Reaction kettle control method and system for regulating and controlling hotpot condiment based on Maillard reaction

Abstract

The invention discloses an integrated intelligent hotpot condiment control method based on Maillard reaction flavor regulation and a reaction kettle system, and relates to the technical field of food processing. According to the control method, the whole process is planned through a central control system and comprises the steps that main grease is preheated and then accurately pumped into a reaction kettle, and solid raw materials are put in according to a specific sequence; the jacket is used for controlling the temperature in a segmented mode, high-speed dispersion and low-speed wall scraping are achieved in cooperation with a lifting combined stirring device, and meanwhile data are collected in real time and technological parameters are dynamically adjusted through multiple sensors; and after the flavor reaches the standard, quickly cooling, adding spices, homogenizing and discharging, and starting in-situ cleaning / sterilization after the production is finished. The corresponding reaction kettle system integrates a combined stirring module, a multi-path accurate feeding module, a partitioned temperature control module, an exhaust condensation recovery module, a weighing module and a central control module. The method solves the problems that traditional production depends on manpower, the flavor is unstable and the like, directional regulation and intelligent production of the flavor of the hotpot condiment are achieved, and the product percent of pass and the flavor richness are improved.

Description

Technical Field

[0001] This invention relates to the field of food processing technology, specifically to a reaction vessel control method and system for regulating hot pot base based on Maillard reaction. Background Technology

[0002] Current hot pot base production relies heavily on manual experience, which has the following drawbacks:

[0003] 1) The temperature, pH and other parameters of the Maillard reaction (the key reaction that generates the characteristic aroma of hot pot base) are determined manually, which leads to large differences in flavor between batches and low pass rate;

[0004] 2) High-viscosity materials are prone to coking on the reactor wall during the stirring process, which is time-consuming to clean manually and can easily contaminate the product;

[0005] 3) Volatile aroma components are lost with water vapor, resulting in insufficient aroma intensity of the base ingredients;

[0006] 4) The existing reactors lack precise weighing and automatic feeding functions, and the raw material ratio error exceeds ±5%, which further affects the flavor stability. Summary of the Invention

[0007] To address the aforementioned technical issues, this application resolves the problem that the Maillard reaction, as a key reaction for generating characteristic aromas of the base material, relies on manual judgment for key parameters such as temperature and pH, leading to significant flavor differences between batches of products.

[0008] To achieve the above objectives, the technical solution adopted in this application is: an integrated intelligent control method for hot pot base based on Maillard reaction flavor regulation, comprising the following steps:

[0009] Step 1: Heat the main oil (at least one of butter, vegetable oil, and salad oil) in a preheating tank to a preset initial temperature of 60-80℃ (60-65℃ for butter, 70-75℃ for vegetable oil, and 75-80℃ for salad oil). According to the selected flavor formula, the central control system instructs the actuator to pump the preheated oil into the reaction vessel (101). Then, solid raw materials are added into the reaction vessel (101) in the order and timing of "first ginger and garlic, then broad bean paste, then chili peppers and Sichuan peppercorns".

[0010] Step 2: The jacket heating of the reactor is used, and the stirring device is used for frequency conversion stirring. At the same time, the temperature sensor, pH sensor and viscosity sensor integrated in the upper section of the reactor are used to collect material data in real time. The data is transmitted to the central control system and compared with the preset target flavor model curve. The jacket heating power and stirring speed are dynamically adjusted according to the comparison results. If necessary, a trace amount of water or pH adjuster is added and the vacuum degree is adjusted.

[0011] Step 3: When the online monitoring system (composed of near-infrared sensor + electronic nose) determines that the flavor index has reached the preset optimal value, stop heating and turn on the cooling system. First, start the stirring and cooling function built into the reactor (101) (maintain low-speed stirring), and after a delay of 30-60 seconds, turn on the cooling water system to cool the material to below 70-80℃ within 30-60 seconds, terminate the Maillard reaction, and avoid residual heat causing oxidation of flavor substances. Among them, 1) Preset target flavor model curve: refers to the curve of the correspondence between "temperature-time-pH-viscosity-flavor substance concentration" established through previous experiments. Different flavor formulas (such as spicy type and clear soup type) correspond to different curves. For example, in the spicy type curve, the pH value of the Maillard reaction stage needs to be maintained at 5.5-6.0, and the concentration of flavor substances (such as furans and sulfides) needs to reach 1200-1500ppm; 2) Online monitoring system: consists of PT100 temperature sensor (accuracy ±0.1℃), pH sensor (accuracy ±0.01), viscosity sensor (accuracy ±1cP), near-infrared sensor (detects flavor substance concentration) and electronic nose (identifies aroma type). It collects data in real time and transmits it to the central control system. When all parameters match the target curve, the flavor is judged to meet the standard.

