WO2018018358A1 - 一种浓缩苹果清汁的制备工艺 - Google Patents

一种浓缩苹果清汁的制备工艺 Download PDF

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WO2018018358A1
WO2018018358A1 PCT/CN2016/091540 CN2016091540W WO2018018358A1 WO 2018018358 A1 WO2018018358 A1 WO 2018018358A1 CN 2016091540 W CN2016091540 W CN 2016091540W WO 2018018358 A1 WO2018018358 A1 WO 2018018358A1
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apple
temperature
juice
pulp
steam
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PCT/CN2016/091540
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English (en)
French (fr)
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崔政伟
俞建峰
陈海英
崔捷
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江南大学
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Priority to PCT/CN2016/091540 priority Critical patent/WO2018018358A1/zh
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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
    • A23L2/00—Non-alcoholic beverages; Dry compositions or concentrates therefor; Their preparation
    • A23L2/02—Non-alcoholic beverages; Dry compositions or concentrates therefor; Their preparation containing fruit or vegetable juices
    • A23L2/08—Concentrating or drying of juices

Definitions

  • the invention belongs to the technical field of food and beverage, and in particular relates to a preparation process of a browning apple concentrated juice.
  • apple juice is widely circulated in Western countries, meaning that apples and their processed products have high nutritional value and health care effects, which is why Apple and its processed products have become consumers in developed markets.
  • the results of nutritional science research show that the carbohydrates in apple juice are mainly composed of sugar, which is easily converted into glucose and fructose which are easily absorbed by human body. Apple juice is also rich in soluble phosphorus and iron, which helps infants to digest and Absorption; apple juice also has health care functions such as moisturizing the lungs, appetizing, quenching thirst, and spleen and diarrhea, neutralizing excessive gastric acid, and promoting adrenaline secretion.
  • Medical research has also shown that flavonoids in apple juice combined with polyphenolic compounds can inhibit the growth and spread of cancer cells in human body and have anticancer effects. It can be seen that apple juice, as the main processed product of apple, has higher nutritional value.
  • Apple juice is the second largest juice consumer in the world, mainly used as the basic ingredient in beverage production. 90% of foreign beverage manufacturers use apple juice as the basic ingredient in beverage production. In addition, apple juice is also used in fruit wine making, cosmetics, health care products, pharmaceutical additives and the like. Since the 1990s, China's apple juice industry has experienced a development process from scratch and from small to large. In 2010, there were 449 fruit juice and vegetable juice beverage processing industries with a capacity of over 10,000 tons in the national beverage industry, including nearly 100 concentrated apple juice production enterprises with a processing capacity of 20 tons/hour or more. This development has prompted the world's apple juice production and trade centers to be significantly transferred to China.
  • the concentrated apple juice is divided into two types: concentrated apple clear juice and concentrated apple turbid juice.
  • the clear juice needs to undergo an enzymatic hydrolysis process, so it does not contain soluble solid matter, and the turbid juice contains non-soluble solid matter without enzymatic hydrolysis and ultrafiltration treatment.
  • apple turbid juice contains pectin, protein, cellulose, natural pigments, aromatic substances and Vitamins are far more than apple juice, have a softer taste, more sensory state, more reflect the original taste of apple fruit, have higher nutritional value, but the current concentrated apple juice on the market is still clear juice
  • the turbid juice is less, because the production process of concentrated apple turbid juice is complicated, especially the technical problems such as browning and sedimentation have not been fundamentally solved.
  • apple juice or turbid juice is basically a process of heating the slurry to kill enzymes after cold crushing, or adding a certain amount of ascorbic acid (Vc) to suppress browning during cold crushing, but polyphenol oxidase promotes browning. More serious. It is found that about 83% of the browning reaction in apple processing occurs within a few minutes of the crushing process, so solving the enzymatic browning in the crushing process is the key to preparing high-quality apple clear juice.
  • the present invention is directed to the problems existing in the prior art, and provides a technique for rapidly heating steam to an enzyme-killing process in a crushing process, and then performing ultra-fast cooling, thereby realizing the inactivation of an easily browned apple by a physical method. And anti-browning treatment, in line with the concept of green and safe processing of contemporary food.
  • the pulp after the enzyme is cooled by ultra-rapid cooling to normal temperature to avoid the ripening of the pulp, retaining the original color and flavor of the apple and providing nutrients, which provides a reliable guarantee for the preparation of high-quality concentrated apple juice, thus eliminating the need for subsequent
  • the resin adsorption decolorization step greatly reduces the production cost.
  • the invention will greatly improve the apple concentrated juice
  • the preparation process improves the quality of the product and has extremely high economic and social benefits.
  • the invention provides a preparation process of concentrated apple clear juice, comprising the following steps:
  • step (2) Integration of crushing pulping and steam inactivation: the apple treated in step (1) is crushed and pulped, and the apple is broken by the high-speed knife paddle to the particle diameter of about 2 mm, and the control knife is passed.
  • the sharpness, rotation speed and time of the paddle cutter can control the size of the crushing particle size.
  • the apple should not be broken and fine, and the core is harder. It should not be broken during the process of crushing and pulping.
  • a few minutes before the start of the crushing steam is taken off to drive off the air in the crushing chamber. The steam is evenly sprayed to the broken apple.
  • the pressure of the steam injected here is 0.12 ⁇ 0.25MPa, and the temperature of the pulp is rapidly increased within 1-3 minutes.
  • the steam is stopped and maintained for 48 to 12 s.
  • step (3) ultra-fast cooling the apple pulp obtained in step (2) is rapidly cooled by means of vacuum cooling and chilled brine conduction cooling, so that the slurry is rapidly cooled to below 40 ° C in 1-2 minutes, specifically The apple pulp is quickly pumped into the vacuum cooler in 1-2 minutes, and the pulp is lowered in the form of a film.
