RU2744135C2 - Automated line for vacuum impregnation of food products and the method of processing products implemented in it - Google Patents

Abstract

FIELD: food tech.SUBSTANCE: automated line for vacuum impregnation of food products with high density contains a cylindrical vacuum chamber, equipped in the upper part with a perforated annular insert located coaxially to it, having a gap with the wall of the vacuum chamber, and a removable horizontally located mesh shutter separating the zone free from the product, a sealed hatch cover for loading and unloading the product, a solution level sensor and a branch pipe for pumping out air, connected through an electric contact vacuum meter, a ball valve of a vacuum pump, a liquid and dust separator with a vacuum pump, another input of an electric contact vacuum gauge through a ball valve of a vacuum pump, a manometer with a pressure regulator is connected to the air compressor with a receiver and a filter for air purification, the vacuum chamber in the middle part is rigidly connected to the shaft of the tipping drive equipped with an inductive position sensor, in the lower part the vacuum chamber has a supply and drain pipe for infusion solution, which is connected to a ball valve for supplying and pumping out the solution, which is connected to a three-way ball valve for changing the direction of the suction flow of the impregnating liquid and a three-way ball valve for changing the direction of the suction flow of the impregnating liquid, these ball valves have electric drives and are installed with the ability to turn on and off by the control unit signals, and the power supply of the electric drives of the ball valves, the vacuum pump, the self-priming pump, the gear motor of the vacuum chamber tilting device is carried out by connecting to a three-phase AC 380 V network through a circuit breaker, the control unit contains a programmable controller configured by means of a remote control having buttons "Solution preparation", "Start", "Unloading", "Initial position", setting and monitoring the air pressure in the vacuum chamber, the duration of exposure to vacuum and impregnating liquid on the product, turning on the impregnating liquid solution preparation command, and switching on the device for tilting the vacuum chamber for unloading the finished product after the end of the impregnation process. The method of food processing, implemented in an automated vacuum impregnation line, is characterized by the fact that food product is loaded into a cylindrical vacuum chamber to the level of a mesh damper that limits a damper zone free of product, air is pumped out of the vacuum chamber using a vacuum pump and the product is held in for a for a short preset time, determined by the type of product, at the end of the vacuuming of the dry product, the vacuum chamber is filled from the bottom with the impregnating liquid from the container with the impregnating solution above the level of the mesh damper to 90% of the volume of the vacuum chamber using a self-priming pump and the product is kept in the impregnating liquid for a given time determined by the type of product, at the end of the exposure, the vacuum is released to atmospheric pressure or higher, the product is held for a specified time, determined by the type of product, then the remaining impregnating liquid is pumped back into the container, the hatch is opened, the mesh damper is turned over and the vacuum chamber is turned over to unload the finished product into the storage hopper for subsequent washing and drying.EFFECT: invention improves consumer properties of food products by ensuring the uniformity of their impregnation with an impregnating solution.12 cl, 6 dwg, 1 tbl

Description

The invention relates to the food industry and is intended for carrying out the process of vacuum diffusion with impregnating solutions of a wide range of products with high density, mainly cereals (sunflower, corn, etc.), walnut and legumes.

Vacuum diffusion is a process in which the air inside the product is removed using a vacuum, and the freed pores are filled with flavoring, vitamin, salt, sugar or other impregnation.

Known device for continuous vacuum impregnation, JPS55134667 (A), IPC A23L13 / 00; A3L17 / 00; A23L19 / 00; A23L3 / 00; A23L3 / 34; A23L3 / 3589; B05C3 / 10; B05C3 / 12, publ. 1980-10-12) / 1 /, in which continuous vacuum impregnation of objects processed by a vertical installation of a vacuum impregnation tower is performed. In the liquid impregnation tank, a vacuum impregnation tower is vertically mounted with a suction inlet connected to a vacuum pump on the top of the tower, and the bottom of the tower opens into a liquid reservoir. When the vacuum pump is operating, the impregnating liquid is introduced from the reservoir into the vacuum impregnation column. The method is particularly well suited for preparing apples for storage under normal refrigeration or for extending the shelf life of apple pieces that have been frozen after processing.

