the storage hopper, to ensure uninterrupted operation of the equipment. To account for the amount of processed raw materials, the scales built into the storage hopper are used. Soybeans are plumbed on 2 parallel weighing devices.

Weighted unsorted soybeans are fed to a magnetic selector to remove metallic impurities, which is connected to a sorting machine. The magnetic selector is cleaned of metal impurities before each production.

Soybeans enter the grid of the sorting machine, where debris is cleaned (peel of dry pods, stems, large pebbles of the earth) and the beans are sized in size (the size of the lower sieve is not more than 3 mm, the upper one is not more than 5 mm). The number of beans loaded into the machine should not be large, this affects the quality of cleaning. Under the exit hatch there is a container or bag.

2. Calibrated and purified from impurities soybeans enter the machine to remove stones.

Beans are fed onto a sieve with a slope so that the stones can exit the stone exit hatch and avoid removing the beans along with the stones. Before using the stone trapping machine, the exhaust and air supply systems are first turned on, and then the beans are loaded. Under the hatch of the exit of impurities is a container or bag.

3. Drying, peeling, and cotyledoning soybeans

Soybeans enter the conveyor of the dryer. Here, excess moisture from soybeans evaporates to improve husking. Hot air enters the drying chamber, heated by a steam generator. Cooling is carried out by air taken from the premises of the soybean preparation site.

The number of incoming beans is regulated by changing the speed of the conveyor. Drying parameters vary depending on the quality of incoming soybeans.

During operation, the drying temperature is set and adjusted so that the output peeling quality is 75-80%. The temperature range is from 100 ° C to 150 ° C, (in the spring-summer period, the drying temperature is from 100 ° C to 135 ° C, in the autumn-winter period from 135 ° C to 150 ° C).

4. Peeling

Dry chilled soybeans are fed by pneumatic transport (product is supplied through pipelines by air) to the storage hopper of the husking units. Beans by gravity fall into the husking units, where they are subjected to mechanical processing (the husks are peeled off from the beans and partial division into cotyledons occurs).

5. The separation of the husk

Hulled beans fall onto the screw conveyor and are loaded into the machine to separate the husk. Due to the air supply from below, the husk, as a lighter substance, rises upward and is pulled away from the total mass by an exhaust cyclone.

Husked and soybeans that have passed through the primary husk are fed to a magnetic selector to remove metallic impurities. Then enter the exfoliating drum. Unfinished husk is beaten off from soybeans by silicone blades soldered to a perforated drum along the contour of which the beans move. Due to the air supply from below, the husk, as a lighter substance, rises upward and is pulled away from the total mass by an exhaust cyclone.

6. Calibration

Exfoliated beans are conveyed by pneumatic transport to a calibration machine. Here, the separation of shelled, whole, not shelled beans and germ occurs. The removal of the embryos is carried out in order to exclude anti-nutritional substances in the finished product. Whole, unpeeled beans are returned to the husking units.

7. Temporary reservation

Hulled, peeled soybeans are collected in a storage bin for further processing. The beans are fed to the line for obtaining an aqueous extract of soybeans on 2 parallel weighing devices.

8. Inactivation of peeled beans

The process of soaking, washing and inactivation (destruction of the trypsin inhibitor, the presence of which in the finished product can lead to intestinal disorders) of soya peeled beans occurs in the cooking chamber of the cooker. Harmful substances contained in soybeans dissolve in water, and the remnants of husks and dirt are removed along with water.

Beans via pneumatic conveying (product is fed through pipelines by air) through a dosing device to a cooker (cooking chamber) filled with hot water. Inside the camera there is a mesh drum with a screw. The process of inactivation of enzymes occurs by supplying steam inside the drum and increasing the temperature inside the chamber to 92-95 ° C. The countdown of inactivation of soybeans begins from the moment the first portion is fed into the drum and lasts 4-5 minutes.

The beans move in a spiral of the screw, washed, steamed and unloaded into the intermediate chamber, from where the beans are pumped together with water to the device for rinsing the steamed soybeans from the husk residues and dirty washing water after the cooker. The device for rinsing steamed soybeans is a perforated drum with a screw in the middle. Irrigation pipelines are supplied to the screw, through which hot purified water is supplied to rinse the beans. Water flows down the pipeline back to the cooker.

The kooker is constantly supplied with more water than it holds. The drainage of the water from which the garbage is washed out occurs through a recess in the upper level of the cooker. To catch particles, a prefabricated container with a perforated grate is placed under the recess.

The hot water used to inactivate the enzymes is preheated with a plate pasteurizer to a temperature of 85-88 ° C and pumped to a cooker. Simultaneously with the inactivation of the enzymes, the beans are softened and fed to the coarse mill.