  • the vacuum cooler uses a centrifugal scraper film vacuum evaporator, and the evaporator jacket is provided with chilled brine, vacuum.
  • the cooling vacuum is 0.075 to 0.09 MPa, and the chilled brine temperature is less than -4 °C.
  • the apple pulp prepared in step (3) is filtered to remove the core, and then subjected to ultrafine pulverization, enzymatic hydrolysis, ultrafiltration, multi-effect low-temperature concentration, pasteurization and aseptic filling to obtain concentrated apple. Finished product of clear juice.
  • the granularity of the pulp in the pulp after the integrated treatment of the broken enzyme is generally not more than 2 mm, the core is hard, and it is not broken as much as possible in the process of crushing and pulping, and the apple core is removed by filtration using a 10-mesh sieve;
  • the pulverization is to pulverize apple pulp and apple pomace to 100-120 mesh to realize full utilization of apple fruit nucleus;
  • enzymatic hydrolysis is to add appropriate amount of pectinase and amylase to enzymatic cleavage and enzymatic hydrolysis temperature in the enzymolysis tank.
  • the temperature is 50-53 ° C
  • the enzymatic hydrolysis time is 45-60 minutes
  • the pectinase is 60-800 ppm
  • the amylase is 10-50 ppm.
  • Ultrafiltration is the enzymatic clarification of the juice through the pore size.
  • ultrafiltration membrane Ultrafiltration to remove the remaining apple meat and impurities in the juice; low temperature concentration is to degas the apple after low temperature concentration treatment, using a falling film type four-effect evaporator, the first effect temperature is 45 ⁇ 55 ° C, the second effect temperature It is 38 ⁇ 45°C, the three-effect temperature is 30 ⁇ 38°C, the four-effect temperature is 20 ⁇ 30°C, the soluble solid content of concentrated apple juice is 50 ⁇ 70Brix after four effects; the pasteurization temperature is 80 ⁇ 95°C, keep 50 to 20 seconds; aseptic filling is to fill the concentrated juice after sterilization and cooling with an aseptic filling machine to obtain the finished product.
  • the vacuum cooler used in the step (3) for ultra-fast cooling has the following structure: Referring to FIG. 1, the vacuum cooler includes a squeegee 1, an inner cylinder 2, a jacket 3, a distribution disc 4, and a block
  • the disc 5 and the motor 6, the inner cylinder 2 has a cylindrical shape, wherein the squeegee 1 is disposed inside the inner cylinder 2 and the gap with the inner cylinder 2 is 1 to 3 mm, and the jacket 3 is disposed at the outer periphery of the inner cylinder 2
  • the distribution disc 4 is connected above the scraper 1, the motor 6 controls the rotation of the scraper 1, the distribution disc 4 and the retaining disc 5;
  • the vacuum cooler is provided with a vacuum port A connected to the vacuum pump,
  • the feed port B is disposed at a position parallel to the distribution disc 4, a coolant inlet D is disposed below the jacket 3, a coolant outlet C is disposed above the jacket 3, and a discharge is provided at the bottom of the inner cylinder 2 Moutine E.
  • the motor 6 of the vacuum cooler drives the scraper 1 and the distribution disc 4 to rotate via the reducer, and the pulp enters through the feed port B through the pump, and the pulp is along the distribution disc 4 and the scraper 1 along the pulp.
  • the inner wall of the inner cylinder 2 of the vacuum cooler is lowered in a film shape, and the vacuum pump is connected to the vacuum pump so that the inner cylinder 2 of the vacuum cooler is in a vacuum state, and the pulp is in a film-like manner under the action of gravity. Part of the water quickly evaporates and consumes latent heat of evaporation to cause the temperature of the pulp to drop rapidly.
  • the jacket 3 is provided with chilled brine, which enters from the coolant inlet D and flows out from the coolant outlet C, accelerating the cooling rate of the pulp. And reducing the amount of water evaporation in the pulp, is conducive to the cooling rate and product quality improvement, and finally the ultra-rapid cooling slurry is discharged from the discharge port E, collected, into the post-treatment process.
  • the pulp after the enzyme is destroyed must be ultra-quickly cooled immediately, so that the pulp is rapidly reduced from near 90 ° C to normal temperature within 1 to 2 minutes, avoiding the ripening of the pulp.
  • the rapid design and rapid activation of steam requires special design and manufacture of equipment, such as the patent CN201510862729.4 declared by the inventor.
  • the feed volume of steam pressure, flow and material needs to be adjustable and controllable.
  • the invention realizes the physical method of killing the enzyme and creates a green safe high-quality concentrated clear juice production process.
  • Steam is introduced at the same time as the steaming, the steam instantly heats the broken material to the desired temperature and maintains the required time, and can quickly inactivate the polyphenol oxidase in the fruit, and maintain the original color of the fruit well.
  • the technology of coupling ultra-fast cooling because of the extremely fast cooling speed, avoids the overheating of the juice to produce a cooked taste, can maintain the original flavor and nutrition of the fruit well, and lays a foundation for the production of high-quality concentrated apple clear juice products.
  • the pulp obtained by the combination of crushing pulping and steam-killing enzyme is pumped into the distribution tray and descends along the inner wall of the inner cylinder under the action of centrifugal force and gravity. At this time, the temperature of the material just entering the ultra-fast cooler is much greater than the degree of vacuum used. Under the saturated evaporation temperature of the water, the water in the pulp is rapidly vaporized to consume the latent heat of vaporization, and is protected by the rotating scraper to ensure that the pulp is reduced in shape when the pulp is lowered, and the resistance of the escape is extremely small.
  • the present invention is highly efficient and minimizes enzymatic browning.
  • Most of the prior art adopts cold crushing, and then the heat exchanger is used to heat the slurry to destroy the enzyme; however, the method of killing the enzyme after the cold crushing is actually the majority of browning has been completed in the cold crushing process, followed by Inhibition of enzymes inhibits browning and has limited effect.