There is a known method of vacuum impregnation of food products and a device for its implementation (RU2517227, publ. 05/27/2014) / 2 /, according to which the products are evacuated simultaneously with their impregnation with an impregnating composition due to its circulation using a pump, at the outlet of which the impregnating composition is pumped under pressure through the processed products, captures oxygen from them and, after additional evacuation of the composition, is supplied again to the pump inlet. The impregnating composition can be, for example, a brine for pickling mushrooms or cucumbers, or some other food liquid mixture, for example, various kinds of seasonings for dishes, juices, etc. The device for implementing the method comprises a pump, a heater, a container, a vacuum chamber connected by a pipeline through a valve with a loading container, connected by a pipeline with controls, while the inlet pipeline located inside the vacuum chamber contains a perforated plate for breaking the impregnating solution into jets. At the end of the impregnation, the product can be in a container in accordance with the expiration date of this product. During operation of the device, gaseous fractions can be released, which, when evacuated, can be absorbed by a food product, for example, fish, receiving various kinds of smoked products. Products in containers can be placed in a cylindrical sealed heat-resistant cling film. After processing the products, they are removed from the container and with the same film from the ends are hermetically sealed from air. The container contains meshes on both sides to hold the products and pass the impregnating composition. The inlet of the container through the heater is connected to a pump by means of a pipeline, which circulates the impregnating composition and impregnates the processed products.

The known method and device are not intended for impregnation of products with a high density, such as sunflower, corn, etc., walnut and legumes.

Uniform impregnation of high-density materials can be carried out in the method of impregnating a support matrix with solid and / or liquid compounds using a compressed gas (mixture of gases), which consists in the fact that solid or liquid compounds and an insoluble support matrix are brought into contact with a compressed gas at a gas density between 0.15 and 1.3 kg / l during at least two asymmetrically flowing pressure change sequences (pulsations) (RU2257961, B05D 1/00, EP01 / 09669 from 21.08.2001) / 3 /. Due to the complexity of the technology and the lack of means for technical implementation in the description, the use of this method is not advisable for the impregnation of solid food products on an industrial scale.

From the prior art, the closest analogue is not identified - the prototype of the claimed invention in terms of the problem to be solved and the means of its implementation.

The objective of the claimed invention is the development of an automated line for vacuum impregnation of food products with high density, mainly cereals (sunflower, corn, etc.), walnut and legumes, and a method for processing such products, implemented in it. As a result, an improvement in the consumer properties of these food products is achieved by ensuring the uniformity of their impregnation with the impregnating solution.

The specified technical result is achieved by the fact that the automated line for vacuum impregnation of food products with high density contains a cylindrical vacuum chamber equipped in the upper part with a perforated annular insert located coaxially to it, having a gap with the wall of the vacuum chamber and a removable horizontally located mesh shutter separating the zone, free of product, a sealed hatch cover for loading and unloading the product, a solution level sensor and a branch pipe for pumping out air, connected through an electrocontact vacuum gauge, a ball valve of a vacuum pump, a liquid and dust separator with a vacuum pump, another input of an electrocontact vacuum gauge through a ball valve of a vacuum pump, a manometer with a pressure regulator is connected to an air compressor, which has a receiver and a filter for air purification. The vacuum chamber in the middle part is rigidly connected to the shaft of the tipping drive equipped with an inductive position sensor.

In the lower part, the vacuum chamber has a pipe for supplying and draining the impregnating solution, which is connected to a ball valve for supplying and pumping out the solution, which is connected to a three-way ball valve for changing the direction of the suction flow of the impregnating liquid and a three-way ball valve for changing the direction of the suction flow of the impregnating liquid, these ball valves have electric drives and are installed with the ability to turn on and off according to the signals of the control unit, and the power supply of electric drives of ball valves, vacuum pump, self-priming pump, gear motor of the vacuum chamber tilting device is carried out by connecting to a three-phase AC 380 V network through a circuit breaker.

The control unit contains a programmable controller made with the possibility of setting and monitoring the air pressure value, duration of exposure to vacuum and impregnation in the vacuum chamber by means of a remote control having buttons "Preparation of the solution", "Start", "Unload", "Initial position" liquid on the product, preparation of the impregnating liquid solution, switching on the device for tilting the vacuum chamber to unload the finished product after the end of the impregnation process.

