Efficient tea beverage extraction production system and process thereof

Abstract

The invention relates to the technical field of bottled beverage production, in particular to a tea beverage efficient extraction production system which comprises a pre-treatment unit, a tea soup preparation unit and a waste heat recovery unit, the pre-treatment unit comprises a water tank, a hydraulic filter and an ion exchanger, and the hydraulic filter is provided with a water inlet and a water outlet; the tea soup preparation unit comprises a three-stage counter-current extraction tower, a standing tank and a cooling tower; the waste heat recovery unit comprises a steam condensation device and a heat energy storage tank, one end of the steam condensation device is communicated with the material inlet and outlet of the three-stage counter-current extraction tower, and the other end of the steam condensation device is externally connected with a CIP cleaning system. Through dynamic gradient temperature control extraction, a multi-stage counter-current extraction technology and an instantaneous cooling system, the production efficiency and the energy utilization rate are remarkably improved while the tea soup quality is guaranteed, and therefore efficient, energy-saving and intelligent tea beverage production is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of bottled beverage production, and in particular to a tea beverage efficient extraction production system and process thereof. Background Art

[0002] In the current field of tea beverage production, the equipment composition of the tea beverage production line is relatively complex, covering multiple parts such as CIP cleaning system, water treatment system, extraction system, filtration system, mixing system, sterilization system and filling system. Among them, the extraction system, as a key link in tea extraction, has significant technical defects: in the traditional extraction process, after the extraction time is reached, the tea soup needs to go through the startup procedure in sequence to reach the buffer tank, and the buffer tank needs to go through the startup procedure to enter the liquid storage tank through the vibrating screen, and the liquid storage tank needs to enter the static tank after the startup procedure is cooled. This series of processes consumes a lot of time and seriously affects production efficiency. In addition, traditional tea beverage production lines generally use single-temperature zone extraction technology, which has prominent problems such as low extraction efficiency, high energy consumption, and serious loss of flavor substances. Specifically, it is manifested as follows:

[0003] (1) Existing extraction systems mostly use a constant temperature (70-80°C) and long time (20-30 minutes) extraction method, which leads to the volatilization of heat-sensitive aroma components, the simultaneous excessive dissolution of tea polyphenols and caffeine, and a strong bitter taste in the product;

[0004] (2) The post-processing of tea soup relies on multi-stage storage tank transfer, and the cooling process adopts step-by-step natural cooling, which is not only time-consuming but also prone to secondary precipitation of tea soup;

[0005] (3) The energy utilization rate is low. The waste heat of steam in the extraction process is directly discharged, and the cleaning system consumes an additional 20% to 30% of energy.

[0006] Therefore, developing an innovative tea beverage efficient extraction production system and process thereof to solve the problems existing in the above-mentioned prior art has important practical significance and market value. Summary of the Invention

[0007] In order to solve the technical defects raised in the above-mentioned background technology, the purpose of the present invention is to provide a tea beverage efficient extraction production system and process, aiming to solve the problems of low extraction efficiency, large loss of effective ingredients, high energy consumption and other problems of traditional processes; and through dynamic gradient temperature control extraction, multi-stage countercurrent extraction technology and instantaneous cooling system, significantly shorten the tea soup processing time and improve the extraction efficiency.

[0008] In order to achieve the above object, the present invention adopts the following technical solutions:

[0009] A tea beverage efficient extraction production system and process thereof, comprising

[0010] A pre-treatment unit for water purification includes a water tank, a hydraulic filter, and an ion exchanger. The hydraulic filter has a water inlet and a water outlet. The water inlet of the hydraulic filter is connected to the water tank via a water inlet pipe, and the water outlet of the hydraulic filter is connected to the ion exchanger via a water delivery pipe. Both the water inlet and water delivery pipes are provided with a high-pressure pump and a control valve.

[0011] The tea soup preparation unit is used to perform segmented temperature-variable extraction on tea leaves, and includes a three-stage countercurrent extraction tower, a standing tank, and a cooling tower. The first stage of the three-stage countercurrent extraction tower is provided with a low-temperature extraction zone, the second stage is provided with a high-temperature ultrasonic extraction zone, and the third stage is provided with a balanced extraction zone. Each stage of the extraction tower has an independent intelligent temperature control module and a material inlet and outlet. The standing tank is connected to the three-stage countercurrent extraction tower via an infusion pipeline, and a tubular separator is provided on the infusion pipeline. The cooling tower and the standing tank are connected via a cooling circulation pipe.