9. Grinding

Washed, boiled beans are fed to a coarse mill, where, under the action of sharp blades, the beans are cut into particles up to 2-4 mm. The temperature of the suspension at the outlet of the cooker must not be lower than 88-92 ° С (due to the fact that the soybean suspension is cooled until the protein is extracted, the temperature is maintained at 88-92 ° С.At this temperature, the transition of the soy protein from the insoluble to the soluble state occurs more intensively) .

In the process of grinding soybeans to prevent foaming and regulation of active acidity (pH = 6.9-7.9) of an aqueous extract of soybeans, an aqueous solution of a mixture of antifoam and baking soda is added.

To improve the extraction of soy protein and thoroughly clean the soy suspension is fed to a finely ground mill. Here, the soybean mixture is ground to smaller particles of not more than 0.2 microns.

10. Intermediate accumulation of soy suspension

After passing through the fine grinding unit, the soybean slurry is pumped into the intermediate storage tank by a screw pump before being sent for cleaning — the decanter. In order to avoid a change in the color of the soybean suspension and an increase in acidity, as well as to improve the solubility of the soybean protein, the mixture is sent for decantation (separation of the solid coarse phase (okara) from the liquid) 15 minutes after accumulation. Accumulation occurs with constant stirring.

11. Okara separation on the decanter

Soybean suspension at a temperature of 88-92 ° C from the tank for intermediate accumulation by a centrifugal pump is fed to the decanter.

The decanter is a horizontally located auger centrifuge with a cylindrical-conical drum with a continuous casing for continuous separation of the solid phase from the suspension. Soya suspension passes through a centrally located inlet pipe into the inlet chamber of the screw, passes through openings into the separation chamber of the drum and accelerates to a working rotation speed of 3000 rpm. Under the influence of centrifugal force, okara particles are deposited on the wall of the drum for the shortest time (2-3 seconds). The screw, rotating at a slightly higher speed than the drum casing, continuously conveys a centrifuged okara to the narrow end of the drum.

In the drainage zone, okara is released from the aqueous extract of soybeans (due to the conical shape of the drum) and is freed from the existing fluid under the influence of centrifugal force.

At the end of the drum, the okara is centrifuged into the capture chamber of the housing and discharged through the solid phase shaft. Liquid flows between the turns of the screw into the cylindrical end of the drum. Passing through the purification zone, light impurities remaining in the soybean water extract are discarded by centrifugal force and are fed by the screw to the solid phase outlet. The purified aqueous extract of soybeans leaves the centrifuge chamber through a removable adjustment disk and is discharged under a pressure of 1.5 MPa.

The quality of cleaning the water extract of soybeans from insoluble particles is assessed by checking the amount of micro suspensions, which should not exceed 0.3 cm ^{3 of} crude sediment.

12. Separation of an aqueous extract of soybeans

Purified from solid particles (okara), the aqueous extract of soybeans is fed to a cream separator, where vegetable fat is removed by centrifugal force. The temperature of the extract before separation of 88-90 ° C. In the process of degreasing, soy cream with a fat content of at least 19%, an acidity of not more than 10 ° T and a non-fat aqueous extract of soybeans with a fat content of not more than 0.7%, an acidity of 10-11 ° T are obtained.

The GEA Westfalia separator is designed directly for the separation of an aqueous extract of soybeans and cannot be used to process natural cow's milk.

The design feature of the equipment is that the drum rotation speed is 4700 rpm, which is lower than the milk separator - 6500 rpm. This is because the size and composition of the fat globules of soybean extract is different from milk fat. Therefore, during separation, fat is more difficult to separate from the extract. Therefore, the separation temperature is 80-100 ° С, which increases the rate of fraction separation, the separation temperature in the milk separator is 35-45 ° С. The design feature of this separator is the height of the separation chamber, which provides for a longer stay of the product in it with the aim of better degreasing. The separator has an increased sludge space of up to 90 liters, which reduces the number of sludge discharges, which gives a more stable separation process. Milk separators have a sludge space of up to 11 liters, are often discharged, which leads to large losses of raw materials for fat and protein.

13. Sterilization and cooling of non-fat aqueous soybean extract

Fat-free water extract of soybeans enters the tank for intermediate accumulation and ensure continuous operation of the sterilizer. During the accumulation process, the aqueous extract of soybeans is constantly mixed by turning on a stirrer mounted inside the tank.

To destroy the pathogenic microflora of an aqueous extract of soybeans and to improve the palatability (pronounced taste of pasteurization, which softens the soya taste), the product is sterilized by supplying it with a centrifugal pump to a plate pasteurization-cooling unit. The installation consists of 4 sections: pasteurization, regeneration, pre-cooling and ice-cooling sections. The sterilization temperature is set depending on the further processing of the aqueous extract of soybeans. If it is used for the production of dairy products (except cottage cheese), dry soy products, drinks, mayonnaise, phyto-yogurt, then the sterilization temperature is set at 135-137 ° C, the sterilization duration at this temperature is 3 minutes. Cooling to a temperature of no more than 7 ° C.

