Processing technology of quinoa oat porridge

Abstract

The invention discloses a processing technology of quinoa oat porridge, and belongs to the technical field of food processing. The process aims at solving the problems that traditional porridge products are single in taste, insufficient in nutrient release and unstable in quality. According to the technical scheme, the method mainly comprises the following steps: mixing oat grains and quinoa grains according to a specific ratio, cleaning and dehydrating; preparing an oat extracting solution rich in nutrition through a step-by-step enzymolysis and concentration process; dividing the mixed grains into two parts, respectively carrying out cooking gelatinization and warm water soaking treatment, and then combining to obtain a pretreated mixture with gelatinized matrix and particle taste; and finally, mixing with xylitol and the residual extracting solution, homogenizing, filling and sterilizing. The method is mainly used for producing the instant quinoa oat porridge product which is rich in texture level, easy in nutrition absorption and high in storage stability.

Description

Technical Field

[0001] This invention relates to the field of food processing technology. More specifically, this invention relates to the processing technology of quinoa and oat porridge. Background Technology

[0002] In existing processing technologies for grain porridge, especially products involving whole grains such as oats and quinoa, the production process typically relies on basic unit operations such as washing, mixing, steaming or boiling, filling, and sterilization. While these conventional methods achieve the basic edible function of the product, they also come with some long-standing technical limitations.

[0003] Firstly, regarding the final taste and texture of the product, conventional processes often struggle to achieve both a smooth, pasty base and a distinct, chewy texture. Existing technologies mostly involve heat-processing all grain ingredients together, such as prolonged steaming or high-temperature, high-pressure treatment. This method often leads to over-gelatinization of grain particles, especially relatively loosely structured grains like quinoa and oats. The result is a uniform, mushy final product that lacks depth and texture, losing the unique granular texture that the grains themselves can provide. Attempts to preserve the granular texture by shortening the heating time or lowering the temperature often result in undercooked centers, uneven firmness, or insufficient overall consistency, making it as thin as soup and failing to meet consumers' expectations for a porridge with a "soft yet chewy" texture. The difficulty lies in the fact that a single heat treatment process cannot simultaneously and within the same system achieve differentiated cooking control for different types and states of grain particles.

[0004] Secondly, in terms of nutrient release and utilization, simple physical cooking methods are inefficient. Grains like oats are rich in dietary fiber (such as β-glucan) and protein, which are tightly encased within cell walls composed of cellulose and hemicellulose. Conventional hot water extraction and cooking processes have limited ability to break down these cell walls, resulting in these water-soluble components not fully dissolving into the porridge. This not only limits the final content of functional components and nutritional value but also affects the natural thickness and flavor of the porridge. Although some technologies attempt to introduce enzymatic hydrolysis to improve extraction efficiency, in practice, if only a single amylase is used or the processing conditions (such as pH and temperature) are unsuitable, it is difficult to synergistically and efficiently decompose the multiple structural components in the cell walls, resulting in unsatisfactory enzymatic hydrolysis effects and difficulty in precise process control.

[0005] Third, regarding the stability and consistency of product quality, existing processes face the challenge of finished product fluctuations caused by batch-to-batch variations in raw materials. Factors such as the origin, year, and storage conditions of grains lead to natural differences in their basic components, such as starch, protein, and fiber content. In standardized production processes using fixed temperatures and times, such raw material fluctuations directly cause significant changes in key indicators of intermediate products (such as enzymatic hydrolysates), such as viscosity and sugar content, as well as the viscosity and texture of the final product. For example, enzymatic hydrolysis of a fixed duration may result in one batch of product being too thin and another too thick due to different raw materials. Attempts to correct these fluctuations through final product blending often introduce new instabilities. Maintaining a high degree of consistency in texture, viscosity, and flavor between batches is an ongoing challenge, rooted in the lack of a process control mechanism that can adapt to changes in raw materials and adjust process parameters in real time.

[0006] The technical problems mentioned above are interconnected and collectively hinder the development of high-quality, standardized grain porridge. Therefore, seeking a comprehensive processing method that can systematically solve these problems is a direction that needs to be pursued in this field. Summary of the Invention

[0007] One object of the present invention is to provide a processing technology for quinoa oat porridge that not only enhances the nutritional value of the product, but also provides the system with a natural thick base and rich flavor.

[0008] To achieve these objectives and other advantages of the present invention, according to one aspect of the present invention, a method for preparing quinoa and oat porridge is provided, comprising the following steps: Step 1: Take oat rice and quinoa rice and mix them in a dry weight ratio of 1:(2~3.5). Wash them with ultrasonic waves 3 to 4 times, and then centrifuge them for 2 to 4 minutes to reduce the moisture content of the mixed grains to 18% to 25% to obtain the mixed grains. Step 2: Take an additional 10% to 60% of the total dry weight of the mixed grains in Step 1, crush and slurry it, and then sequentially subject it to medium-temperature α-amylase hydrolysis, enzyme inactivation treatment, and compound plant hydrolytic enzyme hydrolysis. Then filter and vacuum concentrate the hydrolyzed mixed slurry to obtain oat extract. The compound plant hydrolytic enzyme contains cellulase, β-glucanase and protease in a weight ratio of 1:(0.5~1.5):(0.3~1.0). Step 3: Divide the mixed grains obtained in Step 1 into two parts by dry weight, with the first part accounting for 70%~85% and the second part accounting for 15%~30%. Mix the first part of grains with the oat extract obtained in Step 2, which is equivalent to 120%~180% of the dry weight of the first part of grains, and cook it under a steam pressure of 0.08~0.12MPa for 10~18 minutes to obtain a gelatinized matrix slurry. Soak the second part of grains in warm water at 60~70℃ for 15~25 minutes to make its moisture content reach 35%~45%, and then mix it with the gelatinized matrix slurry cooled to below 70℃ to obtain a pretreated mixture. Step 4: Mix the pretreated mixture obtained in Step 3, xylitol accounting for 20% to 40% of the total dry weight of the mixed grains in Step 1, and the oat extract prepared in Step 2 that was not used in Step 3, and homogenize them. Step 5: After homogenization, the material is quantitatively filled and sealed, and then sterilized to obtain the quinoa and oat porridge.

[0009] Preferably, the process of preparing oat extract in step two is as follows: Oat groats are pulverized and passed through a 20-40 mesh sieve to obtain broken oat groats. These are then mixed with water at a ratio of 1:(8-12). The pH of the mixture is adjusted to 5.0-5.5 using food-grade citric acid. Medium-temperature α-amylase, equivalent to 0.2%-0.4% of the dry weight of the broken oat groats, is added. Enzymatic hydrolysis is performed at 60-65℃ for 40-60 minutes. The temperature of the hydrolyzed system is then raised to 85-90℃ and maintained for 10-15 minutes to inactivate the enzyme. The pH of the inactivated system is adjusted to [value missing] using food-grade sodium bicarbonate. Add 0.1% to 0.2% of a compound plant hydrolytic enzyme, comprising cellulase, β-glucanase, and protease, at a temperature of 6.5 to 7.0°C. Continue enzymatic hydrolysis for 60 to 80 minutes at 50 to 55°C. Filter the enzymatically hydrolyzed mixture through a 200 to 300 mesh vibrating sieve. Concentrate the filtrate under vacuum conditions of -0.07 to -0.09 MPa and 60 to 65°C until the soluble solids content reaches 25% to 30%, thus obtaining the oat extract.

[0010] Preferably, the mesophilic α-amylase hydrolysis process in step two specifically comprises: When the enzymatic hydrolysis time reaches 40 minutes, the viscosity and sugar content of the enzymatic hydrolysis system are monitored simultaneously. The criteria for determining the success of the enzyme hydrolysis were: the enzymatic hydrolysis time was within the range of 40 to 60 minutes, the viscosity value decreased to 1500 to 2500 cP, and the sugar content reached 8.5% to 10.5%. When the monitoring data simultaneously meet the judgment conditions, and each parameter remains stable within the corresponding range for at least 90 seconds, it is determined that the first enzymatic hydrolysis endpoint has been reached, and then enzyme inactivation treatment is performed. If the viscosity or sugar content still does not reach the specified range after 60 minutes of enzymatic hydrolysis, the enzymatic hydrolysis will be forcibly terminated and enzyme inactivation will be performed immediately. At the same time, an alarm will be triggered and the batch will be marked as an abnormal batch.