In a preferred embodiment of the device:

- the volume of the vacuum chamber is 180 liters;

- a rotary vane vacuum pump was used as a vacuum pump to obtain an industrial vacuum;

The method of food processing, implemented in an automated line for vacuum impregnation of food products with high density, is characterized by the fact that food is loaded into a cylindrical vacuum chamber to the level of a mesh damper that limits a damper zone free of product, air is pumped out of the vacuum chamber using a vacuum pump and the product is held for a short time for a specified time, determined by the type of product, at the end of the evacuation of the dry product, the vacuum chamber is filled with an impregnating liquid from the bottom with a self-priming pump from a container with an impregnating solution above the level of the mesh damper up to 90% of the volume of the vacuum chamber and the product is kept in the impregnating liquid for a specified time, determined by the type of product, at the end of the exposure, the vacuum is released to atmospheric pressure or higher, the product is held for a specified time, determined by the type of product, then the remaining impregnating liquid is pumped out back into the container, open the hatch, remove the mesh flap and turn the vacuum chamber over to unload the finished product into the storage bin for subsequent washing and drying.

In a preferred embodiment of the method:

- the vacuum chamber is loaded with food up to 80% of its volume;

- seeds of sunflower, corn, walnut and leguminous crops are used as products with a high density;

- the holding time of dry seeds of sunflower, nuts and legumes in a vacuum equal to 0.09 MPa is 2 minutes;

- the holding time of seeds of sunflower nuts and legumes in the impregnating liquid at a vacuum above the liquid level equal to 0.09 MPa is 5 minutes;

- the holding time of sunflower seeds, nuts and legumes in the impregnating liquid when the vacuum is turned off and the effect of excess pressure on the product in the impregnating liquid is 2 minutes;

- the holding time of corn grains in a vacuum equal to 0.07 MPa is 3 min;

- the holding time of corn grains in the impregnating liquid under vacuum above the liquid level equal to 0.07 MPa is 6 minutes;

- the holding time of corn grains in the impregnating liquid when the vacuum is turned off and the effect of excess pressure on the product in the impregnating liquid is 3 minutes.

It is known from the prior art that when a dry food product is evacuated, the air inside the product is removed using a vacuum, and the vacated pores are filled with an impregnating liquid. However, according to the invention, for a deeper penetration of the impregnating liquid into the product with a high density, after holding the product in the impregnating liquid, the vacuum is released, thereby abruptly increasing the pressure in the zone above the product in the impregnating liquid from vacuum to atmospheric or above atmospheric with the help of a compressor, which leads to to the impregnation of the impregnating liquid into the product and promotes a deeper and more uniform penetration of the impregnating liquid into the grain product with a high density.

Uniform impregnation of these food products with flavoring, aromatic, vitamin, salt, sugar, or other impregnation ensures their high consumer properties. The combination of evacuating a dry food product, holding the product in an impregnating liquid under vacuum and then exposing the product to atmospheric or higher atmospheric pressure to increase the penetration depth of the impregnating liquid is not known from the prior art.

Automation of the process of vacuum impregnation of foodstuffs provides control over all stages of the process of uniform impregnation of these products, which increases labor productivity

The essence of the invention is illustrated by the figures of the drawings, where:

FIG. 1 is a diagram of an automated line for vacuum impregnation of food products.

FIG. 2 is a functional diagram of the control unit.

FIG. 3 - device for tipping the finished product, side view from the right. FIG. 4 - device for tipping the finished product, side view from the left.

FIG. 5 is a block diagram of an algorithm for controlling the process of processing a product with a saline solution.

FIG. 6 is a photograph of a prototype of an automated line for vacuum impregnation of food products.

Table. Modes of processing sunflower seeds, nuts, legumes and corn, used in an automated line for vacuum impregnation of food products.

The automated line for vacuum impregnation of foodstuffs contains a cylindrical vacuum chamber 1, which in the upper part has a hatch 2 for loading and unloading the product, equipped with a sealed cover 3. Under the hatch 2, on the annular ledge of the vacuum chamber 1, a perforated annular insert 4 is rigidly fixed to it coaxially to it. the lower part of which is a removable mesh damper 5. The vacuum chamber 1 in the lower part has a suction pipe 6 connected through a two-way ball valve 7 with three-way ball valves 8, 9 with a self-priming liquid pump 10, which is installed in an overflow type device 11 for preparing an impregnating liquid , which contains a container, divided by a partition with an opening into two parts.