  • the invention can save the subsequent complicated resin adsorption decolorization step and greatly reduce the production cost.
  • the invention adopts the integrated coupling technology of crushing pulping and steam-killing enzyme, and then immediately performs ultra-fast cooling, while strictly controlling the process parameters and minimizing the temperature and time of the heat action, thereby realizing the physical method to destroy the enzyme. It maintains the original color, nutrition and aroma of the apple to a great extent, eliminating the subsequent adsorption and decolorization of the resin, reducing the production cost, and realizing the green and high-quality processing of the concentrated apple juice.
  • Figure 1 is a schematic view showing the structure of a vacuum cooler used in a preferred embodiment of the present invention.
  • step (3) Ultra-fast cooling: the apple slurry in step (3) is quickly entered into the vacuum cooler, the degree of vacuum is 0.075 MPa, the temperature of the frozen brine in the jacket is -6 ° C, the material is film-like, part of the water Evaporation, the temperature of the apple slurry rapidly drops to 40 ° C in 1 minute, and has the effect of degassing;
  • Enzymatic hydrolysis adding pectinase 800 ppm, amylase 50 ppm, enzymatic hydrolysis temperature to 50 ° C, and a time of 45 minutes;
  • Low temperature concentration the degassed apple is subjected to low temperature concentration treatment, and the falling film type four-effect evaporator is used.
  • the first effect temperature is 45 ° C
  • the second effect temperature is 38 ° C
  • the three effect temperature is 30 ° C
  • the four effect temperature is 20 ° C.
  • the soluble solid content of the concentrated apple juice is 50 Brix;
  • Pasteurization using a tube-type sterilizer, the temperature is 80 ° C, for 50 seconds, the sterilized juice enters the cooler and rapidly cools to about 30 ° C;
  • Aseptic filling The concentrated juice after sterilization and cooling is filled with an aseptic filling machine to obtain a finished product.
  • step (3) Ultra-fast cooling: the apple slurry in step (3) is quickly entered into the vacuum cooler, the degree of vacuum is 0.09 MPa, the temperature of the frozen brine in the jacket is -10 ° C, the material is film-like, part of the water Evaporation, the temperature of the apple slurry rapidly drops to 40 ° C in 1 minute, and has the effect of degassing;
  • Enzymatic hydrolysis adding pectinase 500 ppm, amylase 30 ppm, enzymatic hydrolysis temperature to 53 ° C, and time of 60 minutes;
  • Pasteurization using a tube-type sterilizer, the temperature is 95 ° C, for 20 seconds, the sterilized juice enters the cooler and rapidly cools to about 30 ° C;
  • Aseptic filling The concentrated juice after sterilization and cooling is filled with an aseptic filling machine to obtain a finished product.
  • step (3) Ultra-fast cooling: the apple slurry in step (3) is quickly entered into the vacuum cooler, the vacuum degree is 0.085 MPa, the temperature of the frozen brine in the jacket is -6 ° C, the material is film-like, part of the water Evaporation, the temperature of the apple slurry rapidly drops to 40 ° C in 2 minutes, and has the effect of degassing;
  • Enzymatic hydrolysis 60 ppm of pectinase, 10 ppm of amylase, and 50 ° C for 60 minutes in the enzymatic hydrolysis tank;
  • Low-temperature concentration the degassed apple is subjected to low-temperature concentration treatment, and the falling film type four-effect evaporator is used.
  • the temperature is 50°C, the temperature is 40°C, the temperature is 35°C, and the temperature is 28°C. After the effect, the soluble solid content of the concentrated apple juice is 60 Brix;
  • Pasteurization using a tube-type sterilizer, the temperature is 90 ° C, for 30 seconds, the sterilized juice enters the cooler and rapidly cools to about 30 ° C;
  • Aseptic filling The concentrated juice after sterilization and cooling is filled with an aseptic filling machine to obtain a finished product.
  • the product prepared by the invention is a colorless, transparent, clear liquid, concentrated apple juice without impurities and precipitates, and no additive or preservative is added during the processing. It has the inherent taste and aroma of apple, and the product index meets the requirements of GB17325 "Sanitary Standard for Concentrated Fruit Juice for Food Industry".
  • Comparative Example 1 replaced step (3) and step (4) in Example 2 with natural beating with a beater
  • Step (3) in Example 2 was replaced by natural beating with a beater, and then the pulp was quickly inactivated at 90 ° C for 15 s;
  • Comparative Example 4 Step (4) in Example 2 was replaced by pumping the slurry into a vacuum cooler, and the blade was cooled to room temperature without being rotated.
  • Example 1-3 The scoring criteria of the sensory evaluation are shown in Table 1. Seven samples of Examples 1-3 and Comparative Examples 1-4 were taken, and each sample was divided into 5 portions, evaluated 3 times, and averaged. The color, smell, and concentration of concentrated apple juice The taste and overall rating are scored with a maximum score of 100 points.
  • the L value is usually measured by a color difference meter of HunterLab (Model UltraScan Pro 1166, HunterLab, USA), and the data results are represented by L, a, and b.
  • a cylindrical sampler (diameter: 58 mm, depth: 15 mm) is used to hold the same quality of the pulp under the color difference meter (50 mm diameter).
  • Polyphenols are important flavor substances and coloring substances of apples and processed products, and are closely related to the sensory quality of apples and processed products.
  • Apple polyphenols mainly include catechins, proanthocyanidins, hydroxycinnamic acids, dihydrochalcones, flavonols, anthocyanins.
  • the total amount of polyphenols was determined by the forinol method: (1) Preparation of the standard curve, accurately taking 0.05, 0.10, 0.15, 0.20, 0.25, 0.30 mL of the gallic acid standard solution at a concentration of 100 ⁇ g/mL in a 5 mL volumetric flask. Distilled water 1.95, 1.90, 1.85, 1.80, 1.75, 1.70 mL, respectively, and then add 1.0 mL of Forint reagent, shake well for 3-4 min, add 1.0 mL of 10% Na 2 CO 3 solution, shake and place at constant temperature.
