Chaetomium globosum solid state fermentation extraction production system and method

Abstract

The invention discloses a chaetomium globosum solid-state fermentation extraction production system and method, and the production system comprises a metering and batching system which is used for weighing and metering raw materials required by preparation of a culture medium; the stirring and mixing tank is used for preparing a culture medium; the liquid fermentation tank is used for providing strain fermentation liquor; the solid-state fermentation tank is used for carrying out solid-state fermentation; the airing system is used for airing the solid-state fermentation product; the collecting system is used for collecting spores in the fermentation product; the metering and batching system conveys raw materials to the stirring and mixing tank through the conveying system, the solid-state fermentation tank is respectively connected with the stirring and mixing tank and the liquid-state fermentation tank through pipelines, the airing system is connected with the collecting system through a pipeline, and products obtained by the solid-state fermentation tank are conveyed to the airing system through the conveying system. The system and the method are suitable for chaetomium globosum solid state zymophyte and spore extraction, the chaetomium globosum solid state zymophyte and spore extraction is changed from a laboratory to a production line, and industrialization of chaetomium globosum fermentation and spore extraction is achieved.

Description

Technical Field

[0001] The invention belongs to the technical field of microbial fermentation and bacterial spore extraction, and particularly relates to a solid-state fermentation extraction production system and method for Chaetomium globosum. Background Art

[0002] Chaetomium globosum belongs to the phylum Ascomycota, class Sordariomycetes, and family Chaetomiaceae. It is a saprophytic ascomycete widely distributed in soil, plant debris, and cellulose-containing materials. Some Chaetomium globosum strains are important biocontrol agents for plant diseases. As an endophyte, it exhibits excellent disease prevention, growth promotion, and stress tolerance in plants. This not only improves crop yield and quality but also reduces environmental pollution. This strain exhibits excellent antiseptic, growth promotion, and stress tolerance in plants. It is environmentally friendly, does not damage the soil ecosystem, and contributes to the maintenance of ecological balance. Chaetomium globosum is susceptible to environmental disturbances, which can affect transportation and storage. Appropriate formulations can minimize damage and extend shelf life. Studies have shown that endophytes primarily infect plants in the form of spores through deformation, haustoria, or penetration. During infection and colonization, endophytes produce secondary metabolites that influence plant growth.

[0003] The prior patent application "A kind of Chaetomium sphaeroceae QM and its application" (application number: CN202411065028.3) provides a kind of Chaetomium sphaeroceae QM powder, which is made by soaking the solid fermentation raw materials in water and sterilizing them at high temperature; after cooling to room temperature, the suspension of Chaetomium sphaeroceae QM spores is added, cultured at room temperature, aerated and cultured, and then dried and crushed to obtain the powder. "A solid-state fermentation method of Chaetomium sphaeroceae, prepared bacterial agent and its application" (application number: CN202010908690.6) provides a method for preparing Chaetomium spores by solid-state fermentation. However, in the prior art, there are no relatively complete and accurate relevant standards in terms of solid-state fermentation and extraction. In the construction of solid-state fermentation and extraction production equipment and facilities on the production line, each company has its own way of doing things, and each company has explored its own production equipment and process solutions, without forming standardization and normalization. Summary of the Invention

[0004] In view of the deficiencies in the prior art, the present invention provides a solid-state fermentation extraction production system and method for Chaetomium globosum.

[0005] In order to achieve the above technical objectives, the technical solutions implemented by the present invention are:

[0006] As a first aspect of the present invention, a solid-state fermentation extraction production system and method of Chaetomium globosum is provided, comprising:

[0007] Measuring and batching system, which weighs and measures the raw materials required for culture medium preparation;

[0008] Stirring and mixing tank, used for preparing culture medium;

[0009] Liquid fermentation tank, used to provide bacterial fermentation liquid;

[0010] Solid-state fermentation tank, used for solid-state fermentation;

[0011] A drying system, used for drying the solid-state fermentation product;

[0012] a collection system for collecting spores from the fermentation product;

[0013] The metering and batching system transports the raw materials to the stirring and mixing tank through the conveying system. The solid fermentation tank is connected to the stirring and mixing tank and the liquid fermentation tank through pipelines respectively. The drying system is connected to the collection system through pipelines. The product obtained from the solid fermentation tank is transported to the drying system through the conveying system.

[0014] In an embodiment of the present invention, a steam generator is also included. The steam generator is connected to the inside of the solid fermentation tank and the liquid fermentation tank and the tank jacket through a pipe, and is used for in-situ steam sterilization in the tank and controlling the tank temperature. The steam generator is also connected to the tank jacket of the stirring and mixing tank through a pipe, and is used for adjusting the temperature and keeping the tank warm.

[0015] In an embodiment of the present invention, a water supply system is also included, including a pure water tank and a water supply pipe, on which a ball valve, a peristaltic pump, a Y-type filter and a rotor flowmeter are provided; the pure water tank is connected to the steam generator through the water supply pipe to supply pure water to the latter; the pure water tank is also connected to a chiller through the water supply pipe, and the outlet pipe of the chiller is respectively connected to a liquid fermentation tank, a solid fermentation tank and a stirring and mixing tank; the water supply system provides water for bacterial fermentation on the one hand, and is used for temperature control on the other hand.