[0011] Preferably, the compound plant hydrolysis enzymatic hydrolysis process in step two specifically includes: When the enzymatic hydrolysis time reaches 60 min, the viscosity and sugar content of the enzymatic hydrolysis system are monitored simultaneously. The criteria for determining the outcome are: the enzymatic hydrolysis time is within the range of 60-80 minutes, the viscosity value decreases to 800-1200 cP, and the sugar content reaches 10.0%-12.5%. When the monitoring data simultaneously meet the judgment conditions, and each parameter remains stable within the corresponding range for at least 120 seconds, it is determined that the second enzymatic hydrolysis endpoint has been reached, and then the filtration operation is performed. If the viscosity or sugar content still does not reach the specified range after 80 minutes of enzymatic hydrolysis, the enzymatic hydrolysis will be forcibly terminated and the filtration operation will be performed immediately. At the same time, an alarm will be triggered and the batch will be marked as an abnormal batch.

[0012] Preferably, the texture adaptation pretreatment process in step three specifically includes: The dehydrated mixed grains obtained in step one are divided into two parts by dry weight. The first part is texture-building grains, accounting for 70% to 85% of the total dry weight of the mixed grains; the second part is grains with retained grains, accounting for 15% to 30% of the total dry weight of the mixed grains. The first part of the textured grains is mixed with oat extract obtained in step two at 120% to 180% of their dry weight, and cooked at a steam pressure of 0.08 to 0.12 MPa for 10 to 18 minutes to obtain a gelatinized matrix slurry. The second part of the grain particles is soaked in warm water at 60-70℃ for 15-25 minutes to make its moisture content reach 35%-45%, and then mixed with the gelatinized matrix slurry to obtain a pretreated mixture.

[0013] Preferably, the homogenization process in step four specifically involves: pre-mixing the pretreated mixture, xylitol, and the remaining oat extract in a stirred tank until the xylitol is completely dissolved to obtain a homogeneous slurry; subjecting the slurry to a first-stage homogenization at a pressure of 18-22 MPa, followed by a second-stage homogenization at a pressure of 5-8 MPa.

[0014] Preferably, after the homogenization process in step four, the viscosity of the material system is adjusted, and the specific process is as follows: The viscosity of the homogenized material was monitored in real time using an online viscometer, and the preset viscosity range of the material was set to 2500~4500 cP. When the monitored viscosity remains above 4500 cP, add 1% to 3% of the total mass of the pretreated mixture of purified water to the material and mix for 2 to 4 minutes under stirring conditions of 60 to 80 rpm. When the monitored viscosity remains below 2500 cP, add 2% to 5% of the oat extract prepared in step two to the material, and then perform supplementary homogenization at a pressure not exceeding 5 MPa.

[0015] Preferably, the sterilization process in step five is carried out using a water bath autoclave. The specific process is as follows: the filled and sealed product is placed in the autoclave, and the temperature is first raised from room temperature to 85-90°C at a rate of 1-1.5°C / min and held for 5-8 minutes; then the temperature is raised to 115-121°C at a rate of 0.8-1.2°C / min and held at this temperature for 15-25 minutes; after sterilization, the system is cooled to 70-75°C at a rate of 0.5-1.0°C / min, and then the product is rapidly cooled to below 40°C using a combination of air cooling and water cooling. The F0 value of the entire sterilization process is controlled within 8-12 minutes.

[0016] The present invention provides at least the following beneficial effects: The processing technology of the quinoa and oat porridge described in this invention, by mixing oat groats and quinoa groats in a specific ratio and employing ultrasonic cleaning and centrifugal dehydration, provides a clean and stable raw material base for subsequent processing, ensuring the uniformity of the process starting point. By pulverizing a portion of the oat groats and then sequentially subjecting them to stepwise enzymatic hydrolysis using medium-temperature α-amylase and a specific ratio of compound plant hydrolytic enzymes, followed by residue removal and vacuum concentration to prepare oat extract, the cell walls and macromolecular nutrients in the oats can be efficiently and synergistically decomposed, significantly promoting the dissolution of water-soluble dietary fiber, small-molecule sugars, and flavor substances such as amino acids. This not only enhances the nutritional value of the product but also provides a natural, thick base and rich flavor to the system. The mixed grains are pre-treated in two parts: most are cooked with the oat extract to form a gelatinized matrix, while a small portion is soaked in warm water to retain its granular state. The two are then mixed. This method simultaneously constructs a smooth paste-like background and clearly chewable particles in the final product, effectively solving the problem of a monotonous texture in porridge and achieving a layered textural experience. Introducing a real-time monitoring and dynamic endpoint determination mechanism based on viscosity and sugar content into the enzymatic hydrolysis step allows the process to adapt to natural fluctuations in raw materials, overcoming batch-to-batch quality variations caused by fixed-time enzymatic hydrolysis and significantly improving the consistency of intermediate and final products in key indicators. A two-stage homogenization process—high-pressure crushing followed by low-pressure homogenization—helps obtain a finely textured, uniformly distributed slurry, enhancing system stability and preventing sedimentation or stratification during storage. Online viscosity monitoring and control measures after homogenization allow for precise fine-tuning of the final product's viscosity, ensuring it remains within the preset ideal range and guaranteeing stable sensory quality. Finally, programmed control of the heating and cooling rates and precise control of sterilization intensity during the sterilization process ensures the product meets commercial aseptic safety requirements while minimizing the negative impact of excessive heat processing on product color, flavor, and intentionally retained particulate texture, thus maintaining the product's excellent overall sensory properties.

[0017] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to specific embodiments, so that those skilled in the art can implement it based on the description.

[0019] It should be understood that terms such as “having,” “comprising,” and “including” as used herein do not exclude the presence or addition of one or more other elements or combinations thereof.

[0020] This invention provides a processing method for quinoa and oat porridge, comprising the following steps: Step 1: Take oat rice and quinoa rice and mix them in a dry weight ratio of 1:(2~3.5). Wash them with ultrasonic waves 3 to 4 times, and then centrifuge them for 2 to 4 minutes to reduce the moisture content of the mixed grains to 18% to 25% to obtain the mixed grains. Step 2: Take an additional 10% to 60% of the total dry weight of the mixed grains in Step 1, crush and slurry it, and then sequentially subject it to medium-temperature α-amylase hydrolysis, enzyme inactivation treatment, and compound plant hydrolytic enzyme hydrolysis. Then filter and vacuum concentrate the hydrolyzed mixed slurry to obtain oat extract. The compound plant hydrolytic enzyme contains cellulase, β-glucanase and protease in a weight ratio of 1:(0.5~1.5):(0.3~1.0). Step 3: Divide the mixed grains obtained in Step 1 into two parts by dry weight, with the first part accounting for 70%~85% and the second part accounting for 15%~30%. Mix the first part of grains with the oat extract obtained in Step 2, which is equivalent to 120%~180% of the dry weight of the first part of grains, and cook it under a steam pressure of 0.08~0.12MPa for 10~18 minutes to obtain a gelatinized matrix slurry. Soak the second part of grains in warm water at 60~70℃ for 15~25 minutes to make its moisture content reach 35%~45%, and then mix it with the gelatinized matrix slurry cooled to below 70℃ to obtain a pretreated mixture. Step 4: Mix the pretreated mixture obtained in Step 3, xylitol accounting for 20% to 40% of the total dry weight of the mixed grains in Step 1, and the oat extract prepared in Step 2 that was not used in Step 3, and homogenize them. Step 5: After homogenization, the material is quantitatively filled and sealed, and then sterilized to obtain the quinoa and oat porridge.

[0021] In the above technical solution, the dry weight ratio of oat groats to quinoa groats can be selected as 1:2.0, 1:2.5, 1:3.0, or 1:3.5. The number of ultrasonic cleaning cycles can be 3 or 4, with each cycle lasting between 5 and 8 minutes. The centrifugal dehydration time can be 2, 3, or 4 minutes, reducing the moisture content of the mixed grains to 20%, 22%, or 25%, respectively. A basket-type ultrasonic cleaner can be used for cleaning, and a three-legged centrifuge can be used for dehydration. Naked oats from North China can be used, and white quinoa from Shanxi can be used. In the workshop layout, the ultrasonic cleaner can be placed after the raw material weighing and feeding area, and the centrifuge can be directly connected to the outlet of the cleaner via a conveyor belt for continuous operation. The working process involves feeding the proportionally weighed mixed grains into the cleaner, which is then automatically discharged and transported to the centrifuge for dehydration after cleaning.