  • the enzymatic browning is better suppressed, the antioxidant active components such as polyphenols are retained to some extent, but the natural cooling is the comparative example 3, and only the vacuum is used. Cooling, that is, Comparative Example 4, because the cooling rate is not fast enough, the product has a cooked taste, and even if the enzymatic digestion is not eliminated, the results of sensory evaluation are still not satisfactory. Only by using the ingenious combination of the crushed steam inactivating enzyme coupling and the ultra-rapid cooling provided by the present invention, as in the first, second and third embodiments, the enzymatic browning can be best suppressed, and the antioxidant active ingredients such as polyphenols are most retained. Moreover, the product has no cooked flavor, and can basically maintain the original taste of the fruit, and obtain high-quality concentrated apple juice.

Abstract

一种浓缩苹果清汁的制备工艺：苹果原料质量控制、破碎制浆和蒸汽灭酶耦合、制浆灭酶后立即进行超快冷却、过滤分离、超细粉碎、酶解、超滤、多效低温浓缩、巴氏杀菌和无菌灌装。

Description

一种浓缩苹果清汁的制备工艺 技术领域
本发明属于食品饮料技术领域，具体地，涉及一种易褐变苹果浓缩清汁的制备工艺。
背景技术
谚语“每天一苹果，疾病远离我”在西方国家广为流传，意味着苹果及其加工产品具有很高的营养价值和医疗保健作用，这也是苹果及其加工产品在发达国家市场成为被消费者普遍接受的主要原因。营养科学研究成果表明：苹果汁中的碳水化合物主要由糖构成，这种糖很容易转化为人体易吸收的葡萄糖和果糖；苹果汁也富含可溶性的磷和铁，有助于婴幼儿消化和吸收；苹果汁还具有润肺悦心、生津开胃、止渴解暑、和脾止泻、中和过多的胃酸、促进肾上腺素分泌等医疗保健功能。医疗研究也表明：苹果汁中的黄酮类化合物与多酚化合物结合在一起，能抑制人体的癌细胞生长和扩散，具有抗癌作用。可见，苹果汁作为苹果的主要加工产品，其营养价值较高。
苹果汁是全球第二大果汁消费品种，主要用作饮料生产的基础配料，国外90％的饮料生产厂商将苹果汁作为饮料生产的基础配料。此外，苹果汁还用于果酒酿制、化妆品、保健品、药品添加剂等。从上世纪九十年代开始，我国苹果汁产业经历了从无到有、从小到大的发展过程。2010年，全国饮料业万吨规模以上的果汁和蔬菜汁饮料加工业共有449家，其中加工能力20吨/小时以上的浓缩苹果汁生产型企业近百家。这种发展态势促使世界苹果汁生产、贸易中心明显向中国转移和聚集；2010年中国苹果汁出口量达到78.84万吨，出口金额为7.47亿美元，占世界浓缩苹果汁生产总量的近50％，苹果汁已成为我国重要的出口农产品之一，我国已成为国际市场中最大的苹果汁生产国和出口国。
浓缩苹果汁分为浓缩苹果清汁与浓缩苹果浊汁两种，清汁需要经过酶解工序，故不含可溶性的固形物，而浊汁不经酶解和超滤处理而含有非可溶性固形物。虽然理论上苹果浊汁含有果胶、蛋白质、纤维素、天然色素、芳香物质及 维生素等都远远多于苹果清汁，拥有更柔和的口感，感官状态更自然，更能体现苹果果实原有的滋气味，具有更高的营养价值，但目前市场上的浓缩苹果汁仍然以清汁为主，浊汁较少，原因是浓缩苹果浊汁生产工艺复杂，特别是褐变、沉淀等技术问题没有得到根本的解决。
由于苹果在加工中，一经粉碎多酚氧化酶就会与底物接触，立即触发酶促褐变反应，给苹果的加工利用和产品开发带来了极大的困难，这一问题在我国乃至国际上至今未有实质性的突破和进展。目前苹果清汁或浊汁基本上是采用先冷破碎后加热浆体灭酶的工艺，或在冷破碎过程中加入一定量的抗坏血酸(Vc)来抑制褐变，但多酚氧化酶促褐变仍然比较严重。研究发现苹果加工过程中约83％以上的褐变反应发生在破碎过程短暂的几分钟内，所以解决破碎过程中的酶促褐变是制备高品质苹果清汁的关键。
目前我国工厂生产苹果汁的主要工艺流程如下：
Figure PCTCN2016091540-appb-000001