[0016] In an embodiment of the present invention, a sterile gas supply system is also included, including an air compressor, a sterile gas filter device and an air supply pipeline. The air supplied by the air compressor is filtered by the sterile gas filter device and then enters the liquid fermentation tank, the solid fermentation tank and the stirring and mixing tank to provide air for fermentation in the liquid fermentation tank and the solid fermentation tank; a rotor flowmeter is set on the pipeline of the sterile gas supply system.

[0017] The water supply system, steam generator and sterile gas supply system realize the control of temperature and humidity in each tank and the sterilization treatment in the fermentation tank.

[0018] In an embodiment of the present invention, a control system is also included: the control system adopts a PID intelligent controller, which is respectively connected to the motor of the solid fermentation tank, the motor of the stirring and mixing tank, and the motor of the liquid fermentation tank, and records and controls the start and stop and operating speed of each motor; is connected to the peristaltic pump and flowmeter of the water supply system by signal, and records and controls the flow; is respectively connected to the electric control valves on each pipeline and the rotor flowmeter on the pipeline of the sterile gas supply system by signal, and records and controls the opening of the electric control valve and the flow of sterile gas; and records the values of the pressure gauges of the sterilized culture fermentation tank, the stirring and mixing tank, and the bacterial fermentation inoculation tank.

[0019] The invention also includes a lighting lamp arranged in the sterilized culture fermentation tank to implement light culture and dark culture.

[0020] In an embodiment of the present invention, a detection system is further included, including:

[0021] Pressure gauges installed on liquid fermentation tanks, solid fermentation tanks and stirring and mixing tanks detect the pressure inside the tanks.

[0022] Temperature detection and control system: PT-100 temperature electrodes are installed on the covers of liquid fermentation tanks, solid fermentation tanks and stirring mixing tanks, which are electrically heated by a PID intelligent controller. Electric control valves are installed in the water supply system pipelines to adjust drainage. Pipes are connected outside the tanks, and water circulation is achieved through a circulating pump on the pipelines, realizing online temperature detection and automatic control.

[0023] Moisture detection: A humidity electrode is installed on the exhaust pipe of the sterilized culture fermentation tank to detect the humidity, and the humidity inside the tank is automatically adjusted using an atomized water spray system.

[0024] pH: A pH meter is installed on the bacterial fermentation inoculation tank and the sterilization culture fermentation tank to detect the pH value in the tank. The pH value is controlled by controlling the amount of material added through a peristaltic pump.

[0025] Dissolved oxygen (DO): Utilizes sterile air to control the flow through the rotor; can be linked to the stirring and feeding speed control, that is, the dissolved oxygen is adjusted by changing the stirring speed.

[0026] In an embodiment of the present invention, the drying system uses a drying room, which includes multiple layers of drying belts, an ozone generator to provide ozone sterilization, and a bottom-up circulating air duct. In an embodiment of the present invention, the drying room is an automatic temperature and humidity control drying room.

[0027] In an embodiment of the present invention, the collection system includes a rotary breaker for breaking the sporangium to release spores;

[0028] The pulse bag collector is used to collect spores by suction, and then transport them to the storage silo; the waste is directly bagged by the waste outlet of the rotary scatterer and can be recycled for field planting.

[0029] As a second aspect of the present invention, there is provided a solid-state fermentation extraction production method of Chaetomium globosum, comprising the following steps:

[0030] The present invention provides a solid-state fermentation extraction production system for Chaetomium globosum, comprising the following steps:

[0031] S1, metering and feeding of raw materials from the raw material warehouse;

[0032] S2, the raw materials are transferred to the mixing tank through sealed lifting;

[0033] S3, preparation of culture medium: metering materials from the raw material bin, adding water to soak the raw materials in the mixing tank and stirring to prepare the culture medium;

[0034] S4, the prepared culture medium is transported to the solid-state fermentation tank through a sealed pipeline, the steam generator is turned on to sterilize the sterilization culture fermentation tank, and then the steam generator is turned off, and the pipeline between the culture fermentation inoculation tank and the culture medium is opened to inoculate the bacteria; dark culture and light culture are performed;

[0035] Preferably, the sterilization process utilizes steam heating, and the temperature is increased from 0 to 100°C while releasing air, and the temperature is held when it reaches 100°C, and then the temperature is continued to rise to 121°C, and this temperature is maintained for 25 minutes; sterilized air is first used and then tap water is used to cool the temperature to 70°C, and then the temperature is increased to 121°C, and this temperature is maintained for 25 minutes; finally, cold water provided by a chiller is used to cool the temperature to room temperature, and the sterilization is completed, and stirring is continued throughout the entire process.

[0036] Preferably, the inoculation process uses sterile compressed air differential pressure to transfer the seeds; inoculate and mix in situ, and spray water for inoculation by differential pressure; inoculation automatically begins after sterilization is completed, and the pipeline is sterilized with high-temperature steam before inoculation, and stirring is performed while inoculating.

[0037] Preferably, the culture is not stirred during dark culture, stirred once after 10 days of culture, and then cultured for another 4 days.

[0038] Light culture: Turn on the light, use yellow scattered light, and the light intensity is 300-1000 lux. Stir once, culture for 7 days, and then transfer to the drying room.