[0012] Step 4: Add the added spices, start the homogenizer, then open the discharge valve at the bottom of the reactor and pump the finished product to the filling section;

[0013] Step 5: After production is completed, start the cleaning system and sterilize if necessary.

[0014] To better realize the present invention, in step 1, the main oil is at least one of butter, vegetable oil, and salad oil; the solid raw materials are added in the following order: ginger, garlic, and broad bean paste are added first, followed by chili peppers and Sichuan peppercorns.

[0015] To better realize the present invention, further, in step 2, the stirring device includes a three-phase asynchronous motor, a pressure sensor, a coupling, a stirrer, a mounting base, a first rotating shaft, a second rotating shaft, a mixing cylinder, a low-speed scraping stirrer, and a reducer. The top of the reactor is provided with a mounting base via a hydraulic telescopic rod. The three-phase asynchronous motor and the reducer are fixedly connected to the mounting base. The output end of the three-phase asynchronous motor is connected to the input end of the reducer. The output end of the reducer is vertically connected to the first rotating shaft. The end of the first rotating shaft extends into the mixing cylinder inside the reactor. The end of the first rotating shaft is connected to the top of the stirrer via a coupling and a transition shaft. The bottom of the stirrer is connected to the top of the second rotating shaft. A low-speed scraping stirrer is provided at the bottom of the second rotating shaft. A pressure sensor is provided on the inner circumferential wall of the lower section of the mixing cylinder.

[0016] When the Maillard reaction precursor is added, the hydraulic telescopic rod is activated, causing the agitator and low-speed scraping agitator to move upward until the outer side of the low-speed scraping agitator separates from the inner wall of the mixing cylinder. The three-phase asynchronous motor is then started, causing the agitator to run at high speed for 1-3 minutes. Then, the hydraulic telescopic rod is activated again, causing the agitator and low-speed scraping agitator to move downward until the outer side of the low-speed scraping agitator is in contact with and pressed against the inner wall of the mixing cylinder. When the pressure signal collected by the pressure sensor is transmitted to the central control system and is equal to the preset pressure value in the central control system, the downward movement of the agitator and low-speed scraping agitator driven by the hydraulic telescopic rod is stopped. Then, the three-phase asynchronous motor is started again, causing the low-speed scraping agitator to continuously scrape the wall at low speed.

[0017] To better realize the present invention, further, in step 2, the jacket heating uses a high-temperature thermal oil furnace as the heat source, the high-temperature heat medium enters the jacket through a high-precision pneumatic regulating valve, the temperature sensor is a PT100 sensor, and the central control system dynamically adjusts the valve opening through PID calculation to achieve segmented program temperature control of 105℃ for sautéing, 110-130℃ for Maillard reaction, and 145-155℃ for stir-frying sauce.

[0018] To better realize the present invention, in step 2, the Maillard reaction precursor is added after the aromatic vegetables are stir-fried and removed and before the water-containing material of the fermented bean paste is added, and is automatically added through a special feeding port integrated on the reactor cover. The Maillard reaction precursor includes amino acids, reducing sugars, and vitamin B1 complex, wherein the amino acid is at least one of cysteine, methionine, glycine, and alanine, and the reducing sugar is at least one of xylose, glucose, and D-allulose.

[0019] To better realize the present invention, in step 1, when the raw materials are put into the reactor, the added fluid raw materials are automatically measured by the weighing module, and the weight of the powder or materials put in through the manhole is checked. Before weighing, the tare and zeroing operation is performed through the touch screen. When tare and zeroing, it is ensured that there are no additional equipment on the reactor and that personnel do not lean on the equipment. The compressed air drainage function is activated to remove residual moisture in the jacket.

[0020] To better realize the present invention, in step 1, when adding tallow to the reaction vessel, precise quantitative addition is achieved through the cooperation of a weighing module, a pneumatic ball valve, and a front-end oil supply pump.

[0021] To better realize the present invention, in step 3, when the cooling system is turned on, the reactor cooling function is turned on first, and then the cooling water system is turned on. After all cooling processes are completed, the cooling water system is turned off, and the corresponding pipes and valves connecting the reactor and the jacket are in the open state when working normally.