现有工艺冷破碎中绝大多数酶促褐变已经完成，后续的加热灭酶效果有限，所以后续需要繁琐的树脂吸附脱色。对已有的专利和期刊论文研究分析不难发现，苹果清汁的生产大多数采用冷破碎，而忽略了水果破碎过程中果浆的酶促褐变。
发明内容
本发明针对现有技术存在的问题，提供了一种在破碎过程中将蒸汽快速加热到灭酶工艺，并随后进行超快冷却的技术，实现了利用物理方法对易褐变的苹果进行灭酶和抗褐变处理，符合当代食品绿色、安全加工的理念。灭酶后的果浆采用超快速冷却到常温，避免果浆煮熟，保留了苹果原有的色香味和营养，为制备高品质的浓缩苹果清汁提供了可靠的保证，因而可以省去后续的树脂吸附脱色步骤，大大降低生产成本。本发明将在极大程度上改善苹果浓缩清汁的 制备工艺，提高产品的质量，具有极高的经济效益和社会效益。
为实现上述目的，本发明的技术方案如下所述：
本发明提供了一种浓缩苹果清汁的制备工艺，包括以下步骤：
(1)原料选择与预处理：选择新鲜、成熟度较高，无霉变腐烂、无虫蛀，农药残留合格的苹果作为原料，其糖度最好大于12Brix，采用鼓泡清洗机清洗干净，将每个苹果切成4～8瓣，以利于后续的破碎制浆和灭酶一体化处理。
(2)破碎制浆和蒸汽灭酶一体化：将步骤(1)处理后的苹果进行破碎制浆，切瓣苹果在高速刀桨的作用下将苹果破碎到颗粒直径为2mm左右，通过控制刀桨刀韧的锋利度、转速和时间可控制破碎粒度的大小，此处苹果不宜破碎过细，此外果核较硬，在破碎制浆灭酶过程中尽量不被破碎。破碎开始前几分钟就预通蒸汽赶走破碎腔中的空气，蒸汽均匀地喷向破碎的苹果，此处喷入蒸汽的压力为0.12～0.25MPa，果浆温度在1～3分钟内快速升高到80～92℃后停止通蒸汽，并保持48～12s，此步骤中升温最终温度与最终温度保持时间遵循线性反比关系：T＝-t/3+96，T为最终温度，单位是℃，t为保持时间，单位是s；在破碎制浆的同时可任选地添加占苹果原料质量0.006～0.04％的维生素C或柠檬酸(w/w)，进一步发挥维生素C或柠檬酸的护色功能并且可以起到调节果浆酸度的作用。
(3)超快冷却：将步骤(2)所得的苹果浆采用真空冷却和冷冻盐水传导冷却相耦合的方式快速降温，使得浆料在1～2分钟内迅速冷却到40℃以下，具体是将苹果浆在1-2分钟内迅速泵送到真空冷却器中，使果浆呈薄膜状下降，所述真空冷却器采用离心刮板式薄膜真空蒸发器，蒸发器夹套内设有冷冻盐水，真空冷却的真空度为0.075～0.09Mpa，冷冻盐水温度小于-4℃。
(4)后处理：将步骤(3)所制的苹果浆过滤除去果核后，再经超细粉碎，酶解，超滤，多效低温浓缩，巴氏杀菌和无菌灌装得到浓缩苹果清汁的成品。
其中，破碎灭酶一体化处理后的果浆中果肉粒度一般不超过2mm，果核较硬，在破碎制浆灭酶过程中尽量不被破碎，采用10目的筛网过滤除去苹果核；超细粉碎是将苹果浆及苹果皮渣粉碎到100～120目，实现苹果果核之外的全利用；酶解是在酶解罐中添加适量果胶酶和淀粉酶进行酶解澄清，酶解温度为50～53℃，酶解时间为45～60分钟，果胶酶的添加量为60～800ppm，淀粉酶的添加量为10～50ppm；超滤是将步中经酶解澄清的果汁通过孔径0.02μm的超滤膜 进行超滤，除去果汁中的剩余的苹果肉和杂质；低温浓缩是将脱气后的苹果进行低温浓缩处理，采用降膜式四效蒸发器，一效温度是45～55℃，二效温度是38～45℃，三效温度是30～38℃，四效温度是20～30℃，四效后浓缩苹果汁可溶性固形物含量50～70Brix；巴氏杀菌的温度是80～95℃，保持50～20秒；无菌灌装是对经杀菌降温后的浓缩果汁采用无菌灌装机进行灌装，得到成品。
优选地，所述步骤(3)超快冷却使用的真空冷却器具有如下结构：参见附图1，所述真空冷却器包括刮板1、内筒2、夹套3、分配圆盘4、挡盘5和电机6，所述内筒2呈圆柱形，其中刮板1设置在内筒2的内部并且与内筒2的间隙为1～3mm，夹套3设置在内筒2的外围，所述分配圆盘4连接在刮板1的上方，所述电机6控制着刮板1、分配圆盘4和挡盘5的转动；该真空冷却器设有抽真空口A与真空泵连接，在与分配圆盘4相平行的位置设置进料口B，在夹套3的下方设有冷却液进口D，在夹套3的上方设有冷却液出口C，在内筒2的底部设有出料口E。
使用时，真空冷却器的电机6经减速器带动刮板1及分配圆盘4转动，果浆经泵由进料口B进入，在分配圆盘4和刮板1的作用下果浆沿着真空冷却器的内筒2的内壁呈薄膜状下降，抽真空口A处接入真空泵使得真空冷却器的内筒2内处于真空状态，果浆在重力作用下呈薄膜状下降的过程中果浆中的部分水分迅速蒸发消耗蒸发潜热而使果浆温度迅速下降，同时夹套3内设有冷冻盐水，其从冷却液进口D进入，从冷却液出口C流出，加速了果浆的降温速度，并减少果浆中的水分蒸发量，有利于降温速度和产品质量的提高，最终经过超快冷却的浆液由出料口E流出、收集，进入后处理的工序。