[0039] Control the pressure, temperature, humidity, pH, light and stirring speed inside the tank.

[0040] S5, the material cultured in the sterilized culture fermentation tank is transported to a drying room through an auger conveyor for dehumidification and drying, and then transported to a rotary breaking tank through an auger conveyor for rotary breaking of the sporangium to break the spores;

[0041] In S6, the dispersed spores enter the pulse bag collector under the action of the pulse bag collector fan to collect the spores, and then are finely screened by the electric circular swing powder screen. The qualified spores are screened out and enter the packaging machine for packaging; the entire production process is automated and controlled, with manual inspection and setting of corresponding parameters.

[0042] Compared with the prior art, the present invention has the following beneficial effects:

[0043] (1) The present invention provides a solid-state fermentation extraction production system and method for Chaetomium globosum, which is suitable for solid-state fermentation of Chaetomium globosum and spore extraction, realizing its transition from "laboratory" to "production line" and industrializing the fermentation and spore extraction of Chaetomium globosum.

[0044] (2) The energy-saving modular equipment configuration structure of the present invention is adapted to the production needs of different scales; it realizes precise control of fermentation parameters such as temperature, humidity, tank pressure, stirring speed, pH, air flow, time, etc. The adjustment and control of each parameter are independent modules, which do not interfere with each other and are easy to maintain.

[0045] (3) The production system provided by the present invention adopts variable frequency rotary beating + pulse bag collector extraction technology to separate crude extracts, and an electric circular swing powder screen achieves high-precision screening.

[0046] (4) By recording various parameters through the controller, the operator can create and analyze trend curves of all parameters, helping the operator to judge the mutual influence between parameters, so as to quickly modify and adjust the fermentation process and realize intelligent control and parameter optimization.

[0047] (5) The present invention discloses an intelligent equipment for solid-state fermentation spore extraction of the microbial species Chaetomium globosum. The process operation is simple and the parameters are easy to control. The microbial agent produced by solid-state fermentation has broad application prospects and significant economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The accompanying drawings, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0049] Figure 1 A schematic structural diagram of a solid-state fermentation extraction production system for Chaetomium globosum provided in Example 1 of the present invention;

[0050] Figure 2a Schematic diagram of the sterilized culture fermentation tank structure in the solid-state fermentation extraction production system structure of Chaetomium globosum provided in Example 1 of the present invention; (a) is a schematic diagram from the left side, and (b) is a schematic diagram from the main perspective;

[0051] Figure 2bA schematic diagram of a sterilized culture fermentation tank from a right angle in the structure of a solid-state fermentation extraction production system for Chaetomium globosum provided in Example 1 of the present invention;

[0052] Figure 3a Schematic diagram of the structure of the stirring and mixing tank in the solid-state fermentation extraction production system of Chaetomium globosum provided in Example 1 of the present invention; (a) is a schematic diagram from the left side, and (b) is a schematic diagram from the main side;

[0053] Figure 3b A schematic diagram of a right-side view of a stirring and mixing tank in a solid-state fermentation and extraction production system for Chaetomium globosum provided in Example 1 of the present invention;

[0054] Figure 4 A schematic diagram of the structure of a bacterial fermentation inoculation tank in a solid-state fermentation extraction production system structure of Chaetomium sphaeroides provided in Example 1 of the present invention; wherein (b) is a left view of (a), (c) is an AA cross-sectional view of Figure (a), (d) is a BB cross-sectional view of (b), and (e) is a CC cross-sectional view of (b).

[0055] Figure 5 A schematic diagram of the drying room structure in a solid-state fermentation extraction production system for Chaetomium globosum provided in Example 1 of the present invention;

[0056] Figure 6 A schematic diagram of the connection between the drying room and the rotary disintegrator in the structure of a solid-state fermentation extraction production system for Chaetomium globosum provided in Example 1 of the present invention;

[0057] Figure 7 A schematic diagram of the sampling port structure in a solid-state fermentation extraction production system for Chaetomium globosum provided in Example 1 of the present invention;

[0058] Figure 8 This is a water supply and drainage flow chart of the solid-state fermentation extraction production system structure of Chaetomium globosum provided in Example 1 of the present invention.

[0059] Among them, 0101-1# raw material feeding bin, 0102-2# raw material feeding bin, 0103-3# raw material feeding bin, 0104-4# raw material feeding bin, 0105-5# raw material feeding bin, 0106-first electric control valve, 0107-first conveyor, 0108-main control console;

[0060] 0201-stirring and mixing tank, 0202-second electric control valve, 0203-sterilization culture fermentation tank, 0204-third electric control valve, 0205-second conveyor, 0206-steam generator, 0207-bacteria fermentation inoculation tank, 0208-water chiller, 0209-air compressor, 0210-sterile gas filtration device;

[0061] 020301-Silicone plug, 020302-Pressure cap, 020303-Sealing pressure head, 020304-O-ring;

[0062] 0301-Automatic temperature and humidity control drying room, 0302-Third conveyor;

[0063] 0401- Rotary disintegrator, 0402- Pulse bag collector, 0402a- Fan, 0402b- First variable frequency motor grating wheel, 0403- First packaging machine, 0404- Second variable frequency motor grating wheel, 0405- Second packaging machine, 0406- Electric circular swing powder sieving machine, 0407- Storage bin, 0408- Pneumatic three-way discharge valve;

[0064] 0501-peristaltic pump, 0502-pure water tank, 0503-ball valve, 0504-Y-type filter, 0505-rotor flowmeter. DETAILED DESCRIPTION

[0065] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present invention belongs.