[0012] The waste heat recovery unit recovers heat energy and uses it for sterilizing pipelines and equipment, and includes a steam condensing device and a heat energy storage tank. One end of the steam condensing device is connected to the material inlet and outlet of the three-stage countercurrent extraction tower, and the other end of the steam condensing device is externally connected to the CIP cleaning system; the heat energy storage tank is provided with multi-level temperature zones, and the multi-level temperature zones are respectively connected to the heating pipeline through the arrangement of electric valves.

[0013] Preferably, the outer wall of the three-stage countercurrent extraction tower is provided with a jacketed heat exchange structure, and the jacketed heat exchange structure consists of a steam heating jacket and a cooling water jacket. The steam heating jacket is spirally wrapped around the upper part of the outer wall of the three-stage countercurrent extraction tower, and the cooling water jacket is spirally wrapped around the lower part of the outer wall of the three-stage countercurrent extraction tower. An insulating layer is provided between the steam heating jacket and the cooling water jacket.

[0014] Preferably, the low-temperature extraction zone is built with multiple layers of sieve plates, and the apertures of the multiple layers of sieve plates increase in a step-by-step manner.

[0015] Preferably, the high-temperature ultrasonic extraction zone is provided with an array-type ultrasonic generator, and the ultrasonic generator is connected to a PLC control system via a signal.

[0016] Preferably, a micro-pressure controller is provided at the top of the equilibrium extraction zone, and the micro-pressure controller is electrically connected to a PLC control system.

[0017] Preferably, the stationary tank is connected to the jacketed heat exchange structure by providing a guide pipe, and a spiral guide vane with a certain inclination angle is provided in the stationary tank, and the inclination angle of the spiral guide vane is 30 to 45 degrees.

[0018] A high-efficiency extraction process for tea beverages comprises the following steps:

[0019] a. Water treatment: Raw water passes through a hydraulic filter to remove suspended particles, is desalinated through a reverse osmosis membrane, enters an ion exchanger to reduce hardness, and is sterilized by ultraviolet light before being transported to a three-stage countercurrent extraction tower.

[0020] b. Material Proportioning: The tea leaves are pre-treated before feeding, including grading and screening, and microwave sterilization. The pre-treated tea leaves are then mixed with filtered and purified water at a ratio of 1:22 and transported to the three-stage countercurrent extraction tower.

[0021] c. Segmented extraction: The tea soup is extracted in a three-stage countercurrent extraction tower through an intelligent temperature control module with gradient temperature control. The temperature difference of each section is ≥10°C, and the extraction time of each section is ≤5 minutes.

[0022] d. Centrifugal filtration: The extracted tea soup is separated into solid and liquid by a tubular separator equipped with an automatic slag discharge system and an online turbidity monitoring device;

[0023] e. Instantaneous cooling: The separated tea soup enters the cooling tower and is instantly cooled to below 25°C within 30 seconds; the cooled tea soup is then transported to a standing tank and left to stand for 5 to 10 minutes;

[0024] f. Waste heat recovery: The high-temperature steam discharged from the steam heating jacket is recovered through the steam condensing device and used in the CIP cleaning system.

[0025] Preferably, the reverse osmosis membrane in step a adopts a cross-flow filtration method and is provided with an automatic backwashing device.

[0026] Preferably, the intelligent temperature control module in step c implements gradient temperature control extraction including:

[0027] In the low-temperature stage, the heating temperature is 50℃±0.5℃ and the extraction time is 1-2 minutes;

[0028] In the high temperature stage, the heating temperature is 80℃±0.3℃ and the extraction time is 3-5min;

[0029] In the medium temperature stage, the heating temperature is 65℃±0.2℃ and the extraction time is 2 to 3 minutes.

[0030] Preferably, 20-40kHz ultrasound is applied simultaneously in the high temperature stage to rupture the tea cell walls through the cavitation effect and accelerate the dissolution of the contents. The ultrasound power density is controlled at 0.3-0.5W / mL, and the action time is synchronized with the extraction time in the high temperature stage, which is 3-5 minutes.