本领域技术人员知晓，引起果汁褐变最主要的酶是多酚氧化酶，实验数据证明，80℃加热1min或90℃加热15s可完全失活。本发明经过反复试验研究，发现将温度控制在80～92℃，保持时间控制在48～12s，温度低时间长，温度高时间短，升温的最终温度和保持时间遵循线性反比关系：T＝-t/3+96，T为最终温度，单位是℃；t为保持时间，单位是s。另一方面，灭酶后的果浆必须立即进行超快冷却，使得果浆在1～2分钟内从近90℃快速降至常温，避免了果浆的煮熟。只有“破碎制浆和蒸汽灭酶一体化”与“超快冷却”这两项工艺的结合，并严格控制工艺参数才能制备获得高品质的苹果汁饮品。实现蒸汽快速加热和灭酶需要特殊设计制造的设备，如本发明人申报的专利CN201510862729.4，其 中蒸汽压力、流量和物料的进料量需要可调可控。
本发明有益的技术效果在于：
本发明实现了物理方法灭酶，创造了一种绿色安全的高品质浓缩清汁的生产工艺。在打浆的同时就通入蒸汽，蒸汽在瞬间将破碎的物料加热到所需的温度并保持所需的时间，能迅速灭活水果中的多酚氧化酶，很好地保持水果原有的色泽；同时耦合超快冷却的技术，由于冷却速度极快，从而避免果汁过热产生煮熟味，能很好地保持水果原有的风味和营养，为生产高品质的浓缩苹果清汁制品奠定了基础。破碎制浆和蒸汽灭酶耦合制得的果浆，泵送至分配盘中，在离心力和重力作用下沿内筒内壁下降，此时刚进入超快冷却器中物料的温度远大于使用真空度下的水的饱和蒸发温度，果浆中的水分迅速气化而消耗气化潜热，受转动刮板的作用，保证果浆下降时呈薄膜状使得水分气化而外逸的阻力极小，物料温度急剧下降，夹套中的冷冻盐水从内筒外壁带走果浆的温度，不仅加快了果浆的冷却速度，而且减少了果浆中风味成分的真空挥发损失，进一步保证了产品的质量。
本发明高效并最大程度地抑制了酶促褐变。现有技术绝大多数采用冷破碎，然后再用换热器加热浆体灭酶；然而这种先冷破碎后灭酶的方法实际上绝大多数褐变已在冷破碎过程中完成，随后的灭酶其抑制褐变程度和效果有限。本发明可以省去后续复杂的树脂吸附脱色步骤，大大降低了生产成本。
综上所述，本发明采用破碎制浆和蒸汽灭酶一体化耦合技术，随后立即进行超快冷却，同时严格控制工艺参数并最大限度减少热作用的温度和时间，实现了物理方法灭酶，在极大程度上保持了苹果原有的色泽、营养和香气，省去了后续的树脂吸附脱色，减少了生产成本，实现了真正意义上的浓缩苹果清汁绿色和高品质加工。
附图说明
图1为本发明优选方案中所使用的真空冷却器的结构示意图
其中，1、刮板，2、内筒，3、夹套，4、分配圆盘，5、挡盘，6、电机，A、抽真空口，B、进料口，C、冷却液出口，D、冷却液进口，E、出料口
具体实施方式
实施例1
(1)原料选择与处理：选择新鲜成熟的红富士苹果，无霉变腐烂，无虫蛀，农药残留合格，糖度大于12Brix，将苹果充分洗净；
(2)切瓣：选用切瓣机，将苹果一切4瓣；
(3)破碎灭酶耦合：在破碎过程中将蒸汽喷向苹果，选择蒸汽的压力为0.12MPa，先通蒸汽2分钟赶走设备内的氧气，边破碎边通蒸汽加热，浆料在3分钟内升温到80℃，保留48s后出料；
(4)超快冷却：将步骤(3)中的苹果浆料快速进入真空冷却器中，真空度为0.075MPa，夹套中冷冻盐水的温度为-6℃，物料呈膜状下降，一部分水分蒸发，苹果浆料温度在1分钟内急速下降到40℃，并兼有脱气的作用；
(5)过滤：浆液通过10目的筛网除去苹果核；
(6)超细粉碎：将苹果浆及苹果皮渣粉碎到100目，实现苹果果核之外的全利用；
(7)酶解：在酶解罐中添加果胶酶800ppm，淀粉酶50ppm，酶解温度为50℃，时间为45分钟；
(8)超滤：将酶解后澄清的果汁通过孔径为0.02μm的超滤膜进行超滤，除去果汁中剩余的果肉和杂质；
(9)低温浓缩：脱气后的苹果进行低温浓缩处理，采用降膜式四效蒸发器，一效温度45℃，二效温度38℃，三效温度30℃，四效温度20℃，四效后浓缩苹果汁可溶性固形物含量为50Brix；
(10)巴氏杀菌：采用列管式杀菌机，温度为80℃，保持50秒，灭菌后的果汁进入冷却器迅速降温至30℃左右；
(11)无菌灌装：对杀菌降温后的浓缩果汁用无菌灌装机进行灌装，得到成品。
实施例2
(1)原料选择与处理：选择新鲜成熟的红富士苹果，无霉变腐烂，无虫蛀，农药残留合格，糖度大于12Brix，将苹果充分洗净；
(2)切瓣：选用切瓣机，将苹果一切6瓣；
(3)破碎灭酶耦合：在破碎过程中将蒸汽喷向苹果，选择蒸汽的压力为 0.20MPa，先通蒸汽2分钟赶走设备内的氧气，边破碎边通蒸汽加热，浆料在3分钟内升温到92℃，保留12s后出料；
(4)超快冷却：将步骤(3)中的苹果浆料快速进入真空冷却器中，真空度为0.09MPa，夹套中冷冻盐水的温度为-10℃，物料呈膜状下降，一部分水分蒸发，苹果浆料温度在1分钟内急速下降到40℃，并兼有脱气的作用；
(5)过滤：浆液通过10目的筛网除去苹果核；
(6)超细粉碎：将苹果浆及苹果皮渣粉碎到100目，实现苹果果核之外的全利用；
(7)酶解：在酶解罐中添加果胶酶500ppm，淀粉酶30ppm，酶解温度为53℃，时间为60分钟；
(8)超滤：将酶解后澄清的果汁通过孔径为0.02μm的超滤膜进行超滤，除去果汁中剩余的果肉和杂质；
(9)低温浓缩：脱气后的苹果进行低温浓缩处理，采用降膜式四效蒸发器，一效温度55℃，二效温度45℃，三效温度38℃，四效温度30℃，四效后浓缩苹果汁可溶性固形物含量为70Brix；
(10)巴氏杀菌：采用列管式杀菌机，温度为95℃，保持20秒，灭菌后的果汁进入冷却器迅速降温至30℃左右；