[0066] Example 1, a solid-state fermentation extraction production system for Chaetomium globosum

[0067] The Chaetomium solid-state fermentation intelligent system equipment provided by the present application is a processing production line equipment used for the solid-state fermentation bacteria and spore material extraction process using sawdust, wheat bran, white powder, black powder and other materials.

[0068] The present invention aims to realize the industrial automation of solid-state fermentation and spore extraction of Chaetomium globosum. Its main components are as follows: Figure 1 Shown, including:

[0069] (1) Sterilization culture fermentation tank 0203 is a solid fermentation tank. It realizes in-situ steam sterilization; full capacity: 50-500L; liquid filling sequence: 40-60%. Tank structure: Made of SUS304 high-quality stainless steel.

[0070] like Figure 2a (a), (b) and Figure 2bThe tank is a horizontal, rotating tank with a motor connected to the shaft, which rotates and agitates the material. It is jacketed and equipped with a safety vent valve. The lid and tank body are equipped with a first feeding port a, sight glass observation ports b1-b2, illumination ports b3-b4, an inoculation port c, a temperature electrode connector d, an exhaust port e1, an air inlet e2, a sampling port e3, a hand hole for cleaning e4, a water inlet f1, a drain port f2, a second feeding port g with an Rd65 inoculation port, a transfer port h, and a transfer port i. The design pressure is 0.35 MPa, the operating pressure is 0.01-0.2 MPa, and the surface treatment is mirror polished inside and outside with a polishing accuracy of Ra 0.4. The sterile culture fermentation tank 0203 is tilted at a 1° angle, with the feeding port a higher on one end.

[0071] The present invention provides a special sampling port e3, such as Figure 7 As shown, the can includes a sealed silicone plug 020301 mounted on the can lid, a pressure cap 020302 embedded in the silicone plug 020301, and a sealing head 020303 sealed against the pressure cap 020302. An O-ring 020304 is provided at the contact point between the sealing head 020303 and the pressure cap 020302. During sampling, a sampling needle is inserted into the sealed silicone plug 020301. After sampling, the sampling needle is removed, and the silicone plug 020301 remains sealed, ensuring a sterile environment within the can. After use, the can is sealed with the sealing head 020303.

[0072] (2) A stirring and mixing tank 0201 is used for preparing a culture medium. The culture of the sphaerotheca globosum involved in the present invention uses sawdust (material 1), wheat bran (material 2), white powder (material 3), black powder (material 4), added powder (material 5) and other materials.

[0073] During implementation, material 1 + material 2 are covered with water, stirred evenly and soaked for 24 hours, the water is removed and the moisture is continuously measured, material 3 is added and stirred evenly, and then material 4 and powder (the amount is the same as that of white powder) are added and stirred evenly, the pH value is tested, and after stirring evenly, the mixture is transferred to the sterilized culture fermentation tank 0203.

[0074] like Figure 3a (a), (b) and Figure 3bAs shown, the tank lid and tank body are equipped with a discharge port a, a light port b, a sight glass observation port c, a hand hole e1, a breathing port e2, and a sampling port e3, respectively. The motor uses a variable-speed AC motor with timed forward and reverse rotation. The stirring interval and action time can be set to ensure uniform mixing of the materials. The speed range is adjustable from 0 to 99 min. It is supplemented by a straight flat paddle and a chute structure within the tank body, which ensures both radial and axial mixing of the materials during stirring. The stirring shaft design and stirring paddle material are made of 316L stainless steel, with ventilation holes 020301 on the shaft and paddle, ensuring effective mixing of sterile air and materials during stirring. Automatic speed control and online detection are provided. The speed range is 0 to 50, with a control accuracy of ±1 rpm / min.

[0075] (3) The bacterial strain fermentation inoculation tank 0207 is a liquid fermentation tank that allows rapid mycelial growth. It is connected to the sterilized culture fermentation tank 0203 and supplies the fermented bacterial strain to the latter. Figure 4 As shown, a discharge port a, a cooling water inlet b, sensor interfaces c / d / e / f, a cooling water outlet g, a lamp hole k, an inoculation port N1, a feeding port N2-7, and an exhaust port (not shown in the figure) are respectively provided on the tank cover and the tank body.

[0076] (4) Water supply system: Figure 1 and Figure 8 As shown, the system includes a pure water tank 0502 connected to a tap water source and a water supply pipeline. The water supply pipeline is equipped with a ball valve 0503, a peristaltic pump 0501, a Y-type filter 0504, and a rotor flowmeter 0505. Pure water tank 0502 is connected to steam generator 0206 via a water supply pipeline, supplying purified water to the latter. Pure water tank 0502 is also connected to a chiller 0208 via a water supply pipeline. The outlet piping of chiller 0208 includes two branches: one connecting to a bacterial fermentation and inoculation tank 0207, and the other connecting to a sterilization and culture fermentation tank 0203. Pure water tank 0502 is also connected to a mixing tank 0201 via a peristaltic pump 0501, supplying water to the latter. This water supply system not only provides water for bacterial fermentation and culture medium preparation and mixing processes, but also serves for temperature control.