[0022] The enzymatic hydrolysis process involves the selection of several parameters. The amount of α-amylase added at medium temperature can be selected as 0.25%, 0.3%, or 0.35% of the dry weight of broken oats. In the compound plant hydrolase, the weight ratio of cellulase, β-glucanase, and protease can be selected as 1:0.8:0.5, 1:1.0:0.6, or 1:1.2:0.8. The amount of compound enzyme added can be selected as 0.12%, 0.15%, or 0.18% of the dry weight of broken oats. Regarding the hydrolysis temperature, α-amylase hydrolysis can be performed at 62℃ or 64℃, while plant hydrolase hydrolysis can be performed at 52℃ or 54℃. A hammer mill can be used to grind the extra oats, and a jacketed stirring tank can be used for slurry preparation and enzymatic hydrolysis. A plate and frame filter press can be used to filter the hydrolyzed slurry, and a single-effect rising film vacuum concentrator can be used for concentration. Medium-temperature α-amylase and compound plant hydrolase can be enzyme preparations that meet national food additive standards. In terms of equipment layout, the grinder, mixing tank, filter, and concentrator can be arranged in a straight line according to the process flow. The equipment is connected by corrosion-resistant pumps and pipelines to form a continuous extract preparation unit. The working process is as follows: the ground oat flour enters the mixing tank and is mixed with water, where the two enzymes sequentially undergo enzymatic hydrolysis. After the reaction is complete, the mixture is pumped into the filter, and the resulting filtrate enters the concentrator until the specified soluble solids content is reached.

[0023] In the texturing and final product shaping, the proportion of the first part of the mixed grains can be selected as 75%, 80%, or 85%. The steam pressure used for cooking can be selected as 0.09 MPa, 0.10 MPa, or 0.11 MPa. The temperature for soaking the second part of the grains in warm water can be selected as 65℃ or 68℃, and the soaking time can be selected as 18 minutes, 20 minutes, or 22 minutes. The amount of xylitol added can be selected as 20%, 30%, or 40% of the total dry weight of the mixed grains. A vertical cooker can be used for cooking the first part of the grains and the extract. A soaking tank with an insulation layer can be used for warm water treatment of the second part of the grains. A high-speed mixing tank can be used for premixing, and a high-pressure homogenizer can be used for homogenization. An automatic filling and capping machine can be used for quantitative filling and sealing. A water bath sterilizer can be used for final sterilization of the product. Food-grade crystalline xylitol can be used. In terms of production line layout, the cooker, soaking tank, and mixing tank can be arranged in a concentrated manner at the front end of the homogenizer. The sterilization autoclave can be installed after the filling and sealing process, forming an independent heat treatment area. The working process is as follows: the gelatinized matrix slurry is mixed with the soaked grain particles in a mixing tank, then xylitol and the remaining oat extract are added. After homogenization, the mixture is filled and finally enters the sterilization autoclave for sterilization.

[0024] This quinoa and oat porridge processing technology achieves a comprehensive improvement in product texture, nutrition, and stability through a systematic combination of steps. After the raw materials are mixed in a specific ratio and ultrasonically cleaned, centrifugal dehydration controls the moisture content to a suitable range, providing a consistent material base for subsequent processing. A stepwise enzymatic hydrolysis technique is used to prepare the oat extract. The synergistic action of medium-temperature α-amylase and complex plant hydrolases effectively breaks down cell wall structures, promoting the full dissolution of nutrients such as β-glucan. After vacuum concentration, an extract with a rich flavor and natural thickening effect is formed. The grains are processed differently in two parts: most of the grains are cooked with the extract to form a gelatinized matrix, while a small portion is soaked in warm water to retain particle integrity. The mixture of these two parts creates a layered texture that combines a smooth base with a chewy feel. Finally, homogenization stabilizes the emulsion, and a programmed sterilization process ensures the product meets commercial sterility requirements while maintaining nutritional components and designed textural characteristics, allowing the finished product to maintain stable viscosity and uniformity during storage.

[0025] In other technical solutions, the process of preparing oat extract in step two is specifically as follows: Oat groats are pulverized and passed through a 20-40 mesh sieve to obtain broken oat groats. These are then mixed with water at a ratio of 1:(8-12). The pH of the mixture is adjusted to 5.0-5.5 using food-grade citric acid. Medium-temperature α-amylase, equivalent to 0.2%-0.4% of the dry weight of the broken oat groats, is added. Enzymatic hydrolysis is performed at 60-65℃ for 40-60 minutes. The temperature of the hydrolyzed system is then raised to 85-90℃ and maintained for 10-15 minutes to inactivate the enzyme. The pH of the inactivated system is adjusted to [value missing] using food-grade sodium bicarbonate. Add 0.1% to 0.2% of a compound plant hydrolytic enzyme, comprising cellulase, β-glucanase, and protease, at a temperature of 6.5 to 7.0°C. Continue enzymatic hydrolysis for 60 to 80 minutes at 50 to 55°C. Filter the enzymatically hydrolyzed mixture through a 200 to 300 mesh vibrating sieve. Concentrate the filtrate under vacuum conditions of -0.07 to -0.09 MPa and 60 to 65°C until the soluble solids content reaches 25% to 30%, thus obtaining the oat extract.

[0026] In the above technical solution, the particle size of the pulverized oat rice can be selected by passing it through a 20-mesh, 30-mesh, or 40-mesh sieve. The material-to-liquid ratio during slurry preparation can be selected as 1:8, 1:10, or 1:12. Food-grade citric acid can be used to adjust the pH of the mixture to 5.0, 5.2, or 5.4. A hammer mill can be used to pulverize the oat rice, and a standard sieve of the corresponding mesh size can be used for sieving. A jacketed slurry preparation tank with a stirrer and an online pH detection device can be used for slurry preparation and pH adjustment. The citric acid can be a food additive conforming to GB 1886.235 standard. In the workshop layout, the pulverizer can be located upstream of the slurry preparation tank, and the pulverized oat rice can be transported to the slurry preparation tank through a closed pipeline. The working process is as follows: the measured oat rice and water are added to the slurry preparation tank, stirring is started, and a pre-prepared citric acid solution is added dropwise until the pH reaches the set value and remains stable.

[0027] In the stepwise enzymatic hydrolysis and enzyme inactivation treatment, the amount of mesophilic α-amylase added can be selected as 0.25%, 0.3%, or 0.35% of the dry weight of broken oat rice; the hydrolysis temperature can be selected as 61℃, 63℃, or 65℃; and the hydrolysis time can be selected as 45 minutes, 50 minutes, or 55 minutes. The enzyme inactivation treatment temperature can be selected as 86℃, 88℃, or 90℃; and the duration can be selected as 11 minutes, 13 minutes, or 15 minutes. Subsequently, the pH of the system can be adjusted to 6.5, 6.7, or 6.9 using food-grade sodium bicarbonate. The amount of compound plant hydrolase added can be selected as 0.12%, 0.15%, or 0.18% of the dry weight of broken oat rice; the temperature for the second enzymatic hydrolysis can be selected as 51℃, 53℃, or 55℃; and the time can be selected as 65 minutes, 70 minutes, or 75 minutes. A jacketed enzymatic hydrolysis reactor with a precise temperature control system can be used for the two enzymatic hydrolysis reactions. A plate heat exchanger can be used for rapid heating of the material to achieve enzyme inactivation. Sodium bicarbonate can be selected from food additives conforming to GB 1886.2 standards. Enzyme preparations can be selected from food industry enzyme preparations conforming to relevant national standards. In terms of equipment connection, the outlet of the slurry preparation tank can be connected to the inlet of the enzymatic hydrolysis reactor via a pump, while the outlet of the reactor can be connected to the inlet of a plate heat exchanger, enabling continuous material transfer and processing. The working process is as follows: the slurry-prepared material is pumped into the enzymatic hydrolysis reactor, where two enzymatic hydrolysis processes are completed sequentially at a constant temperature. During this process, the pH is precisely controlled by adding acid and alkali solutions. After each enzymatic hydrolysis, the material is rapidly heated or cooled via a plate heat exchanger for enzyme inactivation or transfer.

[0028] In post-processing and concentration, filtration can be performed using a 200-mesh, 250-mesh, or 300-mesh vibrating screen. The vacuum level for vacuum concentration can be selected as -0.075 MPa, -0.08 MPa, or -0.085 MPa, and the temperature can be selected as 62℃, 63℃, or 64℃. The concentration endpoint is defined as a soluble solids content of 26%, 28%, or 30%. A vibrating screen can be used for solid-liquid separation of the enzymatically hydrolyzed slurry. A single-effect rising-film vacuum concentrator can be used to concentrate the filtrate. A handheld refractometer or online refractometer can be used to monitor the soluble solids content. At the end of the production line, a vibrating screen can be installed upstream of the vacuum concentrator, and the filtrate obtained from screening is pumped into the concentrator through a buffer tank. The process is as follows: the mixed slurry after enzymatic hydrolysis and inactivation is transported to a vibrating screen, the filtrate is collected and then enters a vacuum concentrator, where the water is evaporated at a set temperature and vacuum level until the soluble solids content reaches the preset standard, thus obtaining the desired oat extract.