On the side surface of the vacuum chamber 1 in the central part, a shaft 12 is rigidly fixed, connected to a gear motor, which ensures the overturning of the vacuum chamber 1 when unloading the finished product when the inductive position sensor 13 is triggered. In the upper part, the vacuum chamber 1 has a branch pipe 14 for connecting it via an electrical contact vacuum gauge 15, two-way ball valve 16, liquid and dust separator 17 to the vacuum pump 18. On the side surface in the upper part of the vacuum chamber 1, an electrical contact liquid level sensor is fixed by a threaded connection 19. Another input of the electrical contact vacuum meter 15 is connected to a two-way ball valve 20 for vacuum relief, which inlet through a pressure gauge with a pressure regulator 21 (0-8 bar at a speed of 720 l / min) with an air compressor 22 with a receiver and an air purification filter.

The control unit 23 (Fig. 2) contains a programmable controller 24, made on the logical module LOGO, manufactured by Siemens, the first output of which is connected to the input of the self-priming liquid pump 10 through the contactor 25 at 12 A, the second output through the contactor 26 at 9 A is connected to the input of the vacuum pump 18 and to the inlet of the two-way ball valve 16, the third and fourth outputs are connected to the electric drive of the two-way ball valve 20 for vacuum relief, the fifth outlet is connected to the three-way ball valve 9 of the direction of the supplied fluid flow, the sixth outlet is connected to the three-way ball valve 8 for supplying and pumping out the impregnating liquid , the seventh and eighth outputs are connected to the electric drive of the two-way ball valve 7 of the direction of the suction flow of the liquid, the ninth and tenth outputs are connected to the input of the frequency converter 27, the output of which is connected to the shaft 12 of the gear motor of the vacuum chamber 1 tilting device, the eleventh and twelfth outputs are connected to the red and green light LED indicator diodes 28.

The first input of the controller 24 is connected to the "Solution preparation" button 29, the second input to the "Start" button 30, the third input to the "Unload" button 31, the fourth input to the "Home position" button 32. The controller 24 also controls the conveyor switch 33 and the switch of the fan 34 for blowing the finished product, as shown in Fig. 1. The fifth input of the microcontroller 24 is connected to the output of the electrical contact vacuum meter 15, the sixth input is connected to the output of the inductive position sensor 13, the seventh input is connected to the output of the electrical contact liquid level sensor 19. Power supply of electric drives of ball valves, vacuum pump, self-priming pump, gear motor of the vacuum chamber tilting device carried out by connecting to a three-phase AC 380 V network through a circuit breaker (not shown in the drawing).

The algorithm for controlling the process of processing the product with a saline solution is shown in Fig. 5 and is disclosed further in the description of the operation of an automated line for vacuum impregnation of food products.

Load the vacuum chamber through the loading and unloading hatch 2 with a grain product to the level of the mesh gate 5, which is no more than 80% of the volume of the vacuum chamber, fix the mesh gate 5 in the lower part of the perforated ring insert 4 and close the sealed cover 3 of the loading and unloading hatch 2. When pressing the "Start" button 29 on the control unit 23 voltage 24 V is supplied to the second input of the controller 24, which through the output 11 gives a signal to turn off the red LED of the indicator light 28. In this case, the controller 24 through the fourth output sends a signal to the electric drive of the two-way valve 20 for vacuum relief to close.

Further, through the second output, a signal is received that turns on the contactor 26 at 9A, which gives a signal to the electric drive of the two-way ball valve 16 to open and turn on the vacuum pump 18 until the industrial vacuum value is created in the vacuum chamber 1. When the set vacuum value is reached, the electric contact vacuum meter 15 gives a signal to the fifth input of the controller 24, from the second output of which a signal is sent to turn on the contactor 26 at 9A, which turns off the vacuum pump 18 and closes the two-way ball valve 16 of the vacuum pump. A short exposure of the product in a vacuum occurs for a time set by the controller 24 for each product, while the diffusion of moisture and air from the cereal products occurs.