[0031] In summary, the beneficial effects of the present invention are:

[0032] When extracting tea beverages, the pre-treatment unit adopts a combined purification process of hydraulic filters and ion exchangers. A high-pressure pump is used to push the water flow through multiple stages of purification in sequence, effectively removing impurities and ions in the water, and providing stable pure water guarantee for subsequent extraction processes; at the same time, the tea soup preparation unit adopts a three-stage countercurrent extraction tower structure, and uses low-temperature, high-temperature ultrasonic and balanced three-stage gradient extraction, combined with an intelligent temperature control module to accurately adjust the temperature of each section, so that the effective ingredients in the tea can be efficiently dissolved in stages. The extracted tea soup is removed from the residue by a tubular separator and then enters the static tank to ensure that the tea soup maintains a stable flow state during transportation, avoiding temperature fluctuations and secondary precipitation; thereby significantly shortening the tea soup processing time and improving the extraction efficiency; in addition, the waste heat of the steam generated during the extraction process is converted into clean heat energy through a condensing device through a waste heat recovery unit, and stored in a multi-stage temperature zone heat energy tank, which not only provides a sterilization heat source for the CIP cleaning system, but also realizes the recycling of energy. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a layout diagram of the tea beverage efficient extraction production system of the present invention;

[0034] Figure 2 is a cross-sectional view of a three-stage countercurrent extraction tower in the present invention;

[0035] Figure 3 The present invention is a flow chart of the efficient extraction process of tea beverage.

[0036] Description of Reference Numerals

[0037] 1. Pre-treatment unit; 11. Water tank; 12. Hydraulic filter; 13. Ion exchanger; 14. Water inlet pipe; 15. Water delivery pipe; 2. Tea preparation unit; 21. Three-stage countercurrent extraction tower; 211. Low-temperature extraction zone; 212. High-temperature ultrasonic extraction zone; 213. Balanced extraction zone; 22. Standing tank; 23. Cooling tower; 24. Infusion pipeline; 25. Cooling circulation pipe; 26. Tubular separator; 3. Waste heat recovery unit; 31. Steam condensing device; 32. Thermal energy storage tank; 4. CIP cleaning system; 5. Jacketed heat exchange structure; 51. Steam heating jacket; 52. Cooling water jacket; 6. Thermal insulation layer; 7. Sieve plate; 8. Ultrasonic generator; 9. Micro-pressure controller; 10. Spiral guide vane. DETAILED DESCRIPTION

[0038] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention are within the scope of protection of the present invention.

[0039] Those skilled in the art should understand that, in the disclosure of the present invention, the terms "longitudinal", "transverse", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like to indicate orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings, which are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, the above terms should not be understood as limiting the present invention.

[0040] Furthermore, the terms "installed," "disposed," "provided with," "connected," and "connected" should be interpreted broadly. For example, they can refer to fixed connections, removable connections, or integral structures; mechanical connections or electrical connections; direct connections or indirect connections through an intermediary; or internal communication between two devices, elements, or components. Those skilled in the art will understand the specific meanings of these terms in the present invention based on specific circumstances.

[0041] In the description of the present invention, if words such as "several" are used, they mean one or more; "more" means two or more; "greater than," "less than," and "exceed" are understood to exclude the number itself; and "above," "below," and "within" are understood to include the number itself. The terms "first," "second," and "third" are used solely to distinguish technical features and are not to be construed as indicating or implying relative importance, or as implicitly specifying the number of the indicated technical features, or as implicitly specifying the order of the indicated technical features.

[0042] The following is combined with Figure 1-3 , an embodiment of a tea beverage efficient extraction production system and process of the present invention is further described in detail.

[0043] Example 1

[0044] A tea beverage efficient extraction production system, such as Figure 1 、 2 As shown, the pre-treatment unit 1 is used for water purification, including a water tank 11, a hydraulic filter 12 and an ion exchanger 13. The hydraulic filter 12 has a water inlet and a water outlet, and the water inlet of the hydraulic filter 12 is connected to the water tank 11 via a water inlet pipe 14, and the water outlet of the hydraulic filter 12 is connected to the ion exchanger 13 via a water delivery pipe 15. A high-pressure pump and a control valve are provided on both the water inlet pipe 14 and the water delivery pipe 15.

[0045] The tea soup preparation unit 2 is used for performing segmented temperature-variable extraction of tea leaves and includes a three-stage countercurrent extraction tower 21, a standing tank 22, and a cooling tower 23. The first stage of the three-stage countercurrent extraction tower 21 is provided with a low-temperature extraction zone 211, the second stage is provided with a high-temperature ultrasonic extraction zone 212, and the third stage is provided with a balanced extraction zone 213. Each stage of the extraction tower has an independent intelligent temperature control module and material inlet and outlet. The standing tank 22 is connected to the three-stage countercurrent extraction tower 21 by a liquid infusion pipeline 24, and the liquid infusion pipeline 24 is provided with a tubular separator 26. The cooling tower 23 is connected to the standing tank 22 by a cooling circulation pipe 25.