[0029] This method for preparing oat extract achieves efficient transformation from raw materials to extract through a systematic process design. After being pulverized to a specific mesh size, the raw materials are slurried under controlled material-to-liquid ratio and pH conditions, creating a suitable environment for subsequent enzymatic hydrolysis. In the stepwise enzymatic hydrolysis process, the raw materials are first treated with medium-temperature α-amylase, followed by further action with a specifically formulated compound plant hydrolytic enzyme. Precise enzyme inactivation is performed between the two hydrolysis steps. This series of operations helps promote the decomposition of oat cell wall structures and the release of contents. Subsequent filtration to a selected mesh size and vacuum concentration under specific conditions effectively separates solids and yields an extract with stable concentration. The overall process is tightly integrated, with clearly controlled parameters, which is conducive to obtaining an oat extract with consistent composition and good retention of active substances, providing support for the texture and flavor of the final product.

[0030] In other technical solutions, the mesophilic α-amylase hydrolysis process in step two specifically involves: When the enzymatic hydrolysis time reaches 40 minutes, the viscosity and sugar content of the enzymatic hydrolysis system are monitored simultaneously. The criteria for determining the success of the enzyme hydrolysis were: the enzymatic hydrolysis time was within the range of 40 to 60 minutes, the viscosity value decreased to 1500 to 2500 cP, and the sugar content reached 8.5% to 10.5%. When the monitoring data simultaneously meet the judgment conditions, and each parameter remains stable within the corresponding range for at least 90 seconds, it is determined that the first enzymatic hydrolysis endpoint has been reached, and then enzyme inactivation treatment is performed. If the viscosity or sugar content still does not reach the specified range after 60 minutes of enzymatic hydrolysis, the enzymatic hydrolysis will be forcibly terminated and enzyme inactivation will be performed immediately. At the same time, an alarm will be triggered and the batch will be marked as an abnormal batch.

[0031] In the above technical solution, the start time for synchronous monitoring can be selected at 40, 45, or 50 minutes into the enzymatic hydrolysis process. The target parameters for monitoring are the viscosity and saccharification value of the enzymatic hydrolysis system. An online viscometer can be used to continuously measure the system viscosity, with a range covering 0 to 5000 cP. An online refractometer can be used to continuously monitor the saccharification value of the system. These online monitoring instruments can be installed on the outlet pipe or circulation pipe of the enzymatic hydrolysis reactor, connected to the process pipeline via flanges, with their sensor parts in direct contact with the material. The monitoring signals can be transmitted to the display and recording system in the central control room. The working process is as follows: when the enzymatic hydrolysis time reaches the preset start point, the continuous monitoring functions of the online viscometer and online refractometer are automatically activated to collect real-time data on the flowing material.

[0032] In the determination conditions and stability maintenance, the viscosity determination threshold can be set to 1800 cP, 2000 cP, or 2200 cP. The sugar content determination threshold can be set to 9.0%, 9.5%, or 10.0%. The determination duration for parameter stability maintenance can be set to 90 seconds, 100 seconds, or 110 seconds. These determination logics can be implemented through a programmable logic controller (PLC) or a program module in a distributed control system. This control module can receive real-time signals from online instruments and compare them with preset thresholds. An industrial computer or operator station can be used as the human-machine interface to display real-time data, set parameters, and alarm status. The operation process involves the control system continuously comparing whether the real-time viscosity and sugar content data simultaneously enter their respective threshold ranges and starting a timer. Only when both parameters remain within the range for a preset stability time is the first enzymatic hydrolysis endpoint determined to have been reached.

[0033] In the anomaly handling mechanism, the time threshold for forcibly terminating enzymatic hydrolysis is set to 60 minutes. When an alarm is triggered, an audible and visual alarm in the control room can be activated, and a record will be generated in the control system's alarm list. The batch marking function can be implemented by associating the production status data of the batch with a specific "anomaly" identifier in the control system's production batch management database. The audible and visual alarm can be installed on the control room wall or control cabinet. A database server can be used to store batch data and status markers. The working process is as follows: if the enzymatic hydrolysis time reaches the 60-minute upper limit, regardless of whether the monitored parameters meet the standards, the control system automatically executes a pre-programmed command, stops the stirring and heating of the hydrolysis tank, and starts the subsequent enzyme inactivation procedure, while simultaneously activating the alarm and batch marking processes.

[0034] This method for controlling the enzymatic hydrolysis of α-amylase at medium temperature provides an objective basis for determining the hydrolysis endpoint by setting a clear monitoring start point and multiple judgment conditions. After the hydrolysis reaches a specific time, real-time monitoring of the system's viscosity and sugar content is initiated simultaneously. When both data simultaneously enter the preset threshold range and remain stable for the specified duration, the system determines that the reaction has reached its endpoint. This method reduces reliance on operator experience and minimizes batch fluctuations caused by subjective judgment. Furthermore, by setting a maximum hydrolysis time threshold and implementing a corresponding forced termination and alarm marking mechanism, it effectively identifies and isolates atypical reaction batches caused by factors such as abnormal raw materials or equipment malfunctions, preventing abnormal materials from flowing into subsequent processes and providing process assurance for maintaining the stability of the production system and the consistency of product quality.

[0035] In other technical solutions, the enzymatic hydrolysis process of the compound plant in step two specifically includes: When the enzymatic hydrolysis time reaches 60 min, the viscosity and sugar content of the enzymatic hydrolysis system are monitored simultaneously. The criteria for determining the outcome are: the enzymatic hydrolysis time is within the range of 60-80 minutes, the viscosity value decreases to 800-1200 cP, and the sugar content reaches 10.0%-12.5%. When the monitoring data simultaneously meet the judgment conditions, and each parameter remains stable within the corresponding range for at least 120 seconds, it is determined that the second enzymatic hydrolysis endpoint has been reached, and then the filtration operation is performed. If the viscosity or sugar content still does not reach the specified range after 80 minutes of enzymatic hydrolysis, the enzymatic hydrolysis will be forcibly terminated and the filtration operation will be performed immediately. At the same time, an alarm will be triggered and the batch will be marked as an abnormal batch.

[0036] In the above technical solution, the start time for synchronous monitoring can be selected at 60, 65, or 70 minutes into the enzymatic hydrolysis process. The target parameters for monitoring are the viscosity and saccharification value of the enzymatic hydrolysis system. An online viscometer can be used to continuously measure the system viscosity, with a range covering 0 to 2000 cP. An online refractometer can be used to continuously monitor the saccharification value of the system. These online monitoring instruments can be installed on the outlet pipe of the reaction vessel used for compound enzymatic hydrolysis and connected to the process pipeline via sanitary clamps. The working process is as follows: when the hydrolysis time of the compound plant reaches the preset start point, the corresponding timing module in the control system will issue a command to activate the online viscometer and online refractometer, initiating continuous data acquisition and transmission of the material in the circulation pipeline.

[0037] In the determination conditions and stability maintenance, the viscosity determination threshold can be set to 900 cP, 1000 cP, or 1100 cP. The sugar content determination threshold can be set to 10.5%, 11.0%, or 11.5%. The determination duration for parameter stability maintenance can be set to 120 seconds, 130 seconds, or 140 seconds. These determination conditions can be executed through logic function blocks integrated into the process control system. Monitoring software with data logging and trend analysis functions can be used to assist in confirming the stable state of the parameters. The working process is as follows: the control system receives viscosity and sugar content signals in real time and continuously compares them with the preset threshold ranges; only when both signal values ​​simultaneously enter their respective threshold ranges, and the system's internal timer confirms that this stable state has lasted for the set duration, will the control program determine that the second enzymatic hydrolysis endpoint has been reached and issue an instruction to execute the subsequent filtration operation.