Next, the controller 24 generates a signal to open the two-way ball valve 7 for supplying the impregnating liquid and through the fifth output switches the three-way ball valve 9 to supply the impregnating liquid from the container to the vacuum chamber 1. To prepare the impregnating solution, water is poured into one part of the overflow device 11, and the other part is a filler in a given amount, wt%. When the button "Preparation of the solution" 29 is pressed, a signal is sent to the first input of the controller 24, and the controller sends a control signal through the first output and contactor 25 12A to turn on the self-priming liquid pump 10. In this case, the impregnating liquid through the suction pipe 6 fills the product in the vacuum chamber 1 to 90 % of its volume, which is controlled by an electrical contact fluid sensor 19, which sends a signal to the seventh input of the controller 24, which, through the eighth output, sends a signal to the electric drive of the two-way ball valve 7 for supplying the solution and through the fifth output switches the three-way ball valve 9 for liquid supply to its original position. Then the controller 24 turns on the timer for holding the product in vacuum and impregnating liquid. Maintaining a constant vacuum value in a given range is ensured by turning on and off the vacuum pump 18 according to the readings of the electric contact vacuum meter 15 by sending a signal to the fifth input of the controller 24, and from the second output to turn off / on the contactor 26 at 9A, which turns on / off the vacuum pump 18 and opens / closes the two-way ball valve 16 of the vacuum pump. Further, when the vacuum is released, air from the atmosphere enters the damper zone through the suction nozzle 6 and atmospheric pressure acts on the impregnating liquid from above and presses the impregnating liquid into the product, which increases the depth and, consequently, the uniformity of the impregnation of the product.

After the end of the impregnation process, open the sealed cover 3 of the hatch 2 for loading and unloading the product and, according to the signal from the frequency converter 27, which regulates the speed and direction of rotation of the shaft 12 of the gear motor, the vacuum chamber 1 is tilted 180 degrees when the inductive position sensor 13 is triggered, then the processed product into the hopper - the storage of the discharge conveyor, where it is further washed, purged and, if necessary, dried.

Vacuum impregnation of sunflower seeds was carried out in the claimed device in accordance with the operations of the method used therein. An aqueous solution of an impregnating liquid was prepared with a sodium chloride concentration of 20 wt% per liter.

The table shows the values of pressure, MPa, on the scale of the TM-610P05 electric contact vacuum meter and holding time, min., Obtained at three stages of impregnation of grain products in a saline solution.

Table

Modes of processing sunflower seeds, nuts, legumes and corn, used in an automated line for vacuum impregnation of food products.

Processing stage Pressure, MPa Exposure time, min. Sunflower, nuts, legumes Dry evacuation 0.09 2 Product in impregnating liquid 0.09 five Product in impregnating liquid 0.101 2 Corn Dry evacuation 0.07 3 Product in impregnating liquid 0.07 3 Product in impregnating liquid 0.101

After the end of the impregnation process, the processed product is unloaded into the hopper - the storage of the discharge conveyor, where it is further washed, purged and, if necessary, dried.

Vacuum impregnation of sunflower seeds was carried out in the claimed device in accordance with the operations of the method used in it and the pressure and holding conditions at the stages of processing. An aqueous solution of an impregnating liquid was prepared with a sodium chloride concentration of 20 wt% per liter. To prove the uniformity of the impregnation of sunflower seeds, a red food coloring was added to the impregnating liquid and impregnated in accordance with the present invention. From the sunflower seeds treated in this way, control lots of 10 weighed portions of seeds, 50 g each, were selected for visual indication of color. After separation from the husk and cutting the grain, all samples showed a uniform pink color over the entire section.

Technical documentation has been developed and a prototype of an automated line for vacuum impregnation of food products has been manufactured and tested; serial production for use in the food industry is planned. The claimed automated line can be successfully used for vacuum impregnation of grain crops with impregnating compositions for disinfection or increasing the yield during pre-planting processing.

Sources of information:

1.JPS55134667 (A), IPC A23L13 / 00; A3L17 / 00; A23L19 / 00; A23L3 / 00.