[0022] To better realize the present invention, further, in step 2, during the intelligent reaction process, the water vapor and volatile flavor substances generated in the reactor are exported to the shell-and-tube condenser, the water vapor is condensed and separated and discharged, the volatile aroma components are recovered through a cold trap or oil circulation system, and the recovered aroma components can be added back to the reactor.

[0023] The central control system is a PLC control system with a touch screen. The PLC control system has a built-in formula management function, which can save formulas with different process parameters and automatically record the key parameters of each batch of production, supporting traceability by batch number.

[0024] To achieve the above objectives, the technical solution adopted in this application is: an integrated intelligent reaction vessel system for hot pot base flavor regulation based on Maillard reaction, characterized in that it includes a reaction vessel, a combined stirring system, a multi-channel precise feeding device, a zoned temperature control thermal system, an exhaust and condensation recovery system, a weighing system, and a central control system.

[0025] The reactor body is made of 316L stainless steel and is a single-layer vessel body, and is equipped with a large surface area semi-pipe jacket or a double spiral flow guide jacket.

[0026] The combined stirring system is a liftable structure, including an anchor-type wall scraper that rotates close to the vessel wall and bottom, and an independently driven high-speed dispersion homogenizing head;

[0027] The multi-channel precision feeding device is integrated into the reactor cover plate, including a liquid / oil phase inlet for initial oil feeding, a solid feeding port with a quick-opening lid for feeding large materials, and a sauce feeding port for feeding sauces.

[0028] The zoned temperature control thermal system includes a high-temperature thermal oil furnace, a high-precision pneumatic regulating valve, and a PT100 temperature sensor. The high-temperature heat medium provided by the high-temperature thermal oil furnace enters the jacket through the high-precision pneumatic regulating valve, and the PT100 temperature sensor monitors the material temperature in real time and feeds back the signal.

[0029] The exhaust and condensation recovery system includes a shell-and-tube condenser connected to the reactor to remove water vapor and volatile flavor substances generated during the reaction. The system is also equipped with a cold trap or oil circulation system for recovering volatile aroma components, as well as a return path that can return the recovered aroma components to the reactor.

[0030] The weighing system is electrically connected to the central control system and is used to automatically measure the input fluid raw materials and to verify the weight of powder or materials input through the manhole.

[0031] The central control system is a PLC control system with a touch screen. The system has a built-in formula management function to save formulas with different process parameters, a time-series linkage control function to achieve precise linkage of temperature, stirring and feeding actions, and a data recording and traceability function to automatically record the key parameters of each batch of production and support query by batch number.

[0032] The technical solution provided by this invention has the following advantages compared with the prior art:

[0033] 1. This invention employs a zoned temperature control thermal system composed of a PT100 temperature sensor, PLC PID calculation, and a high-precision pneumatic regulating valve. This system achieves segmented temperature control for sautéing at 105℃, Maillard reaction at 110-130℃, and sauce making at 145-155℃. An online monitoring system, consisting of a pH sensor, viscosity sensor, and near-infrared sensor, is used to compare material data with preset flavor model curves in real time. This precisely controls key parameters of the Maillard reaction and dynamically adjusts process conditions to match the target flavor. It avoids parameter deviations caused by manual judgment, ensuring consistent Maillard reaction levels in each batch and targeted generation of characteristic flavor compounds such as roasted aroma and meaty aroma.

[0034] 2. This invention features a height-adjustable combined stirring system, comprising a high-speed dispersing stirrer and a low-speed scraping stirrer. The stirring components are raised and lowered via a hydraulic telescopic rod, and a pressure sensor ensures the low-speed scraping stirrer remains tightly fitted to the vessel wall. When Maillard reaction precursors are added, the stirrer rises to disperse the material at high speed; during the reaction, the stirrer descends, and the low-speed scraping stirrer operates close to the vessel wall. This achieves both uniform mixing of materials and real-time scraping away of high-viscosity materials adhering to the vessel wall, preventing coking.

[0035] 3. In this invention, an exhaust and condensation recovery system is provided to guide the water vapor and volatile flavor substances generated in the reactor into a shell-and-tube condenser. The aroma components are recovered through a cold trap or oil circulation system, and the recovered components can be added back to the reactor. This separates water vapor and volatile aromas, achieving the recovery and reuse of aroma components. It also reduces the loss of characteristic aroma substances during the Maillard reaction and replenishes the aroma concentration of the base material.