[0077] (5) Steam generator 0206: Figure 1 and Figure 8 As shown, steam generated by steam generator 0206 is piped from the steam outlet to the interior and jacket of bacterial culture inoculation tank 0207, and to the interior and jacket of sterile culture fermentation tank 0203, for in-situ steam sterilization and tank temperature control. Steam is also piped to the jacket of mixing tank 0201 for temperature regulation and tank insulation. Steam generator 0206 generates steam through electrical heating.

[0078] (6) Sterile gas supply system: includes air compressor 0209 and sterile gas filter device 0210. Sterile gas filter device 0210 includes pre-filter and fine filter. It adopts sterilization filter with precision of 0.01 μm. The air supplied by air compressor 0209 is filtered through two stages by sterile gas filter device 0210 and then enters sterile culture fermentation tank 0203, bacterial fermentation inoculation tank 0207 and stirring mixing tank 0201 to provide air.

[0079] Pressure gauges are used to display tank pressures in the sterilization culture and fermentation tank, mixing and mixing tank, and bacterial fermentation and inoculation tank, with a display range of 0-0.4 MPa. Electronically controlled valves control air intake and exhaust emissions.

[0080] Ventilation volume: configured at 1:2VVM or above; a rotor flowmeter is installed on the pipeline of the sterile gas supply system to adjust and control the flow of each gas according to the process requirements;

[0081] The air enters the tank through two stages of filtration, namely pre-filter and fine filter, and uses a sterilizing filter with an accuracy of 0.01μm;

[0082] Air distributors are respectively installed in the sterilization culture fermentation tank 0203, the strain fermentation inoculation tank 0207 and the stirring mixing tank 0201 to evenly distribute the gas.

[0083] Check valves are installed on the pipelines between interconnected devices to prevent material backflow, ensure safety and greatly extend service life; electric control valves are also installed to control the material supply.

[0084] (7) Detection and control system:

[0085] A PID intelligent controller is used, which is respectively connected to the motor of the sterilization culture fermentation tank, the motor of the stirring mixing tank, and the motor of the strain fermentation inoculation tank, to record and control the start and stop and operating speed of each motor; it is connected to the peristaltic pump 0501 of the water supply system, to record and control the flow of the peristaltic pump; it is respectively connected to the electric control valve on each pipeline and the rotor flowmeter on the sterile gas supply system pipeline, to record and control the opening of the electric control valve and the flow of sterile gas; it records the values of the pressure gauges of the sterilization culture fermentation tank, the stirring mixing tank, and the strain fermentation inoculation tank.

[0086] The detection system includes:

[0087] Lights installed inside the sterilized fermentation tanks allow for both light and dark incubation. Light incubation conditions include: light on, yellow diffuse light, and an intensity of 300-1000 LUX. Stir once, incubate for 7 days, and then transfer to a drying unit. Dark incubation conditions include: no stirring, stirring once after 10 days, and incubating for an additional 4 days. Sterile gas is maintained throughout both dark and light incubation.

[0088] A pressure gauge is installed on the sterilized culture fermentation tank to detect the pressure inside the tank.

[0089] Temperature monitoring, moisture monitoring, pH detection:

[0090] Temperature control system: PT-100 temperature electrodes are installed on the lids of sterilized culture and fermentation tanks, electrically heated via a PID intelligent controller. Electronically controlled valves are installed in the water supply system piping to regulate drainage. External piping connects the tanks, and water circulates via circulating pumps. Each tank is heated by a steam generator and cooled by electronically controlled valves. A chiller system is configured, with cooling water ranging from +5°C to 65.0°C ± 0.2°C and a measurement range of 0 to 150°C. Online temperature detection and automatic control are achieved using PT100 temperature electrodes.

[0091] A humidity electrode is installed on the exhaust pipe e1 of the sterilized culture fermentation tank. The humidity is controlled within a range of 30% to 100% through the humidity electrode detection. An atomizing pipe is directly connected through the opening in the tank lid. An atomizing nozzle is installed at the end of the atomizing pipe. The atomizing water spray system automatically adjusts the humidity inside the tank. Manual water replenishment is also possible. The water replenishment time is 0 to 99 minutes or seconds on; 0 to 99 minutes or seconds off.

[0092] pH: A pH meter is installed in both the bacterial fermentation inoculation tank 0207 and the sterilized culture fermentation tank 0203. PID control is employed, and a peristaltic pump controls the amount of material added, thereby controlling the pH value. The control range is 2-12 pH, with an accuracy of ±0.1 pH and a resolution of 0.01 pH. The controller records both real-time and historical pH curves.

[0093] Dissolved oxygen (DO): PID automatic control, air flow control through the rotor; can be linked to the stirring and feeding speed control, that is, the dissolved oxygen is adjusted by changing the stirring speed; control range: 0-100%, display range: 0-200%, resolution: 1%; the controller records the real-time curve and historical curve of the DO value.

[0094] Chillers, steam, air, and spray are used to control temperature and humidity to maintain a suitable fermentation environment.