[0046] The waste heat recovery unit 3 recovers heat energy and uses it for sterilizing pipelines and equipment. It includes a steam condensing device 31 and a heat energy storage tank 32. One end of the steam condensing device 31 is connected to the material inlet and outlet of the three-stage countercurrent extraction tower 21, and the other end of the steam condensing device 31 is externally connected to the CIP cleaning system 4; the heat energy storage tank 32 is provided with multi-level temperature zones, and the multi-level temperature zones are respectively connected to the heating pipeline through the provision of electric valves.

[0047] Specifically, the production system optimizes the entire process, from raw material processing to finished product preparation, through the coordinated operation of a pre-treatment unit 1, a tea soup preparation unit 2, and a waste heat recovery unit 3. Pre-treatment unit 1 utilizes a combined purification process involving a hydraulic filter 12 and an ion exchanger 13. A high-pressure pump propels water through multiple stages of purification, effectively removing impurities and ions from the water and providing stable, pure water for subsequent extraction processes. Tea soup preparation unit 2 utilizes a three-stage countercurrent extraction tower 21. Through low-temperature, high-temperature ultrasonic, and balanced three-stage gradient extraction, coupled with an intelligent temperature control module to precisely adjust the temperature of each stage, the active ingredients in the tea leaves are efficiently dissolved in stages. The extracted tea soup passes through a tubular separator 26 to remove residue before entering a settling tank 22. Its unique spiral diversion design significantly shortens the tea soup's stabilization time. The waste heat recovery unit 3 cleverly converts the steam heat generated during the extraction process into clean heat energy through a condenser, which is then stored in a multi-temperature zone thermal energy tank. This provides a sterilization heat source for the CIP cleaning system 4 and enables energy recycling.

[0048] The core advantages of this system are: improving extraction efficiency through the synergistic effect of temperature gradient and ultrasonic cavitation, optimizing the tea soup processing process with a spiral static structure, and significantly reducing energy consumption with intelligent waste heat management. The entire system has a compact layout and a high degree of automation. While ensuring the quality of the tea soup, it significantly improves production efficiency and energy utilization, providing an innovative solution for the industrial production of tea beverages.

[0049] In this embodiment, if Figure 2As shown, the outer wall of the three-stage countercurrent extraction tower 21 is provided with a jacketed heat exchange structure 5, which consists of a steam heating jacket 51 and a cooling water jacket 52. The steam heating jacket 51 spirally surrounds the upper part of the outer wall of the three-stage countercurrent extraction tower 21, and the cooling water jacket 52 spirally surrounds the lower part of the outer wall of the three-stage countercurrent extraction tower 21. An insulation layer 6 is provided between the steam heating jacket 51 and the cooling water jacket 52.

[0050] Specifically, precise temperature control is achieved through the upper and lower partitioned steam heating jackets 51 and cooling water jackets 52, and the steam heating jacket 51 spirally surrounds the upper part of the tower body. During the extraction process, saturated steam is introduced to quickly heat the tea soup in the corresponding temperature zone and maintain a constant temperature; while the cooling water jacket 52 is also arranged in a spiral structure at the lower part of the tower body, and the extracted tea soup is pre-cooled by circulating cooling water. The insulation layer 6 provided between the two-stage jackets effectively blocks the heat conduction between the cold and hot media, ensuring that the temperatures in each temperature zone do not interfere with each other. This design enables the three-stage countercurrent extraction tower 21 to simultaneously achieve independent temperature control in different temperature zones, quickly reach the target temperature in the high-temperature extraction section, and cool down in time in the low-temperature section to avoid over-extraction. The entire temperature conversion process is smooth and continuous. In addition, the spiral jacket structure not only increases the heat exchange area, but also enhances the heat transfer efficiency through the spiral flow of the fluid. In conjunction with the intelligent temperature control module, precise temperature control of ±1°C can be achieved. The advantage of this structure is that it achieves precise control of the temperature gradient during the extraction process, which not only ensures the best extraction effect in each stage, but also reduces energy consumption through thermal energy zoning management. At the same time, the compact design saves equipment space and provides reliable guarantee for the stable production of high-quality tea soup.