2. A23L3 / 34; A23L3 / 3589; B05C3 / 10; B05C3 / 12, publ. 1980-10-12.

3. RU2517227, publ. 05/27/2014.

4. RU2257961, B05D 1/00, EP01 / 09669 dated 21.08.2001.

Claims (12)

1. Automated line for vacuum impregnation of food products with high density, characterized in that it contains a cylindrical vacuum chamber equipped in the upper part with a perforated annular insert located coaxially to it, having a gap with the wall of the vacuum chamber, and a removable horizontally located mesh shutter separating the zone , free of product, a sealed hatch cover for loading and unloading the product, a solution level sensor and a branch pipe for pumping out air, connected through an electric contact vacuum gauge, a ball valve of a vacuum pump, a liquid and dust separator with a vacuum pump, another input of an electric contact vacuum gauge through a ball valve of a vacuum pump , a manometer with a pressure regulator is connected to an air compressor having a receiver and a filter for air purification, the vacuum chamber in the middle part is rigidly connected to the shaft of the tipping drive equipped with an inductive position sensor, in the lower part there is a vacuum chamber has a branch pipe for supplying and draining the impregnating solution, which is connected to a ball valve for supplying and pumping out the solution, which is connected to a three-way ball valve for changing the direction of the suction flow of the impregnating liquid and a three-way ball valve for changing the direction of the suction flow of the impregnating liquid, these ball valves have electric drives and are installed with the possibility switching on and off according to the signals of the control unit, and the power supply of the electric drives of the ball valves, the vacuum pump, the self-priming pump, the gear motor of the vacuum chamber tilting device is carried out by connecting to a 380 V three-phase AC network through a circuit breaker, the control unit contains a programmable controller configured by means of a remote control having buttons "Preparation of solution", "Start", "Unloading", "Initial position", setting and monitoring in the vacuum chamber the value of air pressure, duration of exposure to vacuum and impregnating liquid on the product, turning on the command for preparing the impregnating liquid solution, turning on the device for tilting the vacuum chamber for unloading the finished product after the impregnation process is completed. 2. The automated line according to claim 1, characterized in that the volume of the vacuum chamber is 180 liters. 3. The automated line according to claim 1, characterized in that a rotary vane vacuum pump is used as a vacuum pump to obtain an industrial vacuum. 4. A method of food processing, implemented in an automated vacuum impregnation line, characterized in that food product is loaded into a cylindrical vacuum chamber to the level of a mesh damper that limits a damper zone free of product, air is pumped out of the vacuum chamber using a vacuum pump and held for a short time the product for a specified time, determined by the type of product, at the end of the evacuation of the dry product, the vacuum chamber with the help of a self-priming pump is filled from below with the impregnating liquid from the container with the impregnating solution above the level of the mesh gate to 90% of the volume of the vacuum chamber and the product is kept in the impregnating liquid for a specified time determined by the type of product, at the end of the exposure, the vacuum is released to atmospheric pressure or higher, the product is held for a specified time, determined by the type of product, then the remaining impregnating liquid is pumped back into the container, the hatch is opened , remove the mesh gate and turn over the vacuum chamber to unload the finished product into the storage hopper for subsequent washing and drying. 5. The method according to claim 4, characterized in that the vacuum chamber is loaded with food to 80% of its volume. 6. The method according to claim 4, characterized in that sunflower, corn, walnut and legume seeds are used as high-density products. 7. The method according to claim 4 or 6, characterized in that the holding time of dry sunflower seeds, nuts and legumes in a vacuum equal to 0.09 MPa is 2 minutes. 8. The method according to claim 4 or 6, characterized in that the holding time of sunflower seeds, nuts and legumes in the impregnating liquid under vacuum above the liquid level equal to 0.09 MPa is 5 minutes. 9. The method according to claim 4 or 6, characterized in that the holding time of sunflower seeds, nuts and legumes in the impregnating liquid when the vacuum is turned off and the effect of excess pressure on the product in the impregnating liquid is 2 minutes. 10. The method according to claim 4 or 6, characterized in that the holding time of the corn grains in a vacuum equal to 0.07 MPa is 3 minutes. 11. The method according to claim 4 or 6, characterized in that the holding time of the corn grains in the impregnating liquid under vacuum above the liquid level equal to 0.07 MPa is 6 minutes. 12. The method according to claim 4 or 6, characterized in that the holding time of corn grains in the impregnating liquid when the vacuum is turned off and the effect of excessive pressure on the product in the impregnating liquid is 3 minutes.

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