14. Temporary storage of non-fat aqueous soybean extract

The chilled water extract of soybeans goes for further processing. If it is necessary or impossible to quickly process it, it is allowed to store it in temporary storage tanks with a stirrer and a jacket at a temperature of no higher than 8 ° C for 6-8 hours.

15. Reservation of non-fat water extract of soybeans

The chilled non-fat water extract of soybeans for smooth operation before starting the vacuum evaporation plant is accumulated in tanks with a stirrer and a jacket. Storage temperature not higher than 8 ° C for 6-8 hours. Acidity is not more than 15 ° T.

16. Condensation in a vacuum evaporator

Fat-free aqueous extract of soybeans before drying is concentrated in a vacuum-evaporator "Wigand" to a concentration of mass fraction of solids of 19-20%, acidity 25-35 ° T. Condensation occurs due to evaporation of moisture at low temperature under the influence of vacuum. The evaporation temperature in the first case is 60-65 ° C, in the second 50-55 ° C.

17. Pasteurization of the mixture

The thickened mixture is pasteurized to improve microbiological parameters. The pasteurization temperature is 75-78 ° C with a shutter speed of 15-20 s.

18. Drying the mixture

To dry the mixture, a spray dryer is used with a mixed movement of air and product, which operates in a two-stage mode. The thickened mixture is sprayed in a stream of hot air in a drying chamber, followed by drying of the sprayed particles and their separation from the air stream. Moisture evaporates from the surface of the particles. Due to diffusion, moisture rises from the inner layers to the place of removed moisture. The atomized particles dry and settle in powder form to the bottom of the drying chamber, and then are removed from it. The drying process takes place in the following modes: temperature of incoming air 170-195 ° C, leaving 75-90 ° C. In the second stage, the powder is transferred to the fluidized state and cooled. Particles of the product through which air is passed move, the layer expands and resembles a boiling liquid. The exhaust air, together with the fine fractions of the dry powder, is discharged from the drying chamber to the cyclone for cleaning. During transportation to the unloading cyclone, the dry powder is cooled to a temperature of 10-15 ° C above the temperature of the intake air. From the discharge cyclone, the cooled powder is fed into the storage hopper. Air from the cyclones is vented by a fan and emitted into the atmosphere.

19. Filling, packaging

The dry product from the storage hopper is fed to the packaging machine. Kraft bags with polyethylene liners are filled in 20-25 kg. The liners are sealed, the bags are flashed with a firmware machine.

20. Storage

The finished product is stored for no more than 12 months from the date of manufacture at a temperature of 0 to + 25 ° C and a relative humidity of 85%.

Tables 1, 2, and 3 show the physicochemical, microbiological, and organoleptic characteristics of dry soybean concentrate, respectively.

Table 1 physical and chemical indicators Product name Name of indicator Mass fraction of moisture,%, no more Mass fraction of fat,%, no more Mass fraction of protein,%, not less Solubility index, cm ³ crude precipitate, not more than Acidity, ° T, no more Dry soybean concentrate 5 1,5 65 1,0 18.0

table 2 microbiological indicators Name of indicator Norm KMAFANM, CFU / g, no more 2.5 * 10 ⁴ BGKP (coliforms) in 0.1 g of product not allowed S.aureus in 0.1 g of product not allowed Sulfite-reducing clostridia in 0.1 g of product not allowed Pathogenic, including salmonella, in 25 g of product not allowed Mold, yeast, CFU / g, not more than one hundred

Table 3 Organoleptic indicators Product name Name of indicator Taste and smell Appearance and Consistency Color Dry soybean concentrate Slightly expressed soy, without extraneous smacks and smells Fine dry powder. Lumps crumbling during mechanical
impact Light cream, uniform throughout the mass.

Claims (2)

1. A method of obtaining a dry soybean concentrate, characterized in that it involves the fine grinding of dried and peeled, washed soybeans, while the process of inactivation of the enzymes is carried out in the cooking chamber of the cooker by supplying steam at a temperature of 92-95 ° C from the obtained crushed soy suspension, which is filtered to clean from impurities and fibers, an aqueous extract is isolated, from which vegetable cream is removed by mechanical separation at a temperature of 88-90 ° C and a fat is obtained water extract of soybeans with a fat content of not more than 0.7% and acidity of 10-11 ° T, sterilize it at a temperature of 135-137 ° C for 3 minutes and cool to a temperature of not more than 7 ° C, fat-free water extract of soybeans thicken in a vacuum evaporator, pasteurized at a temperature of 75-78 ° C for 15-20 s and dried in a stream of hot air, with the temperature of the incoming air 170-195 ° C, and the outlet 75-90 ° C, then the dry powder is cooled and Packed up. 2. The method according to claim 1, characterized in that the vegetable cream extracted by separation has a fat content of at least 19% and an acidity of not more than 10 ° T.

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