[0051] In this embodiment, the low-temperature extraction zone 211 is internally provided with multiple layers of sieve plates 7 , and the apertures of the multiple layers of sieve plates 7 increase in a step-by-step manner.

[0052] Specifically, the tea leaves are graded and extracted during the slow sedimentation process by using the sieve plates 7 with gradually increasing apertures. Larger tea fragments stay on the upper sieve plates 7 for a longer time, while finer particles can pass through the lower sieve plates 7 smoothly. This progressive filtration ensures sufficient extraction while avoiding the accumulation of tea residues.

[0053] In this embodiment, the high-temperature ultrasonic extraction zone 212 is provided with an array-type ultrasonic generator 8 , and the ultrasonic generator 8 is connected to a PLC control system via a signal.

[0054] Specifically, the array-type ultrasonic generator 8 configured in the high-temperature ultrasonic extraction area 212 generates a uniform ultrasonic field under the precise control of the PLC system, which promotes the rupture of the tea cell walls through the cavitation effect and accelerates the dissolution of effective ingredients. At the same time, the intelligently adjusted pulse mode avoids the impact of local overheating on the quality of the tea soup.

[0055] In this embodiment, a micro-pressure controller 9 is provided at the top of the equilibrium extraction zone 213 , and the micro-pressure controller 9 is electrically connected to the PLC control system.

[0056] Specifically, the micro-pressure controller 9 at the top of the extraction area monitors and adjusts the pressure in the tank in real time through the PLC system to maintain a stable micro-positive pressure environment, which not only prevents the volatilization of aroma components, but also ensures that the tea soup completes the balance and fusion of flavor substances under optimal pressure conditions.

[0057] It is worth noting that the synergistic effect of these innovative designs enables the entire extraction process to be carried out under the precise control of multiple parameters such as temperature, pressure, and ultrasound. This not only significantly improves the extraction efficiency of effective ingredients such as tea polyphenols, but also better preserves the natural flavor characteristics of tea. At the same time, it reduces human operation errors through automated control, providing reliable technical support for the large-scale production of high-quality tea beverages.

[0058] In this embodiment, the stationary tank 22 is connected to the jacketed heat exchange structure 5 by providing a guide pipe, and a spiral guide vane 10 with a certain inclination angle is provided in the stationary tank 22, and the inclination angle of the spiral guide vane 10 is 30-45 degrees.

[0059] Specifically, spiral guide vanes 10 are installed within the resting tank 22 to create a gentle spiral flow as the tea enters. The inclination angle of spiral guide vanes 10 is preferably 45°, ensuring thorough mixing and homogenization of the tea while avoiding the deterioration of the tea's quality caused by violent agitation. Furthermore, the spiral channel formed by spiral guide vanes 10 extends the flow path of the tea, allowing suspended particles in the tea to naturally settle and promoting the full integration of the various components.

[0060] It's worth noting that the streamlined flow conduit between the resting tank 22 and the jacketed heat exchange structure 5 ensures a stable flow of tea during transport, preventing temperature fluctuations and secondary precipitation. This design also offers the advantage of achieving natural clarification and flavor integration through physical means, eliminating the additives and complex processing steps required in traditional processes. This ensures a clear, translucent tea with a rich flavor, while streamlining the production process and improving overall efficiency.

[0061] Example 2

[0062] A high-efficiency extraction process for tea beverages, such as Figure 3 As shown, the following steps are included:

[0063] a. Water treatment: Raw water passes through a hydraulic filter 12 to remove suspended particles, is desalinated through a reverse osmosis membrane, enters an ion exchanger 13 to reduce hardness, and is sterilized by ultraviolet light before being transported to a three-stage countercurrent extraction tower 21.

[0064] b. Material ratio: Tea leaves are pretreated before feeding, including grading and microwave sterilization; and the pretreated tea leaves are mixed with filtered and purified water in a ratio of 1:22 and transported to the three-stage countercurrent extraction tower 21;

[0065] c. Segmented extraction: The tea soup is subjected to gradient temperature control extraction in a three-stage countercurrent extraction tower 21 through an intelligent temperature control module, with a temperature difference of ≥10°C in each section and a single-stage extraction time of ≤5min;

[0066] d. Centrifugal filtration: The extracted tea soup is separated into solid and liquid by a tubular separator 26; the tubular separator 26 is equipped with an automatic slag discharge system and an online turbidity monitoring device;

[0067] e. Instantaneous cooling: The separated tea soup enters the cooling tower 23 and is instantly cooled to below 25°C within 30s; and the cooled tea soup is transported to the standing tank 22 and allowed to stand for 5-10min;

[0068] f. Waste Heat Recovery: The high-temperature steam discharged from the steam heating jacket 51 is recovered through the steam condensing device 31 and is then recycled to the CIP cleaning system 4 for use.