[0036] 4. This invention integrates a weighing system that automatically measures fluid raw materials and verifies the weight of powder / manhole-feed materials via a weighing module. Before weighing, tareing and zeroing, as well as jacket drainage, are performed. When adding butter, precise metering is achieved through the coordinated operation of the weighing module, pneumatic ball valve, and front-end oil supply pump. This ensures minimal deviation between the amount of raw materials added in each batch and the formula, avoiding dosage errors. It guarantees consistent raw material ratios from the source, laying the foundation for stable Maillard reactions and flavor generation.

[0037] 5. In this invention, a PLC with a touchscreen serves as the central control system, incorporating formula management, sequential control, and data recording and traceability functions. It can store multiple process formulas, automatically execute the entire "feeding-heating-stirring-reaction-cooling-discharging" process, and automatically record key parameters for each batch. This replaces traditional manual operation, reduces human intervention, and achieves standardization and traceability of the production process. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0040] Explanation of reference numerals in the attached drawings: 101-Reaction vessel; 102-Three-phase asynchronous motor; 103-Jacket; 104-Pressure sensor; 105-Coupling; 106-Agitator; 107-Mounting base; 108-First rotating shaft; 109-Second rotating shaft; 110-Mixing cylinder; 111-Weighing module; 112-Low-speed scraping agitator; 113-Feed inlet; 114-Reducer. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0042] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0043] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0044] In the description of this application, it should be noted that the use of terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" to indicate orientation or positional relationships is based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationships commonly used when the product is in use. These terms are used solely for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the use of terms such as "first" and "second" in the description of this application is only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0045] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this application does not imply that the component is required to be absolutely horizontal or suspended, but rather that it may be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but rather that it may be slightly tilted.

[0046] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0047] Example 1

[0048] like Figure 1 As shown, an integrated intelligent control method for hot pot base based on Maillard reaction flavor regulation includes the following steps:

[0049] Step 1: Heat the main oil in the preheating tank to the preset initial temperature. According to the selected flavor formula, the central control system instructs the actuator to pump the preheated oil into the reactor 101. Solid raw materials are then added into the reactor 101 through the feed inlet 113 in the corresponding order and timing.

[0050] Step 2: The jacket 103 of the reactor 101 is used for heating, and variable frequency stirring is carried out in conjunction with the stirring device. At the same time, the temperature sensor, pH sensor and viscosity sensor integrated in the upper section of the reactor 101 are used to collect material data in real time. The data is transmitted to the central control system (PLC / industrial computer) and compared with the preset target flavor model curve. The heating power of the jacket 103 and the stirring speed are dynamically adjusted according to the comparison results. If necessary, trace amounts of water or pH adjuster are added and the vacuum degree is adjusted.

[0051] Step 3: When the online monitoring system determines that the flavor index has reached the preset optimal value, stop heating and turn on the cooling system to cool the material to below 70-80℃ within ten to thirty seconds.

[0052] Step 4: Add the added spices, start the homogenizer, and then open the discharge valve at the bottom of reactor 101 to pump the finished product to the filling section.

[0053] Step 5: After production is completed, start the cleaning system and sterilize if necessary.

[0054] like Figure 1 As shown in this embodiment, in step 1, the main oil is at least one of butter, vegetable oil, and salad oil; the solid raw materials are added in the following order: ginger, garlic, and broad bean paste are added first, followed by chili peppers and Sichuan peppercorns.

[0055] like Figure 1 As shown in this embodiment, in step 2, the stirring device includes a three-phase asynchronous motor 102, a pressure sensor 104, a coupling 105, a stirrer 106, a mounting base 107, a first rotating shaft 108, a second rotating shaft 109, a mixing cylinder 110, a low-speed scraping stirrer 112, and a reducer 114. The top of the reaction vessel 101 is equipped with a mounting base 107 via a hydraulic telescopic rod. The three-phase asynchronous motor 102 and the reducer 114 are fixedly connected to the mounting base 107. The output end of the three-phase asynchronous motor 102 is connected to the reducer 114. The input end of the reducer 114 is connected to the first rotating shaft 108, and the output end of the reducer 114 is vertically connected to the first rotating shaft 108. The end of the first rotating shaft 108 extends into the mixing cylinder 110 inside the reactor 101. The end of the first rotating shaft 108 is connected to the top of the agitator 106 through a coupling 105 and a transition shaft. The bottom of the agitator 106 is connected to the top of the second rotating shaft 109. A low-speed scraping agitator 112 is provided at the bottom of the second rotating shaft 109. A pressure sensor 104 is provided on the lower inner circumferential wall of the mixing cylinder 110.