[0095] (8) Drying system: Use automatic temperature and humidity control drying room 0301, such as Figure 5 As shown, the drying room includes multiple layers of drying belts, an ozone generator for ozone sterilization, and a bottom-up circulating air duct, enabling multi-layer drying, rolling fabrics, and vertical air circulation. The drying temperature is adjusted by the circulating air temperature. Automatic temperature and humidity control: humidity electrodes are installed in drying room 0301 to accurately measure material moisture and monitor drying time. Once the drying room is turned on, it is automatically controlled, intelligently controlling the room's temperature and humidity based on the set temperature and humidity, fed back by temperature and humidity sensors.

[0096] (11) Spore collection system: including rotary spore crusher 0401, pulse bag collector 0402, and third conveyor 0302. Figure 5 、 Figure 6 As shown, the material dried by the drying system is conveyed via a circular stainless steel auger conveyor to the rotary breaker 0401. The rotary breaker simultaneously breaks up the sporangia, releasing spores. The spores are then collected by a pulse bag collector 0402 and conveyed to a storage silo. Waste is directly bagged at the rotary breaker's waste outlet and can be recycled for field planting.

[0097] (12) The materials in the storage silo, including spore powder and tiny waste materials, are finely screened by the electric circular swing powder screening machine 0406 and then packaged by the first packaging machine 0403 and the second packaging machine 0405 respectively.

[0098] (13) Metering and batching system and conveying system: including:

[0099] Feeding silo: including 1# raw material feeding silo 0101, 2# raw material feeding silo 0102, 3# raw material feeding silo 0103, 4# raw material feeding silo 0104, and 5# raw material feeding silo 0105; a measuring scale is set in each feeding silo.

[0100] Conveyors include a first conveyor 0107 between the feed silo and the mixing tank 0201, a second conveyor 0205 between the sterilization and fermentation tank 0203 and the air-drying room 0301, and a third conveyor 0302 between the air-drying room 0301 and the rotary disintegrator 0401. The first conveyor 0107 is a belt conveyor, while the second and third conveyors 0205 and 0302 are circular stainless steel auger conveyors. The material in each feed silo is weighed on a reduction scale and then transported to the mixing tank 0201 via the first conveyor 0107. The material is then dropped from the top of the first conveyor 0107 into a material receiving pipe at the top of the mixing tank 0201. The pipe is equipped with a first electrically controlled valve 0106.

[0101] A second electrically controlled valve 0202 is provided on the pipeline between the stirring and mixing tank 0201 and the sterilization culture fermentation tank 0203, and a third electrically controlled valve 0204 is provided on the discharge pipe of the sterilization culture fermentation tank 0203. The first electrically controlled valve 0106, the second electrically controlled valve 0202 and the third electrically controlled valve 0204 are electric push rod flat gate valves.

[0102] The 0101-0107 metering feed silos and conveyors used in this system utilize high-precision weight-reducing scales, high-angle belts (or auger screw elevators), raw material silos, and electronically controlled valves to control raw materials delivery to the mixing tank, enabling culture medium preparation. The weight-reducing scales enable continuous, intermittent, and quantitative metering of various powdered raw materials, offering high metering accuracy and excellent control stability. Automated control facilitates adjustment of discharge speed and volume. Material is manually poured into the hoppers of each feed silo, achieving automatic metering and batching.

[0103] (14) Equipped with ultraviolet disinfection lamp + ozone generator to achieve on-site disinfection. Set up ultraviolet disinfection lamp in the drying room to irradiate and disinfect the materials, and use ozone generator to implement ozone sterilization.

[0104] Example 2, a solid-state fermentation extraction and production method of Chaetomium globosum

[0105] A solid-state fermentation extraction production system for Chaetomium globosum provided in Example 1 includes the following steps:

[0106] S1, metering and feeding of raw materials from the raw material warehouse;

[0107] S2, sealed lifting using an encapsulated belt conveyor;

[0108] S3, preparation of culture medium: in a mixing tank, first use a peristaltic pump to meter water to soak the raw materials and stir, detect the humidity and control the tank to drain, and control the humidity at around 50%;

[0109] The raw material bin measures and supplies materials, and the mixing tank starts automatic stirring to prepare the culture medium;

[0110] S4, the prepared culture medium is transported to the sterilized culture fermentation tank through a sealed pipeline, the steam generator is turned on to sterilize the sterilized culture fermentation tank, and then the steam generator is turned off, and the pipeline between the culture fermentation inoculation tank 0207 is opened to inoculate the bacteria; dark culture and light culture are performed;

[0111] The sterilization process involves the 0207 bacterial fermentation inoculation tank, the 0203 sterilized culture fermentation tank, the 0206 steam generator, the 0208 water chiller, the 0210 sterile gas filtration device, and the 0209 air compressor. The steam generator 0206 heats the 0207 bacterial fermentation inoculation tank and the 0203 sterilized culture fermentation tank, while the water chiller 0208 cools them down. Steam is used to heat the tank from 0 to 100°C while releasing air. After reaching 100°C, the temperature is held and then raised to 121°C, where it is maintained for 25 minutes. Sterile air is first used, followed by tap water, to cool the tank to 70°C, then to 121°C, where it is maintained for 25 minutes. Finally, the temperature is cooled to room temperature using cold water from the water chiller, completing the sterilization process. Stirring is maintained throughout the entire process.