[0069] Specifically, the comparison between the present invention and the prior art extraction process is shown in the following table:

[0070]

[0071]

[0072] By comparing the above data, it can be seen that the advantages of the extraction process of the present invention are:

[0073] During the water treatment phase, a multi-stage purification process is used to ensure that the water quality reaches the standard of conductivity ≤10μS / cm, which improves the purification efficiency by more than 30% compared with traditional processes.

[0074] The tea pre-treatment stage uses microwave sterilization technology to increase the microbial killing rate to 99.9% while preserving the tea flavor;

[0075] The gradient temperature-controlled extraction process adopts a three-stage variable temperature control of 50℃ / 80℃ / 65℃, and cooperates with the intelligent temperature control module to control the temperature fluctuation within the range of ±1℃. The tea polyphenol extraction rate can reach more than 95%, which is 15% higher than the traditional constant temperature extraction.

[0076] The tubular separator 26 achieves efficient solid-liquid separation at a high-speed centrifuge of 12,000 rpm, with the moisture content of the filter residue controlled below 15% and the light transmittance of the clear liquid ≥ 95%;

[0077] The instantaneous cooling system shortens the cooling time from 25 minutes in the traditional process to 30 seconds, effectively avoiding the degradation of heat-sensitive components.

[0078] The waste heat recovery system recycles the heat energy of steam above 80°C, reducing overall energy consumption by more than 30%.

[0079] Through parameter optimization and equipment innovation, the entire process shortens the total processing time from 90 minutes in the traditional process to 35 minutes. At the same time, it increases the retention rate of effective ingredients such as tea polyphenols by 20% and reduces the caffeine content by 12%, achieving efficient and energy-saving production of high-quality tea beverages.

[0080] In this embodiment, the reverse osmosis membrane in step a adopts a cross-flow filtration method and is provided with an automatic backwashing device.

[0081] Specifically, during the raw water treatment process, water flows at a specific angle to impact the membrane surface, causing most contaminants to exit the system with the concentrated water, leaving only the purified water molecules driven by pressure to permeate the membrane pores. Furthermore, the reverse osmosis membrane system is equipped with an automatic backwash device that monitors the transmembrane pressure differential in real time via a pressure sensor. When the pressure differential rises to a set threshold, it immediately initiates a reverse pulse flushing process, using an instantaneous high-pressure water flow to completely remove contaminants such as colloids and organic matter deposited on the membrane surface, effectively preventing reverse osmosis membrane fouling and clogging. This design enables the reverse osmosis membrane to maintain a stable rejection rate over long-term operation, extending the membrane life by 2-3 times compared to traditional processes while reducing the frequency of chemical cleaning by over 50%. Compared to conventional water treatment systems, this intelligent cross-flow filtration combined with automatic backwash technology not only increases water production efficiency to over 95%, maintains a stable conductivity of ≤10μS / cm, but also significantly reduces maintenance costs and downtime, ensuring a continuous and stable source of high-purity water for the subsequent tea beverage extraction process.

[0082] In this embodiment, the intelligent temperature control module in step c implements gradient temperature control extraction including:

[0083] In the low-temperature stage, the heating temperature is 50℃±0.5℃ and the extraction time is 1-2 minutes;

[0084] In the high temperature stage, the heating temperature is 80℃±0.3℃ and the extraction time is 3-5min;

[0085] In the medium temperature stage, the heating temperature is 65℃±0.2℃ and the extraction time is 2 to 3 minutes.

[0086] Specifically, the intelligent temperature control module achieves efficient and selective extraction of tea's active ingredients through three-stage gradient temperature control. During the 1-2 minute extraction process at a low temperature (50°C ± 0.5°C), the mild thermal environment primarily promotes the preferential dissolution of small molecules such as soluble sugars and amino acids in the tea leaves. At this time, the dissolution rate of tea polyphenols is approximately 15% to 20%, and caffeine leakage is controlled below 5%, effectively avoiding the problem of excessive bitterness in the initial stage.