[0056] When the Maillard reaction precursor is added, the hydraulic telescopic rod is activated, causing the agitator 106 and the low-speed scraping agitator 112 to move upward until the outer surface of the low-speed scraping agitator 112 disengages from the inner wall of the mixing cylinder 110. The three-phase asynchronous motor 102 is then started, causing the agitator 106 to run at high speed (e.g., 800-1500 r / min) for 1-3 minutes. Then, the hydraulic telescopic rod is activated again, causing the agitator 106 and the low-speed scraping agitator 112 to move downward until the outer surface of the low-speed scraping agitator 112 disengages from the inner wall of the mixing cylinder 110. The outer side of the high-speed scraping agitator 112 is in contact with and abuts against the inner wall of the mixing cylinder 110. When the pressure signal collected by the pressure sensor 104 is transmitted to the central control system and is equal to the pressure value preset in the central control system, the hydraulic telescopic rod driven agitator 106 and the low-speed scraping agitator 112 stop moving down, and then the three-phase asynchronous motor 102 is restarted, so that the low-speed scraping agitator 112 continues to scrape the wall at a low speed (e.g., 15-45 r / min).

[0057] like Figure 1 As shown in this embodiment, in step 2, the jacket 103 is heated using a high-temperature thermal oil furnace as the heat source. The high-temperature heat medium enters the jacket 103 through a high-precision pneumatic regulating valve. The temperature sensor is a PT100 sensor. The central control system dynamically adjusts the valve opening through PID calculation to achieve segmented program temperature control for 105℃ for stir-frying, 110-130℃ for Maillard reaction, and 145-155℃ for frying sauce.

[0058] like Figure 1 As shown, in this embodiment, in step 2, the Maillard reaction precursor is added after the aromatic vegetables are stir-fried and removed, and before the water-containing material of the fermented bean paste is added. It is automatically added through a dedicated feeding port integrated on the cover plate of the reactor 101. The Maillard reaction precursor includes amino acids, reducing sugars, and vitamin B1 complex, wherein the amino acid is at least one of cysteine, methionine, glycine, and alanine, and the reducing sugar is at least one of xylose, glucose, and D-allulose.

[0059] like Figure 1 As shown, in this embodiment, in step 1, when raw materials are added into the reactor 101, the added fluid raw materials are automatically measured by the weighing module 111, and the weight of powder or materials added through the manhole is checked. Before weighing, a tare and zeroing operation is performed through the touch screen. During the tare and zeroing operation, it is ensured that there are no additional devices on the reactor 101 and that personnel do not lean against the devices. The compressed air drainage function is activated to remove residual moisture from the jacket 103.

[0060] like Figure 1 As shown in this embodiment, in step 1, when adding tallow to the reaction vessel 101, precise quantitative refueling is achieved through the cooperation of the weighing module 111, the pneumatic ball valve, and the front-end oil supply pump.

[0061] like Figure 1 As shown in this embodiment, in step 3, when the cooling system is turned on, the cooling function of the reactor 101 is turned on first, and then the cooling water system is turned on. After all the cooling processes are completed, the cooling water system is turned off. The corresponding pipes and valves connecting the reactor 101 and the jacket 103 are all in the open state when they are working normally.

[0062] like Figure 1 As shown, in this embodiment, in step 2, during the intelligent reaction process, the water vapor and volatile flavor substances generated in the reactor 101 are exported to the shell-and-tube condenser. The water vapor is condensed and separated and discharged, and the volatile aroma components are recovered through a cold trap or oil circulation system. The recovered aroma components can be added back into the reactor 101.

[0063] The central control system is a PLC control system with a touch screen. The PLC control system has a built-in formula management function, which can save formulas with different process parameters and automatically record the key parameters of each batch of production, supporting traceability by batch number.

[0064] The cooling system and cleaning system can both be implemented using existing mature technologies.

[0065] Working principle

[0066] Oil preheating and quantitative delivery: The main oils (butter, vegetable oil, salad oil) first enter the preheating tank and are heated to the preset initial temperature. Then, the central control system (PLC) commands the front-end oil supply pump to start. Combined with the weighing module 111 and the pneumatic ball valve, the oil is precisely quantitatively pumped into the reaction vessel 101 through the closed-loop control of "weighing feedback - valve opening adjustment", avoiding dosage deviation caused by manual feeding.