[0112] In-situ steam sterilization temperature is 100-130℃, and all operating valves are designed for front operation. Stirring can be carried out simultaneously, which can thoroughly disinfect the culture medium.

[0113] Among them, the inoculation process involves 0207 bacterial fermentation inoculation tank, 0206 steam generator, 0208 chiller, 0210 sterile gas filtration device, 0209 air compressor, and 0203 sterilization culture fermentation tank; using clean compressed air differential pressure to transfer the seeds; inoculation and mixing in situ, inoculation by pressure differential water spraying; automatic inoculation starts after sterilization is completed, and the pipeline is sterilized with high-temperature steam before inoculation, and stirring is performed while inoculating.

[0114] During the dark culture process, the culture medium was not stirred, and was stirred once after 10 days of culture, followed by another 4 days of culture.

[0115] Light culture: Turn on the light, use yellow scattered light, and the light intensity is 300-1000 lux. Stir once, culture for 7 days, and then transfer to the drying device.

[0116] Cultivation and testing: This involves pressure gauges, temperature monitoring, moisture monitoring, pH testing, stirring, and lighting. Sterile gas is maintained throughout both dark and light incubation. A suitable fermentation environment is maintained through the automatic control of the tank's jacketed dehumidification structure, heater, and humidifier.

[0117] S5, the material cultured in the sterilized culture fermentation tank is transported to a drying room through an auger conveyor for dehumidification and drying, and then transported to a rotary breaking tank through an auger conveyor for rotary breaking of the sporangium to break the spores;

[0118] In step S6, the dispersed spores enter pulse bag collector 0402 under the action of the fan. The spores are then finely screened by electric circular swing powder screen 0406, which removes particles larger and smaller than the spore size and collects them separately. The qualified spores are then packaged in first packaging machine 0403 and second packaging machine 0405. The entire production process is automated, with manual inspection and parameter setting. In this embodiment of the present invention, pulse bag collector 0402 is a bag dust collector that collects spores.

[0119] The production equipment of the present invention has a modular design and can realize local or single-machine operation according to actual needs, which is convenient for production adjustment. It adopts automatic metering and proportioning, automatic control of sterilization and inoculation, intelligent fermentation and cultivation, sterile room drying, collection using a rotary beating + pulse bag collector, and selection using a circular swing powder screen for subdivision.

[0120] The BIO-type control system features a Siemens PLC control system and an industrial computer touchscreen display, with a fully Chinese menu and interface. It enables data transfer with a computer, sampling and displaying tank data, system data browsing and analysis, and configuration access. It adapts to input and output signals from various sensors and actuators and includes a signal interference prevention system. It controls and displays a comprehensive range of parameters, including temperature, agitator speed, pH, dissolved oxygen, defoaming, air flow, tank pressure, fermentation broth volume, exhaust O₂, exhaust CO₂, and 14 other direct parameters, and can also calculate indirect parameters.

[0121] Some of the functions are as follows:

[0122] 1. Control mode: ① Manual control mode: You can set the valve opening ratio or valve opening

[0123] ② Automatic control mode: You can choose PID continuous or PID switch control mode ③ Sequential control mode: All control parameters can be pre-set for at least 10 control segments to achieve automatic segmented control ④ Remote control mode: Acceptable host computer control ⑤ Associated control: Dissolved oxygen can be controlled by speed, air flow, tank pressure, feeding, etc.; PH can be controlled by adding acid or alkali.

[0124] 2. Metering function: it can measure feed, soaking, acid and alkali, etc.

[0125] 3. The controller records data such as speed, air flow, tank pressure, feed, dissolved oxygen, pH value, etc., and produces real-time curves and historical curves. Through the X and Y axis trend graphs, it helps the operator to judge the mutual influence between parameters, so as to quickly modify and adjust the fermentation process.

[0126] 4. Data processing function

[0127] It can display and analyze the trend curves of all parameters, store, display and analyze the historical curves of all parameters, display the batch number reports of all parameters, and copy data directly using a USB flash drive.

[0128] 5. The adjustment and control of each parameter are independent modules, which do not interfere with each other and are easy to maintain.

[0129] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A solid-state fermentation extraction production system and method for Chaetomium globosum, characterized in that: include: Measuring and batching system, which weighs and measures the raw materials required for culture medium preparation; Stirring and mixing tank, used for preparing culture medium; Liquid fermentation tank, used to provide bacterial fermentation liquid; Solid-state fermentation tank, used for solid-state fermentation; A drying system, used for drying the solid-state fermentation product; a collection system for collecting spores from the fermentation product; The metering and batching system transports the raw materials to the stirring and mixing tank through the conveying system. The solid fermentation tank is connected to the stirring and mixing tank and the liquid fermentation tank through pipelines respectively. The drying system is connected to the collection system through pipelines. The product obtained from the solid fermentation tank is transported to the drying system through the conveying system.

2. The solid-state fermentation extraction production system and method of Chaetomium globosum according to claim 1, characterized in that: It also includes a steam generator, which is connected to the inside of the solid fermentation tank and the liquid fermentation tank and the tank jacket through pipes, and is used for in-situ steam sterilization in the tank and controlling the tank temperature. It is also connected to the tank jacket of the stirring and mixing tank through pipes, and is used for adjusting the temperature and keeping the tank warm.