(11)无菌灌装：对杀菌降温后的浓缩果汁用无菌灌装机进行灌装，得到成品。
实施例3
(1)原料选择与处理：选择新鲜成熟的红富士苹果，无霉变腐烂，无虫蛀，农药残留合格，糖度大于12Brix，将苹果充分洗净；
(2)切瓣：选用切瓣机，将苹果一切8瓣；
(3)破碎灭酶耦合：在破碎过程中将蒸汽喷向苹果，选择蒸汽的压力为0.25MPa，先通蒸汽2分钟赶走设备内的氧气，边破碎边通蒸汽加热，浆料在1分钟内升温到85℃，保留33s后出料；
(4)超快冷却：将步骤(3)中的苹果浆料快速进入真空冷却器中，真空度为0.085MPa，夹套中冷冻盐水的温度为-6℃，物料呈膜状下降，一部分水分蒸发，苹果浆料温度在2分钟内急速下降到40℃，并兼有脱气的作用；
(5)过滤：浆液通过10目的筛网除去苹果核；
(6)超细粉碎：将苹果浆及苹果皮渣粉碎到120目，实现苹果果核之外的全利用；
(7)酶解：在酶解罐中添加果胶酶60ppm，淀粉酶10ppm，酶解温度为50℃，时间为60分钟；
(8)超滤：将酶解后澄清的果汁通过孔径为0.02μm的超滤膜进行超滤，除去果汁中剩余的果肉和杂质；
(9)低温浓缩：脱气后的苹果进行低温浓缩处理，采用降膜式四效蒸发器，一效温度50℃，二效温度40℃，三效温度35℃，四效温度28℃，四效后浓缩苹果汁可溶性固形物含量为60Brix；
(10)巴氏杀菌：采用列管式杀菌机，温度为90℃，保持30秒，灭菌后的果汁进入冷却器迅速降温至30℃左右；
(11)无菌灌装：对杀菌降温后的浓缩果汁用无菌灌装机进行灌装，得到成品。
如上述实施例1～3中的制备工艺，本发明制备获得的产品为无色、透明、澄清的液体，无杂质、无沉淀的浓缩苹果清汁，在加工过程中不添加任何添加剂和防腐剂，具有苹果固有的滋味和香气，产品指标符合GB17325《食品工业用浓缩果汁卫生标准》要求。
采用实施例2的基本技术方案，对部分步骤进行改变从而得到对比例1-4，如下所述：
对比例1将实施例2中的步骤(3)和步骤(4)换成采用打浆机自然打浆；
对比例2将实施例2中的步骤(3)换成采用打浆机自然打浆，之后迅速将果浆在90℃下灭酶15s；
对比例3将实施例2中的步骤(4)换成使浆液自然冷却至室温；
对比例4将实施例2中的步骤(4)换成将浆液泵送到真空冷却器中，刮板不转动抽真空冷却至室温。
将上述实施例1-3以及对比例1-4中得到的产品进行测定，分别比较了感官评定、褐变、多酚含量等指标，具体如下。
(1)感官评定的打分标准见表1，取实施例1-3以及对比例1-4中的7个样品，每个样品分成5份，评价3次，取平均值。对浓缩苹果清汁的色泽、气味、 滋味和总体评定打分，最高总分为100分。
表1浓缩苹果清汁感官评定打分表
Figure PCTCN2016091540-appb-000002
(2)由于苹果的褐变分为酶促褐变和非酶褐变，酶促褐变是褐变的主要部分，一般在苹果破碎后的10分钟内全部完成。测定果浆颜色及其颜色随时间的变化L值，并与采用了不同处理方式的苹果浆进行色泽的测定和比较。L值越大则果浆越亮，反之越暗。由于偏重亚硫酸钠的防褐变效果好，用加2％(w/w)的偏重亚硫酸钠的苹果浆作为标准样品。
L值的测定通常采用HunterLab(型号UltraScanPro1166，美国HunterLab公司)色差仪测定果汁颜色，数据结果以L、a、b表示。先用标准的白板校验后，用圆筒形样品器(直径58mm，深15mm)盛有相同质量的果浆放在色差计光口(直径50mm)下，L称为明度指数，L＝0表示黑色，L＝100表示白色；a和-a分别表示红色和绿色，a绝对值越大，颜色分别越接近纯红色和纯绿色，a＝0时为灰色；b和-b分别表示黄色和蓝色，b绝对值越大，颜色分别越接近纯黄色和纯蓝色，b＝0时为灰色。
Figure PCTCN2016091540-appb-000003
L对照----苹果加2％偏重亚硫酸钠破碎打浆的L值(基本不随时间变化)；
L自然----苹果自然破碎打浆所制浆放置10分钟后的L值；
L样品----实施例1～3与对比例1～4中所制的苹果浆放置10分钟后的L值。
(3)多酚类物质是苹果及其加工产品重要的风味物质及呈色物质，与苹果及其加工制品的感官品质关系密切。苹果多酚主要包括儿茶素类、原花青素类、羟基肉桂酸类、二氢查耳酮类、黄酮醇类、花色苷类。
多酚总量的测定用福林酚法：(1)标准曲线的制作，准确吸取浓度为100μg/mL的没食子酸标准溶液0.05、0.10、0.15、0.20、0.25、0.30mL，于5mL容量瓶中，分别加入蒸馏水1.95、1.90、1.85、1.80、1.75、1.70mL，再加入福林试剂1.0mL，充分振荡静置3-4min，分别加入10％Na2CO3溶液1.0mL，摇匀置于恒温水浴中反应2h；同时做试剂空白，于765nm下测定吸光度，以含量对吸光度进行直线回归，得回归方程。(2)原料的处理：准确称取苹果浆5.000g于锥形瓶中，加入80mL 70％的乙醇，在80℃的水浴中热回流提取3次，每次2h，4000r/min离心20min，收集合并上清液，用旋转蒸发仪在0.09MPa下浓缩并回收乙醇，浓缩液用蒸馏水定容至50mL，待测。