[0038] In the anomaly handling mechanism, the time threshold for forcibly terminating enzymatic hydrolysis is set to 80 minutes. When an alarm is triggered, audible and visual alarm devices located in the workshop and control room can be activated. Batch marking functionality can be implemented by associating the batch number of the enzymatic hydrolysis operation with a specific status code in the production execution system or batch record. Industrial-grade audible and visual alarms can be selected. A relational database can be used to store and manage batch status information. The process is as follows: if the enzymatic hydrolysis time reaches the maximum limit of 80 minutes, and the viscosity or sugar content still does not meet the judgment criteria, the control system will automatically stop the stirring of the reaction vessel, start the conveying procedure to the filtration equipment, trigger an alarm signal, and mark the current batch as abnormal in the database.

[0039] This method for controlling the enzymatic hydrolysis process of composite plants provides objective data-based endpoint determination by setting clear monitoring start conditions and endpoint judgment parameters. After the enzymatic hydrolysis reaches the specified time, the system simultaneously initiates real-time monitoring of the system's viscosity and sugar content. When both indicators simultaneously reach preset thresholds and remain stable for the specified duration, the system automatically determines that the reaction is complete. This method helps reduce the impact of raw material component fluctuations on the enzymatic hydrolysis effect, promoting consistency in key indicators among different batches of enzymatic hydrolysis products. Simultaneously, by setting a maximum reaction time threshold and corresponding forced termination and alarm marking procedures, abnormal reaction batches can be identified and handled promptly, preventing materials that do not meet process requirements from entering subsequent filtration processes. This provides process control support for maintaining the stability of the production process and the uniformity of the final product quality.

[0040] In other technical solutions, the texture adaptation pretreatment process in step three specifically includes: The dehydrated mixed grains obtained in step one are divided into two parts by dry weight. The first part is texture-building grains, accounting for 70% to 85% of the total dry weight of the mixed grains; the second part is grains with retained grains, accounting for 15% to 30% of the total dry weight of the mixed grains. The first part of the textured grains is mixed with oat extract obtained in step two at 120% to 180% of their dry weight, and cooked at a steam pressure of 0.08 to 0.12 MPa for 10 to 18 minutes to obtain a gelatinized matrix slurry. The second part of the grain particles is soaked in warm water at 60-70℃ for 15-25 minutes to make its moisture content reach 35%-45%, and then mixed with the gelatinized matrix slurry to obtain a pretreated mixture.

[0041] In the above technical solution, during grain distribution, the mixed grains can be divided into two independent streams based on dry weight: a first portion comprising 75%, 80%, or 85%, and a corresponding second portion comprising 25%, 20%, or 15%. A screw conveyor with metering function can be used to divert the material, or a distribution valve combined with a weight sensor can be employed. These distribution devices can be installed downstream of the centrifugal dewatering equipment, at the beginning of the pretreatment process. The working process involves the dewatered mixed grains being conveyed to the distribution unit. Based on the preset weight ratio, the material is accurately divided into two independent streams by controlling the opening and closing time of the distribution valve or adjusting the speed of the screw conveyor.

[0042] In the first part of grain processing, the amount of oat extract added during cooking can be selected to be equivalent to 190%, 220%, or 240% of the dry weight of the first part of grain. The steam pressure can be selected as 0.085 MPa, 0.095 MPa, or 0.105 MPa, and the cooking time can be selected as 12 minutes, 14 minutes, or 16 minutes. A cooking tank with jacketed heating and stirring functions can be used for processing. A vortex air pump can be used to provide steam. The cooking tank can be installed in the hot processing area of ​​the workshop, near the steam pipe interface and the temporary storage tank of the oat extract. The working process is as follows: the first part of grain and the metered oat extract are added to the cooking tank together; steam is introduced to stabilize the pressure inside the tank at the set value; and the stirrer is started to ensure uniform heating of the material. After the specified cooking time, a fully gelatinized matrix slurry is obtained.

[0043] In the second part, grain processing and mixing, the temperature for warm water soaking can be selected as 63°C, 66°C, or 68°C, and the soaking time can be selected as 18 minutes, 20 minutes, or 22 minutes. The target moisture content can be controlled at 38%, 40%, or 42%. Soaking tanks with heating and temperature control functions can be used. Anchor-type agitators can be used for mixing. The soaking tank can be placed near the cooking tank, while the mixing tank is located downstream of both for easy material transfer. The process involves adding the second part of grain to the temperature-controlled soaking tank and soaking it for the set time to soften it and reach the target moisture content. Then, the soaked grain is added together with the gelatinized matrix slurry cooled to below 70°C to the mixing tank, where it is stirred to achieve uniform mixing and obtain a pretreated mixture.

[0044] This texture-adaptive pretreatment process lays the foundation for a complex texture in the final product by proportionally distributing and differentially processing the mixed grains. The first part involves cooking the grains and oat extract under specific pressure and time to form a fully gelatinized, viscous matrix, providing a smooth texture background for the porridge. The second part involves soaking the grains in warm water at controlled temperature and time to soften them while maintaining their particle integrity. When the two are mixed, the gelatinized matrix and the intact particles combine, allowing the product to simultaneously present a dense, smooth base and a clearly discernible chewiness, helping to address the problems of over-gelatinization or insufficient textural layers caused by single heat processing.

[0045] In some other technical solutions, the homogenization process in step four is specifically as follows: the pretreated mixture, xylitol and the remaining oat extract are premixed in a stirred tank until the xylitol is completely dissolved to obtain a homogeneous slurry; the slurry is subjected to a first-stage homogenization at a pressure of 18-22 MPa, and then a second-stage homogenization at a pressure of 5-8 MPa.

[0046] In the above technical solution, the mixing process in the premixing treatment can be carried out under normal pressure and at 60 to 65 degrees Celsius. The stirring speed can be selected as 50, 60, or 70 revolutions per minute until the xylitol is completely dissolved. An anchor-type stirred tank with a jacket for insulation can be used as the premixing equipment. The stirred tank can be installed upstream of the homogenizer, and its outlet is connected to the feed pump of the homogenizer through a pipeline. The working process is as follows: the pretreated mixture, xylitol, and the remaining oat extract are put into the stirred tank, stirring is started to initially mix the components, and the material temperature is maintained by circulating hot water in the jacket until no visible undissolved crystals are observed.

[0047] In the first-stage homogenization process, the homogenization pressure can be selected from 19 MPa, 20 MPa, or 21 MPa. A plunger-type high-pressure homogenizer can be used, which can be equipped with a pressure display and adjustment device. The homogenizer can be installed after the mixing vessel, and the material is fed into the homogenizing valve group by a high-pressure pump. The working process is as follows: the premixed slurry is drawn in by the feed pump and passes through the first-stage homogenizing valve of the homogenizer under high pressure. Due to the shearing effect, cavitation effect, and impact at the slit, the solid particles and droplets in the material undergo initial breakage and refinement.

[0048] In the second-stage homogenization process, the homogenization pressure can be selected as 6 MPa, 7 MPa, or 8 MPa. The second-stage homogenization valve of the aforementioned plunger-type high-pressure homogenizer can be used, or a separate low-pressure homogenizer can be connected in series after the first-stage homogenization. The second-stage homogenizer can be positioned immediately after the outlet of the first-stage homogenizer, allowing the material to pass through both stages continuously. The process involves the material, after the first-stage high-pressure treatment, immediately entering the second-stage homogenization valve for further homogenization at a lower pressure. This helps to make the initially crushed particles more evenly distributed and reduces the re-agglomeration of particles. By applying different mechanical forces in stages, the particle size of the material can be effectively reduced, promoting the integration of components and contributing to the formation of a finer-textured and more stable emulsion system.

[0049] In other technical solutions, after the homogenization process in step four, the viscosity of the material system is adjusted, and the specific process is as follows: The viscosity of the homogenized material was monitored in real time using an online viscometer, and the preset viscosity range of the material was set to 2500~4500 cP. When the monitored viscosity remains above 4500 cP, add 1% to 3% of the total mass of the pretreated mixture of purified water to the material and mix for 2 to 4 minutes under stirring conditions of 60 to 80 rpm. When the monitored viscosity remains below 2500 cP, add 2% to 5% of the oat extract prepared in step two to the material, and then perform supplementary homogenization at a pressure not exceeding 5 MPa.

[0050] In the above technical solution, for real-time viscosity monitoring, the preset lower limit of the viscosity range can be selected as 2500 cP, 3000 cP, or 3500 cP, and the upper limit can be selected as 3500 cP, 4000 cP, or 4500 cP. The determination stabilization time for the monitored data can be selected as 30 seconds, 45 seconds, or 60 seconds. An online rotary viscometer can be used to continuously measure the viscosity of the material. This viscometer can be equipped with a temperature compensation function. The online viscometer can be installed on the discharge pipe of the homogenizer or at the outlet of the temporary storage tank for homogenized material, connected to the pipe through a sanitary flange, with its sensor probe inserted into the flowing material. The working process is as follows: the homogenized material flows through or remains in the pipe section or tank equipped with the online viscometer. The viscometer collects data several times per second and transmits it to the control system. The system smooths the data and compares it with the preset range in real time.