[0087] Then it enters the high-temperature stage (80℃±0.3℃). Through 3 to 5 minutes of precise temperature control and ultrasonic cavitation, the tea cell walls are fully destroyed and the extraction rate of tea polyphenols is significantly improved. This stage contributes 65% to 70% of the total extraction amount, and the design of controlling the temperature fluctuation at ±0.3℃ prevents the volatilization of aroma components caused by high temperature.

[0088] The final medium-temperature stage (65℃±0.2℃) completes the balance of flavor substances within 2 to 3 minutes, so that the various ingredients reach the optimal ratio. Experimental data show that this stage can optimize the ratio of amino acids to tea polyphenols in the tea soup by 12% to 15%, and the flavor coordination is significantly improved.

[0089] Compared with the traditional constant temperature 70℃ extraction process for 20 minutes, the segmented gradient temperature control extraction process of this application shortens the total time by 40%, while the total extraction rate of tea polyphenols is increased from 82% to more than 95%, and the caffeine content is reduced by 8% to 12%, and the retention rate of key flavor substances (such as linalool and geraniol) is increased by 20% to 25%. This segmented temperature control strategy based on the dissolution dynamics of substances, through the ±0.5℃ high-precision adjustment of the intelligent temperature control module, not only ensures the target extraction effect at each stage, but also achieves the energy-saving advantage of reducing energy consumption by 30%, providing a reliable process foundation for the production of high-quality tea beverages.

[0090] In this embodiment, 20-40 kHz ultrasound is applied simultaneously during the high temperature stage to rupture the tea cell walls through the cavitation effect and accelerate the dissolution of the contents. The ultrasound power density is controlled at 0.3-0.5 W / mL, and the action time is synchronized with the extraction time during the high temperature stage, which is 3-5 minutes.

[0091] Specifically, when the ultrasonic generator 8 operates at a power density of 0.3-0.5W / mL, it creates a uniform acoustic field distribution within the tea. The resulting cavitation bubbles, when collapsed, create a localized high-temperature, high-pressure environment that effectively destroys the tea cell structure, rapidly releasing active ingredients such as tea polyphenols and polysaccharides within the cells. Compared to simple high-temperature extraction, this technology increases the dissolution rate of tea polyphenols by 2-3 times, allowing the extraction of the main active ingredients to be completed within 3-5 minutes.

[0092] It is worth noting that the ultrasonic generator 8 in this application adopts an intermittent pulse mode (working for 2 seconds / interval of 1 second) to maintain a stable cavitation intensity while avoiding the problem of local overheating caused by continuous ultrasound. The temperature fluctuation of the tea soup is always controlled within the range of ±0.3°C. Experimental data show that this process combination increases the efficiency of tea polyphenol extraction in the high-temperature stage by more than 40% compared with the traditional process. At the same time, due to the shortening of the high-temperature action time, the loss of heat-sensitive aroma components is reduced by 15% to 20%. The cavitation effect of ultrasound also has a sterilization effect. Combined with an extraction temperature of 80°C, the microbial kill rate can reach 99.99%, which is significantly better than a single thermal sterilization method.

[0093] The examples of this specific embodiment are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, any equivalent changes made based on the structure, shape, and principle of this application should be included in the scope of protection of this application.

Claims

1. A tea beverage efficient extraction production system, characterized in that: include A pre-treatment unit for water purification includes a water tank, a hydraulic filter, and an ion exchanger. The hydraulic filter has a water inlet and a water outlet. The water inlet of the hydraulic filter is connected to the water tank via a water inlet pipe, and the water outlet of the hydraulic filter is connected to the ion exchanger via a water delivery pipe. Both the water inlet and water delivery pipes are provided with a high-pressure pump and a control valve. The tea soup preparation unit is used to perform segmented temperature-variable extraction on tea leaves, and includes a three-stage countercurrent extraction tower, a standing tank, and a cooling tower. The first stage of the three-stage countercurrent extraction tower is provided with a low-temperature extraction zone, the second stage is provided with a high-temperature ultrasonic extraction zone, and the third stage is provided with a balanced extraction zone. Each stage of the extraction tower has an independent intelligent temperature control module and a material inlet and outlet. The standing tank is connected to the three-stage countercurrent extraction tower via an infusion pipeline, and a tubular separator is provided on the infusion pipeline. The cooling tower and the standing tank are connected via a cooling circulation pipe. The waste heat recovery unit recovers heat energy and uses it for sterilizing pipelines and equipment, and includes a steam condensing device and a heat energy storage tank. One end of the steam condensing device is connected to the material inlet and outlet of the three-stage countercurrent extraction tower, and the other end of the steam condensing device is externally connected to the CIP cleaning system; the heat energy storage tank is provided with multi-level temperature zones, and the multi-level temperature zones are respectively connected to the heating pipeline through the arrangement of electric valves.