3. The solid-state fermentation extraction production system and method of Chaetomium globosum according to claim 2, characterized in that: It also includes a water supply system, including a pure water tank and a water supply pipe, on which a ball valve, a peristaltic pump, a Y-type filter and a flow meter are provided; the pure water tank is connected to the steam generator through the water supply pipe to supply pure water to the latter; the pure water tank is also connected to a chiller through the water supply pipe, and the outlet pipes of the chiller are respectively connected to a liquid fermentation tank, a solid fermentation tank and a stirring and mixing tank; the water supply system provides water for bacterial fermentation on the one hand, and is used for temperature control on the other hand.

4. The solid-state fermentation extraction production system and method of Chaetomium globosum according to claim 1, characterized in that: It also includes a sterile gas supply system: including an air compressor, a sterile gas filter device and an air supply pipeline. The air supplied by the air compressor is filtered by the sterile gas filter device and then enters the liquid fermentation tank, the solid fermentation tank and the stirring mixing tank to provide air for fermentation in the liquid fermentation tank and the solid fermentation tank; a rotor flowmeter is installed on the pipeline of the sterile gas supply system.

5. The solid-state fermentation extraction production system and method of Chaetomium globosum according to claim 1, characterized in that: The system also includes a control system: the control system uses a PID intelligent controller, which is respectively connected to the motor of the solid-state fermentation tank, the motor of the stirring and mixing tank, and the motor of the liquid fermentation tank, and records and controls the start and stop and operating speed of each motor; is connected to the peristaltic pump and flow meter of the water supply system, and records and controls the flow rate; and is respectively connected to the electric control valves on each pipeline and the rotor flowmeter on the pipeline of the sterile gas supply system, and records and controls the opening of the electric control valve and the flow rate of the sterile gas. The invention also includes a lighting lamp arranged in the sterilized culture fermentation tank, and the lighting lamp implements light culture and dark culture under the control of the control system.

6. The solid-state fermentation extraction production system and method of Chaetomium globosum according to claim 1, characterized in that: It also includes a detection system, including the following installed on the liquid fermentation tank, the solid fermentation tank and the stirring and mixing tank: Pressure gauge, to detect the pressure inside the tank; Temperature electrode, detecting the temperature inside the tank; Humidity electrode, detecting the humidity inside the tank; pH meter, to check the pH value in the tank.

7. The solid-state fermentation extraction production system and method of Chaetomium globosum according to claim 1, characterized in that: The drying system adopts a drying room, which includes multiple layers of drying belts, an ozone generator to provide ozone sterilization, and a bottom-up circulating air duct.

8. The solid-state fermentation extraction production system and method of Chaetomium globosum according to claim 1, characterized in that: The collection system includes a rotary breaker for breaking the sporangium to release spores; Pulse bag collector is used to collect spores by suction, and the collected spores are then screened and packaged.

9. A solid-state fermentation extraction and production method of Chaetomium globosum, characterized in that: The steps include: S1, metering and feeding of raw materials from the raw material warehouse; S2, the raw materials are transferred to the mixing tank through sealed lifting; S3, preparation of culture medium: metering materials from the raw material bin, adding water to soak the raw materials in the mixing tank and stirring to prepare the culture medium; S4, the prepared culture medium is transported to the solid-state fermentation tank through a sealed pipeline, the steam generator is turned on to sterilize the sterilization culture fermentation tank, and then the steam generator is turned off, and the pipeline between the culture fermentation inoculation tank and the culture medium is opened to inoculate the bacteria; dark culture and light culture are performed; S5, the material cultured in the sterilized culture fermentation tank is sealed and transported to the drying system for dehumidification and drying, and then sealed and transported to the rotary breaking tank, where the sporangium is broken by rotation to break the spores; S6, the spores after being broken up enter the pulse bag collector under the action of the pulse bag collector fan to collect the spores, and then the spores are screened and enter the packaging machine for packaging.

10. The solid-state fermentation extraction production method of Chaetomium globosum according to claim 9, characterized in that: In step S4, the sterilization process uses steam to increase the temperature. During the 0-100°C heating process, the temperature is increased while releasing gas. When the temperature reaches 100°C, the breath is held and the temperature is continuously increased to 121°C, and this temperature is maintained for 25 minutes. Sterile air is first used and then tap water is used to cool the temperature to 70°C, and then the temperature is increased to 121°C, and this temperature is maintained for 25 minutes. Finally, cold water provided by a chiller is used to cool the temperature to room temperature, and the sterilization is completed. Stirring is continued throughout the entire process. During the inoculation process, sterile compressed air is used for differential pressure transfer; inoculation and mixing are carried out on site, and water spraying is used for inoculation under differential pressure; inoculation automatically begins after sterilization is completed, and the pipes are sterilized with high-temperature steam before inoculation, and stirring is carried out during inoculation; During the dark incubation, the culture was not stirred. After 10 days of incubation, the culture was stirred once and then incubated for another 4 days. Light culture: culture with the light on, yellow scattered light, light intensity 300-1000LUX; stir once, culture for 7 days, and transfer to the drying system.

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