[0051] In high viscosity control measures, the amount of purified water added can be selected to be equivalent to 1.5%, 2.0%, or 2.5% of the total mass of the initial mixture. The stirring speed can be selected to be 65, 70, or 75 revolutions per minute, and the mixing time can be selected to be 2.5 minutes, 3.0 minutes, or 3.5 minutes. A metering pump can be used to precisely add purified water to the system. A stirrer with variable frequency speed control can be used to gently mix the materials. The metering pump can be installed on the pipeline between the purified water storage tank and the material buffer tank, while the stirrer is installed inside the buffer tank. The working process is as follows: when the system determines that the viscosity is continuously higher than the upper limit value, the control system starts the metering pump to inject a predetermined amount of purified water with a temperature close to that of the material into the buffer tank, and at the same time starts the stirrer to run at the set speed for a specified time to ensure that the water and the material are thoroughly mixed.

[0052] In low viscosity control measures, the amount of oat extract added can be selected to be equivalent to 3.0%, 3.5%, or 4.0% of the total mass of the initial mixture. The pressure for supplemental homogenization can be selected as 3 MPa, 4 MPa, or 5 MPa. A screw pump can be used to deliver the oat extract. A single-stage homogenizer can be used for supplemental homogenization. The screw pump can be installed on the connecting pipeline between the oat extract storage tank and the material buffer tank, and the single-stage homogenizer can be connected in series after the outlet of the buffer tank. The working process is as follows: when the system determines that the viscosity is continuously below the lower limit, the control system starts the screw pump to add a predetermined amount of oat extract to the buffer tank. Subsequently, the material is pumped into the single-stage homogenizer for homogenization at a set low pressure. After completion, the material is returned to the buffer tank or enters the next process.

[0053] This viscosity control process ensures the viscosity stability of the final product through an online real-time monitoring and feedback mechanism. After homogenization, the viscosity of the material is continuously measured using an online viscometer. When the monitored data deviates continuously from the preset range, the system automatically executes the corresponding control program. For cases of high viscosity, the system consistency is reduced by adding an appropriate amount of purified water and gently stirring; for cases of low viscosity, the system solids content and consistency are increased by adding concentrated oat extract and using low-pressure homogenization. This method can specifically correct for minor fluctuations that may occur in previous processes, adjust the material state in a timely manner, help reduce viscosity differences between batches of products, and make the final product's flowability and texture more consistent.

[0054] In some other technical solutions, the sterilization process in step five is carried out using a water bath sterilizer. The specific process is as follows: the filled and sealed product is placed in the sterilizer, and the temperature is first raised from room temperature to 85-90℃ at a rate of 1-1.5℃ / min and held for 5-8 minutes; then the temperature is raised to 115-121℃ at a rate of 0.8-1.2℃ / min and held at this temperature for 15-25 minutes; after sterilization, the system is cooled to 70-75℃ at a rate of 0.5-1.0℃ / min, and then the product is rapidly cooled to below 40℃ using a combination of air cooling and water cooling. The F0 value of the entire sterilization process is controlled within 8-12 minutes.

[0055] In the above technical solution, during the programmed heating stage, the heating rate from room temperature to the first holding temperature can be selected as 1.1°C, 1.2°C, or 1.3°C per minute; the first holding temperature can be selected as 86°C, 87°C, or 88°C; and the holding time can be selected as 6 minutes, 6.5 minutes, or 7 minutes. Subsequently, the heating rate to the sterilization temperature can be selected as 0.9°C, 1.0°C, or 1.1°C per minute. A water bath sterilizer with an automatic temperature control system can be used for processing. A platinum resistance temperature sensor can be used to monitor the water temperature and the center temperature of the material. The sterilizer can be installed in a separate sterilization area after the filling and sealing process, close to the cooling water system and steam supply pipeline. The working process is as follows: the filled and sealed product basket is placed into the sterilizer; after the valve door is closed, the control system introduces steam according to a preset program, gradually raising the temperature inside the valve to the target temperature at each stage at the set heating rate.

[0056] During the isothermal sterilization stage, the sterilization temperature can be selected as 116°C, 118°C, or 120°C, and the holding time can be selected as 18 minutes, 20 minutes, or 22 minutes. During this stage, a data logger can be used to calculate and accumulate the F0 value in real time. A pressure transmitter can be used to monitor and maintain stable pressure inside the autoclave. The operation is as follows: once the temperature inside the autoclave reaches the set sterilization temperature, the control system adjusts the steam intake to maintain temperature fluctuations within ±0.5°C. Simultaneously, the F0 value calculation module starts working until the accumulated F0 value reaches the range of 8 to 12 minutes, or the set holding time, whichever comes first.

[0057] During the temperature reduction phase, the cooling rate from the sterilization temperature to the intermediate temperature can be selected as 0.7°C, 0.8°C, or 0.9°C per minute, and the intermediate temperature can be selected as 72°C, 73°C, or 74°C. Subsequent rapid cooling can be achieved by combining air cooling with a cooling fan and water cooling with a water spray system. A plate heat exchanger can be used to cool the circulating cooling water. The cooling system can be integrated inside the sterilizer or connected to the sterilizer as an external circulation unit. The process is as follows: after constant temperature sterilization, the control system stops the steam supply and instead introduces cooling water, enhancing heat exchange through a stirring fan to reduce the temperature to the intermediate temperature at the set rate. Then, stronger air and water cooling are activated to rapidly cool the product temperature to below 40°C, completing the entire sterilization process.

[0058] This sterilization process aims to balance food safety and product quality through programmed temperature control and precise F0 value management. Employing a phased heating and cooling strategy, and controlling the rate of temperature change, helps reduce physical stress on packaging materials and mitigates the risk of textural damage to the contents due to thermal shock. During the isothermal sterilization phase, temperature and time parameters are controlled within specified ranges, and the cumulative F0 value meets set requirements, ensuring commercial sterility of the product. The subsequent phased cooling process, particularly combining air and water cooling, aims to ensure a smooth temperature decrease in the product. This method strives to effectively kill microorganisms while protecting the sensory characteristics of the product formed during previous processes, such as the viscosity of the porridge and the morphology of the grain particles.

[0059] Example 1 A processing technique for quinoa and oat porridge, the specific process is as follows: First, the raw materials were pre-treated. 10 kg of oat rice and 25 kg of quinoa rice were weighed and mixed together on dry weight to obtain a mixed grain. This mixed grain was then placed in a basket ultrasonic cleaner and cleaned three times using ultrasound at a frequency of 40 kHz, with each cleaning lasting 6 minutes. After cleaning, the wet grain was transferred to a three-legged centrifuge via a conveyor belt and centrifuged at 1200 rpm for 3 minutes to remove water. After dehydration, a sample was taken for testing, and the moisture content of the mixed grain was found to be 22%. Subsequently, the dehydrated mixed grain was allocated by dry weight, with 80% (28 kg) designated as the first portion and the remaining 20% ​​(7 kg) designated as the second portion for later use.

[0060] Next, oat extract was prepared. 17.5 kg of oat groats (equivalent to 50% of the total dry weight of the mixed grains in step one, 35 kg) were pulverized using a hammer mill and passed through a 30-mesh standard sieve to obtain broken oat groats. The broken oat groats were mixed with 140 kg of purified water in a jacketed mixing tank, and stirring was started. Food-grade citric acid solution was slowly added to adjust the pH of the mixture to 5.2. Then, 20 g of medium-temperature α-amylase (equivalent to 0.4% of the dry weight of the broken oat groats) was added, and enzymatic hydrolysis was performed at 63°C for 50 minutes. When the enzymatic hydrolysis reached 45 minutes, an online viscometer and online refractometer were started for simultaneous monitoring. Monitoring data showed that the system viscosity decreased to 2000 cP, the sugar content reached 9.5%, and this state was maintained stably for 100 seconds, indicating that the first enzymatic hydrolysis endpoint had been reached. The material temperature was immediately raised to 88°C using a plate heat exchanger and maintained for 12 minutes for enzyme inactivation. After enzyme inactivation, food-grade sodium bicarbonate was added to the material to adjust the pH of the system to 6.8. Then, 7.5 grams of a compound plant hydrolase (equivalent to 0.15% of the dry weight of broken oat rice) was added. This compound enzyme was prepared by combining cellulase, β-glucanase, and protease in a weight ratio of 1:1.0:0.6. Enzymatic hydrolysis continued at 53°C for 70 minutes. When the hydrolysis reached 65 minutes, online monitoring was initiated. The data showed that the viscosity decreased to 1000 cP, the sugar content reached 11.2%, and remained stable for 130 seconds, indicating that the second hydrolysis endpoint had been reached. The hydrolysate was filtered through a 250-mesh vibrating sieve, and the filtrate was transferred to a single-effect rising film vacuum concentrator. Concentration was carried out at a vacuum of -0.08 MPa and a temperature of 63°C until the soluble solids content measured by a handheld saccharimeter was 28%, yielding approximately 63 kg of oat extract for later use.