测定原理与方法：多酚类化合物分子上有极易氧化的羟基，在碱性条件下与Folin-Ciocalten试剂反应后呈现蓝色，此反应物在765nm处有最大吸收，一定条件下遵从朗伯--比耳定律，以没食子酸为基准物质可测定苹果多酚的总量。根据这一测定原理，从上述50mL待测液中吸取溶液2mL，按标准曲线制作法测定吸光度，根据回归方程可求得2mL待测液中多酚的含量，再进一步计算出1g样品中酚类物质的含量(以没食子酸计mg/g，DW)。
对上述测定结果进行数据处理，最终结果填入下表2中。
表2不同工艺方法制得的浓缩苹果清汁质量评价表
工艺方法 相对酶促褐变率 多酚总量保留率 感官评定得分 有无煮熟味
对比例1 100％ 13.2％ 68.2 无
对比例2 91.5％ 24.5％ 71.5 有
对比例3 2.9％ 92.9％ 74.6 有
对比例4 2.4％ 93.4％ 81.4 有
实施例1 2.0％ 92.2％ 95.5 无
实施例2 1.7％ 94.3％ 96.0 无
实施例3 1.9％ 93.8％ 95.8 无
表2中所有原料为新鲜成熟的红富士苹果，并且除了个别步骤的变化，基本上采用了相同的加工方法。分析表2可知，采用现有技术中传统的工艺方法：冷破碎自然打浆即对比例1、冷破碎自然打浆后加热灭酶即对比例2的工艺得到的果浆酶促褐变非常严重，酶解后如不进行脱色处理其产品呈现黄褐色，感官评价也是最差的，抗氧化活性成分多酚的保留量非常低。采用了破碎制浆与蒸汽灭酶相耦合的方法之后虽然较好抑制了酶促褐变，在一定程度上保留了多酚等抗氧化活性成分，但是自然冷却即对比例3、仅使用抽真空冷却即对比例4均由于冷却速度不够快，产品有煮熟味，即使进行了酶解煮熟味仍无法消除，感官评定的结果仍然不理想。只有采用本发明所提供的破碎蒸汽灭酶耦合和超快冷却有机巧妙的结合，如实施例1、2和3才能最好地抑制酶促褐变，最高地保留多酚等抗氧化活性成分，而且产品没有煮熟味，基本能够保持水果的原始口味，得到高品质的浓缩苹果清汁。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，任何未脱离本发明技术方案内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (10)

  1. 一种浓缩苹果清汁的制备工艺，其特征在于，包括以下步骤：
    (1)原料选择与预处理：选取苹果作为原料，洗净，切瓣；
    (2)破碎制浆和蒸汽灭酶一体化：将步骤(1)处理后的苹果进行破碎制浆，在破碎制浆的同时向苹果喷入蒸汽，使得果浆温度在1～3分钟内快速升高到80～92℃后停止通蒸汽，并保持48～12秒；
    (3)超快冷却：将步骤(2)所得的苹果浆采用真空冷却和冷冻盐水传导冷却相耦合的方式快速降温，并在1～2分钟内迅速冷却到40℃以下；
    (4)后处理：将步骤(3)所制的苹果浆过滤除去果核后，进一步超细粉碎、酶解、超滤、多效低温浓缩、巴氏杀菌、无菌灌装后得到浓缩苹果清汁的成品。
  2. 根据权利要求1所述的工艺，其特征在于，所述步骤(1)选取的原料为新鲜成熟、无霉变腐烂、无虫蛀、农药残留合格的苹果，所述苹果糖度大于12Brix，清洗采用鼓泡清洗机，清洗后切成4～8瓣。
  3. 根据权利要求1所述的工艺，其特征在于，所述步骤(2)破碎开始前几分钟就预通蒸汽赶走破碎腔中的空气，蒸汽均匀地喷向破碎的苹果，升温最终温度与最终温度保持时间遵循线性反比关系：T＝-t/3+96，T为最终温度，单位是℃，t为保持时间，单位是s。
  4. 根据权利要求1所述的工艺，其特征在于，所述步骤(2)喷入蒸汽的压力为0.12～0.25MPa。
  5. 根据权利要求1所述的工艺，其特征在于，所述步骤(3)是将步骤(2)所得的苹果浆在1～2分钟内泵送到真空冷却器中，使得果浆呈薄膜状下降，所述真空冷却器采用离心刮板式薄膜真空蒸发器，蒸发器夹套内设有冷冻盐水；所述真空冷却器的真空度为0.075～0.09MPa，夹套内的冷冻盐水温度小于-4℃。
  6. 根据权利要求1所述的工艺，其特征在于，所述步骤(4)中的酶解是在酶解罐中添加果胶酶和淀粉酶进行酶解澄清，酶解温度是50～53℃，酶解时间是45～60分钟，果胶酶的添加量为60～800ppm，淀粉酶的添加量为10～50ppm。
  7. 根据权利要求1所述的工艺，其特征在于，所述步骤(4)中的超滤是经酶解澄清的果汁通过孔径为0.02μm的超滤膜进行超滤，除去果汁中的果肉和杂 质。
  8. 根据权利要求1所述的工艺，在特征在于，所述步骤(4)中超滤后的苹果进行低温浓缩处理，采用降膜式四效蒸发浓缩，一效温度是45～55℃，二效温度是38～45℃，三效温度是30～38℃，四效温度是20～30℃，四效后浓缩苹果汁可溶性固形物含量是50～70Brix。
  9. 根据权利要求1所述的工艺，其特征在于，所述步骤(4)中的巴氏杀菌使用列管式杀菌机，杀菌温度为80～95℃，保持50～20s，杀菌后采用管式或板式换热器快速冷却到常温。
  10. 根据权利要求1所述的工艺，其特征在于，所述步骤(4)中的超细粉碎采用高速切割湿法超细粉碎机，控制切割刀桨的转速在2800rpm以上。
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