2. The fruit tea beverage efficient extraction production system according to claim 1, characterized in that: The outer wall of the three-stage countercurrent extraction tower is provided with a jacketed heat exchange structure, which consists of a steam heating jacket and a cooling water jacket. The steam heating jacket spirally surrounds the upper part of the outer wall of the three-stage countercurrent extraction tower, and the cooling water jacket spirally surrounds the lower part of the outer wall of the three-stage countercurrent extraction tower. An insulating layer is provided between the steam heating jacket and the cooling water jacket.

3. The tea beverage efficient extraction production system according to claim 1, characterized in that: The low-temperature extraction zone is internally provided with multiple layers of sieve plates, and the apertures of the multiple layers of sieve plates increase gradually in a step-by-step manner.

4. The tea beverage efficient extraction production system according to claim 1, characterized in that: The high-temperature ultrasonic extraction zone is provided with an array-type ultrasonic generator, and the ultrasonic generator is connected to a PLC control system via a signal.

5. The tea beverage efficient extraction production system according to claim 1, characterized in that: A micro-pressure controller is provided at the top of the equilibrium extraction zone, and the micro-pressure controller is electrically connected to a PLC control system.

6. The tea beverage efficient extraction production system according to claim 1, characterized in that: The stationary tank is connected to the jacketed heat exchange structure by arranging a guide pipe, and a spiral guide plate with a certain inclination angle is provided in the stationary tank, and the inclination angle of the spiral guide plate is 30-45 degrees.

7. An efficient extraction process for tea beverage according to any one of claims 1 to 6, characterized in that: The following steps are involved: a. Water treatment: Raw water passes through a hydraulic filter to remove suspended particles, is desalinated through a reverse osmosis membrane, enters an ion exchanger to reduce hardness, and is sterilized by ultraviolet light before being transported to a three-stage countercurrent extraction tower. b. Material Proportion: Tea leaves are pre-treated before feeding, including grading and screening and microwave sterilization; The pretreated tea leaves are mixed with filtered and purified water in a ratio of 1:22 and then transported to a three-stage countercurrent extraction tower; c. Segmented extraction: The tea soup is extracted in a three-stage countercurrent extraction tower through an intelligent temperature control module with gradient temperature control. The temperature difference of each section is ≥10°C, and the extraction time of each section is ≤5 minutes. d. Centrifugal filtration: The extracted tea soup is separated into solid and liquid by a tubular separator equipped with an automatic slag discharge system and an online turbidity monitoring device; e. Instantaneous cooling: The separated tea soup enters the cooling tower and is instantly cooled to below 25°C within 30 seconds; the cooled tea soup is then transported to a standing tank and left to stand for 5 to 10 minutes; f. Waste heat recovery: The high-temperature steam discharged from the steam heating jacket is recovered through the steam condensing device and used in the CIP cleaning system.

8. The efficient extraction process for tea beverage according to claim 7, characterized in that: In step a, the reverse osmosis membrane adopts a cross-flow filtration method and is provided with an automatic backwashing device.

9. The efficient extraction process for tea beverage according to claim 7, characterized in that: The intelligent temperature control module in step c implements gradient temperature control extraction, including: In the low-temperature stage, the heating temperature is 50℃±0.5℃ and the extraction time is 1-2 minutes; In the high temperature stage, the heating temperature is 80℃±0.3℃ and the extraction time is 3-5min; In the medium temperature stage, the heating temperature is 65℃±0.2℃ and the extraction time is 2 to 3 minutes.

10. The efficient extraction process for tea beverage according to claim 9, characterized in that: During the high temperature stage, 20-40kHz ultrasound is applied synchronously to rupture the tea cell walls through cavitation effect to accelerate the dissolution of the contents. The ultrasound power density is controlled at 0.3-0.5W / mL, and the action time is synchronized with the extraction time in the high temperature stage, which is 3-5 minutes.

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