[0061] Then, textural construction and mixing were performed. The first portion of grain (28 kg) was mixed with 34 kg of oat extract (approximately 121% of its dry weight) in a vertical cooker. Steam was introduced to stabilize the pressure inside the cooker at 0.10 MPa, and the mixture was cooked for 14 minutes to obtain a gelatinized matrix slurry, which was then cooled to below 65°C. Simultaneously, the second portion of grain (7 kg) was soaked in warm water at 65°C for 20 minutes to achieve a moisture content of approximately 40%. The soaked second portion of grain was then mixed with the cooled gelatinized matrix slurry in an anchor-type mixing tank to obtain a pretreated mixture.

[0062] The mixture was then blended, homogenized, and its viscosity was adjusted. 9.8 kg of xylitol (equivalent to 28% of the total dry weight of the mixed grains) and the remaining oat extract (approximately 29 kg; the total extract volume prepared previously was 63 kg, of which 34 kg was used in the first step, and the remainder was added here) were added to the pretreated mixture. The mixture was mixed at 65°C and 60 rpm until the xylitol was completely dissolved. The mixture was then homogenized at 20 MPa, followed by a second homogenization at 7 MPa. After homogenization, the material was monitored using an online viscometer installed on the discharge pipe. The real-time viscosity was 4200 cP, which was within the preset range of 2500-4500 cP; therefore, the viscosity adjustment program was not activated.

[0063] Finally, filling and sterilization are performed. The homogenized material is quantitatively filled into 200g plastic cups and immediately sealed. The sealed product is placed in a water bath sterilizer. First, the temperature is raised from room temperature to 87℃ at a rate of 1.2℃ / min and held for 6 minutes; then, the temperature is raised to 118℃ at a rate of 1.0℃ / min and held at this temperature for 20 minutes. The cumulative F0 value during this stage is calculated to be 10.5 minutes. After sterilization, the system is cooled to 73℃ at a rate of 0.8℃ / min, and then the cold air fan and cooling water spray system are activated to rapidly cool the product to below 38℃. Testing shows that the product's microbiological indicators meet the standards, thus confirming it as the finished quinoa and oat porridge.

[0064] Comparative Example 1 A conventional uniform cooking method was used instead of the texture-adaptive pretreatment scheme. 10 kg of oat rice and 25 kg of quinoa rice (total dry weight 35 kg) from the same source and proportion as in Example 1 were weighed out. After ultrasonic cleaning and centrifugal dehydration under the same conditions, without grain separation, all grains were directly mixed with warm water equivalent to 121% of their dry weight (i.e., 42.35 kg). The mixture was placed in a vertical cooker and uniformly cooked for 25 minutes at a steam pressure of 0.10 MPa to ensure complete gelatinization of all grains. Subsequent steps, including adding xylitol in the same amount as in Example 1, two-stage homogenization under the same conditions, filling, and sterilization, were all consistent with Example 1.

[0065] Comparative Example 2 A physical cooking method was used to replace the stepwise enzymatic hydrolysis method for preparing oat extract. Five kilograms of oat rice from the same source as in Example 1 were crushed and passed through a 30-mesh sieve, then mixed with 50 kilograms of purified water in a jacketed mixing tank. Without using any enzymes, steam was directly introduced to heat the mixture to 95°C, and the mixture was continuously stirred and cooked at this temperature for 120 minutes to promote the dissolution of substances through heat. After cooking, the oat extract was prepared using the same method as in Example 1 (filtered through a 250-mesh vibrating sieve and vacuum concentrated to a soluble solids content of 28% under the same conditions), ultimately yielding approximately 18 kilograms of oat extract. All subsequent processes, including raw material pretreatment, texture construction, mixing, homogenization, filling, and sterilization, strictly followed the parameters and conditions of Example 1.

[0066] Comparative Example 3 A fixed-time method was adopted instead of the dynamic determination scheme of enzymatic hydrolysis endpoint based on real-time monitoring. The preparation process of oat extract was similar to step two of Example 1, but the monitoring of online viscometer and online refractometer was eliminated in the two-step enzymatic hydrolysis process. After the mesophilic α-amylase hydrolysis was strictly carried out at 63°C for 50 minutes, the enzyme was directly inactivated regardless of the viscosity and sugar content. After the complex plant hydrolysis was strictly carried out at 53°C for 70 minutes, the specific parameters were also ignored, and the filtration operation was carried out directly. The prepared oat extract was used for subsequent processes, and all other steps such as raw material pretreatment, texture construction, mixing, homogenization, filling, and sterilization were completely consistent with those in Example 1.

[0067] Comparative Example 4 A method relying on manual experience was adopted instead of online viscosity monitoring and automatic control. All preceding steps, up to the completion of homogenization, were identical to those in Example 1. After homogenization, instead of installing and using an online viscometer, operators took samples from the material pipeline and measured them offline in the laboratory using a benchtop rotational viscometer. If the measured value deviated from the range of 2500-4500 cP, an approximate amount of purified water or oat extract was added manually to the mixing tank based on experience. After a period of empirical stirring, the sample was measured again, and this process was repeated until the viscosity value was adjusted to a suitable range. After adjustment, filling and sterilization were performed under the same conditions as in Example 1.

[0068] The products obtained from Example 1 and Comparative Examples 1-4 were subjected to the following tests: Texture property testing: TPA testing was performed using a texture analyzer. A cylindrical probe was used, with a pre-test velocity of 1.0 mm / s, a test velocity of 1.0 mm / s, and a post-test velocity of 1.0 mm / s. The compression ratio was 50%, and the trigger force was 5 g. Hardness, elasticity, chewiness, and viscosity were recorded. Each sample was tested in parallel 10 times.

[0069] Nutritional composition determination: β-glucan content was determined according to the national standard GB 5009.289-2016 "Determination of β-glucan in food"; soluble solids content was determined using a digital refractometer at 20℃.

[0070] Sensory evaluation: An evaluation panel of 10 trained sensory evaluators will assess the product's overall acceptability, texture, smoothness, consistency, palatability, and flavor. A 9-point preference rating system will be used (1 point indicates strong dislike, and 9 points indicate strong liking).

[0071] Viscosity stability test: The initial viscosity of the product was measured using a rotational viscometer at 25°C and 60 rpm. The product was then placed in a 25°C constant temperature chamber for 14 days, and the viscosity was measured again to calculate the viscosity change rate.

[0072] Batch consistency test: Three independent production batches of Example 1 and three batches of Comparative Example 3 were randomly selected, and the viscosity and soluble solids content of their products were measured respectively. The coefficient of variation (CV%) of the data between each batch was calculated.

[0073] The test results are shown in Table 1.

[0074] Table 1 Comparison of texture property results Table 2 Comparison of Nutritional Components Table 3 Comparison of Sensory Score Results Table 4 Comparison of Storage Stability and Production Consistency Test Results Based on the test data in the table above, Example 1 demonstrates comprehensive advantages in multiple dimensions: In terms of texture: Compared to Comparative Example 1 (all samples were uniformly steamed), Example 1 maintained appropriate hardness while exhibiting significantly higher elasticity and chewiness, and lower viscosity, indicating that it successfully constructed a "soft and chewy" composite texture, rather than the mushy state of Comparative Example 1. The "granularity" category in the sensory evaluation also directly confirms this.

[0075] Nutrition and flavor: Compared with Comparative Example 2 (physical cooking), Example 1 released the functional component β-glucan in oats more effectively through enzymatic hydrolysis, and the content of soluble solids was higher, indicating that its extraction efficiency was higher and the product had richer flavor substances.

[0076] Regarding stability and consistency: The product of Example 1 showed the smallest viscosity change (+3.5%) after 14 days of storage, indicating that its system was the most stable. More importantly, in the batch consistency comparison with Comparative Example 3 (enzymatic hydrolysis at a fixed time), the coefficient of variation (CV%) of viscosity and solids content of Example 1 was much lower than that of Comparative Example 3, demonstrating the key role of the enzymatic hydrolysis endpoint determination method based on real-time monitoring in ensuring a high degree of consistency in product quality between batches.

[0077] Regarding process control: Although the initial product indicators of Comparative Example 4 (artificial viscosity adjustment) were similar to those of Example 1, its viscosity change rate was the highest (+15.5%) and its sensory smoothness score was low, indicating that manual experience-based regulation could not achieve the accuracy and stability of automatic online regulation, resulting in a decline in long-term storage performance and taste.

[0078] In summary, the test results effectively demonstrate the beneficial effects of the present invention in improving product texture, optimizing nutrient release, enhancing storage stability, and ensuring production consistency.

[0079] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and embodiments shown and described herein.

Claims

1. A process for the manufacture of quinoa oat porridge, characterized in that, The method comprises the following steps: Step one, mix oat rice and quinoa rice according to the weight ratio of 1:(2-3.5), and clean the mixture by ultrasonic wave for 3-4 times, then centrifugal dewatering for 2-4 min to reduce the water content of the mixture to 18%-25%, and obtain the mixed grains; Step two, take 10%-60% of the total dry weight of the mixed grains in step one as extra oat rice, crush and mix the oat rice, then sequentially perform mesophilic alpha-amylase hydrolysis, enzyme inactivation treatment, and complex plant hydrolysis enzyme hydrolysis, filter and vacuum concentrate the hydrolyzed mixture to obtain oat extract, wherein the complex plant hydrolysis enzyme comprises cellulase, beta-glucanase and protease in a weight ratio of 1:(0.5-1.5):(0.3-1.0); Step three, divide the mixed grains obtained in step one into two parts according to the dry weight, the first part accounts for 70%-85%, and the second part accounts for 15%-30%; mix the first part of grains with oat extract obtained in step two, which accounts for 120%-180% of the dry weight of the first part of grains, and cook under the steam pressure of 0.08-0.12 MPa for 10-18 min to obtain a gelatinized substrate slurry; soak the second part of grains in warm water at 60-70°C for 15-25 min to make the water content reach 35%-45%, then mix the second part of grains with the gelatinized substrate slurry cooled to below 70°C to obtain a pretreatment mixture; Step four, mix the pretreatment mixture obtained in step three, xylitol accounting for 20%-40% of the total dry weight of the mixed grains in step one, and oat extract prepared in step two but not used in step three, and perform homogenization treatment; Step five, quantitatively fill and seal the homogenized material, and obtain the quinoa oat porridge after sterilization treatment.

2. The process for processing quinoa oat porridge as claimed in claim 1, wherein, The process for preparing the oat extract in step two is as follows: Grind the oat rice, pass it through a 20-40 mesh screen, and obtain oat rice fragments; mix the oat rice fragments with water according to the solid-liquid ratio of 1:(8-12), adjust the pH value of the mixed system to 5.0-5.5 by using food-grade citric acid, and add mesophilic alpha-amylase accounting for 0.2%-0.4% of the dry weight of the oat rice fragments; hydrolyze at 60-65°C for 40-60 min, raise the temperature of the hydrolyzed system to 85-90°C for 10-15 min for enzyme inactivation treatment, adjust the pH value of the system after enzyme inactivation treatment to 6.5-7.0 by using food-grade sodium bicarbonate, and add complex plant hydrolysis enzyme accounting for 0.1%-0.2% of the dry weight of the oat rice fragments; the complex plant hydrolysis enzyme comprises cellulase, beta-glucanase and protease, and continue to hydrolyze at 50-55°C for 60-80 min; filter the hydrolyzed mixture through a 200-300 mesh rotary vibration screen, and vacuum concentrate the filtrate under the vacuum degree of-0.07--0.09 MPa and the temperature of 60-65°C until the soluble solid content reaches 25%-30%, and obtain the oat extract.

3. The process for processing quinoa oat porridge as claimed in claim 2, wherein, The mesophilic alpha-amylase hydrolysis process in step two is as follows: When the hydrolysis time reaches 40 min, start to monitor the viscosity value and sugar content of the hydrolysis system simultaneously. The determination condition is set as: the enzymolysis time is within the range of 40-60 min, and the viscosity value is reduced to 1500-2500 cP, and the sugar content value reaches 8.5%-10.5%; When the monitoring data simultaneously meet the determination condition, and each parameter is stably maintained within the corresponding range for at least 90 s, it is determined that the first enzymolysis end point is reached, and then the enzyme inactivation treatment is performed; If the enzymolysis time reaches 60 min, and the viscosity value or the sugar content value still does not reach the specified range, the enzymolysis is forcibly terminated and the enzyme inactivation treatment is immediately performed, and at the same time, the alarm is triggered and the batch is marked as an abnormal batch.

4. The process for processing quinoa oat porridge as claimed in claim 3, wherein, The complex plant hydrolysis enzyme hydrolysis process in the step two is specifically: When the enzymolysis time reaches 60 min, the viscosity value and the sugar content value of the enzymolysis system are simultaneously monitored; The determination condition is set as: the enzymolysis time is within the range of 60-80 min, and the viscosity value is reduced to 800-1200 cP, and the sugar content value reaches 10.0%-12.5%; When the monitoring data simultaneously meet the determination condition, and each parameter is stably maintained within the corresponding range for at least 120 s, it is determined that the second enzymolysis end point is reached, and then the filtration operation is performed; If the enzymolysis time reaches 80 min, and the viscosity value or the sugar content value still does not reach the specified range, the enzymolysis is forcibly terminated and the filtration operation is immediately performed, and at the same time, the alarm is triggered and the batch is marked as an abnormal batch.

5. The process for processing quinoa oat porridge as claimed in claim 1, wherein, The texture adaptive pretreatment process in the step three specifically includes: The dehydrated mixed grains obtained in the step one are divided into two parts according to dry weight, wherein the first part is a texture construction grain, accounting for 70%-85% of the total dry weight of the mixed grains; and the second part is a particle retention grain, accounting for 15%-30% of the total dry weight of the mixed grains; The first part of the texture construction grain is mixed with the oat extract liquid obtained in the step two, which is equivalent to 120%-180% of the dry weight of the first part, and is cooked under a steam pressure of 0.08-0.12 MPa for 10-18 min to obtain a gelatinized substrate slurry; The second part of the particle retention grain is subjected to warm water soaking treatment at 60-70 ℃ for 15-25 min, so that the water content reaches 35%-45%, and then the particle retention grain is mixed with the gelatinized substrate slurry to obtain a pretreatment mixture.

6. The process for processing quinoa oat porridge as claimed in claim 5, wherein, The homogenization process in the step four is specifically: the pretreatment mixture, xylitol and the remaining oat extract liquid are premixed in a stirred tank until the xylitol is completely dissolved to obtain a uniform slurry; and the slurry is subjected to first-stage homogenization under a pressure of 18-22 MPa, and then is subjected to second-stage homogenization under a pressure of 5-8 MPa.

7. The process for processing quinoa oat porridge as claimed in claim 6, wherein, After the homogenization treatment in the step four, the material system is subjected to viscosity regulation, and the specific process is: An online viscometer is used to monitor the viscosity of the material after homogenization in real time, and the preset viscosity range of the material is set to 2500-4500 cP; When the monitoring viscosity continuously exceeds 4500 cP, pure water equivalent to 1%-3% of the total mass of the pretreatment mixture is added to the material, and the material is mixed under stirring at 60-80 rpm for 2-4 min; When the viscosity is continuously lower than 2500 cP, the oat extract prepared in step two is added to the material, which is equivalent to 2% to 5% of the total mass of the pretreatment mixture, and then a supplementary homogenization treatment is performed under a pressure of no more than 5 MPa.

8. The process for processing quinoa oat porridge as claimed in claim 1 wherein, The sterilization treatment in step five is performed using a water bath type sterilization kettle, and the specific process is as follows: the sealed product is placed in the sterilization kettle, the temperature is first increased from room temperature to 85-90°C at a rate of 1-1.5°C / min, and then kept at this temperature for 5-8 min; then the temperature is increased to 115-121°C at a rate of 0.8-1.2°C / min, and kept at this temperature for 15-25 min; after sterilization, the system is cooled to 70-75°C at a rate of 0.5-1.0°C / min, and then the product is rapidly cooled to below 40°C by combining air cooling and water cooling; the F0 value of the entire sterilization process is controlled to be 8-12 min.

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