[0067] According to the preset flavor formula, the PLC triggers the operation of multiple precision feeding devices in the order of "first scallions, ginger, and garlic, then fermented bean paste, and finally chili peppers and Sichuan peppercorns". Large materials (scallions, ginger, and garlic) are fed in through the solid feeding port with a quick-opening lid, while the sauce (fermented bean paste) is fed in through a dedicated sauce feeding port. The timing of feeding is linked to the temperature inside the reactor 101 to ensure that the raw materials participate in the reaction within the optimal temperature range.

[0068] Before feeding, the operator performs a tare and zeroing operation via the touch screen to ensure that there is no additional equipment or personnel leaning on the reactor 101. At the same time, the compressed air drainage function is activated to remove residual condensate or cooling water in the jacket 103 to avoid interference with the weighing accuracy due to moisture content. During the feeding process, the weighing module 111 measures the fluid raw materials in real time, verifies the powder / manhole materials fed in, and feeds the data back to the PLC to ensure that the proportions of each batch of raw materials are consistent.

[0069] The system automatically adjusts the state of the stirring device according to the process stage. When Maillard reaction precursors (amino acids, reducing sugars, etc.) are added, the PLC commands the hydraulic telescopic rod to drive the mounting base 107 to rise, which in turn moves the stirrer 106 and the low-speed scraper stirrer 112 upwards until the outer side of the low-speed scraper stirrer 112 separates from the inner wall of the mixing cylinder 110. At the same time, the three-phase asynchronous motor 102 is started, and the speed is adjusted to high speed through the reducer 114, driving the stirrer 106 to run at high speed for 1-3 minutes to quickly disperse the precursors and prevent them from clumping in the hot oil, thus creating conditions for the homogeneous Maillard reaction.

[0070] After the Maillard reaction is completed, the hydraulic telescopic rod drives the mounting base 107 to descend, so that the outer side of the low-speed scraping agitator 112 is pressed tightly against the inner wall of the mixing cylinder 110. At this time, the pressure sensor 104 collects the contact pressure signal between the low-speed scraping agitator 112 and the inner wall of the mixing cylinder 110 in real time. When the signal is consistent with the preset pressure value in the PLC, the descent action stops, the three-phase asynchronous motor 102 switches to low-speed mode, and drives the low-speed scraping agitator 112 to scrape and stir at low speed to prevent high-viscosity materials (such as the base material in the stir-frying stage) from scorching on the bottom of the pot wall, while ensuring that the material is heated evenly.

[0071] The power of the three-phase asynchronous motor 102 is reduced by the reducer 114 and then transmitted to the first rotating shaft 108. The first rotating shaft 108 is then connected to the transition shaft through the coupling 105, which drives the agitator 106 to rotate. The bottom of the agitator 106 is connected to the second rotating shaft 109, which in turn drives the low-speed scraping agitator 112 to move synchronously, realizing the coordinated operation of "single motor driving dual agitation components", simplifying the transmission structure and reducing the risk of failure.

[0072] The zoned temperature control thermal system uses a high-temperature thermal oil furnace as the heat source. The PLC dynamically adjusts the opening of the high-precision pneumatic regulating valve through PID calculations to control the flow rate of the high-temperature heat medium into the jacket 103. Specifically, the temperature is stabilized at 105℃ during the sautéing stage to release the aroma of the scallions, ginger, and garlic; the Maillard reaction stage is precisely controlled at 110-130℃ to directionally promote the reaction of amino acids and reducing sugars to generate roasted and meaty flavor compounds; and the sauce-frying stage raises the temperature to 145-155℃ to ensure that the fermented bean paste and chili peppers are fully colored and fragrant.

[0073] The PT100 temperature sensor integrated in the upper section of reactor 101 collects the material temperature in real time and transmits it to the PLC. When the temperature approaches the target value, the valve opening is automatically fine-tuned to avoid large temperature fluctuations. If the temperature drops during the heat preservation stage, the PLC immediately increases the valve opening to replenish the heat medium and maintain temperature stability, ensuring that the Maillard reaction degree is consistent for each batch.

[0074] The water vapor and volatile aroma components (such as sulfides and furan compounds) generated during the reaction process enter the shell-and-tube condenser through the exhaust channel at the top of the reactor 101. The water vapor is condensed and separated and discharged, while the aroma components are recovered through a cold trap or oil circulation system. The PLC can instruct the recovery system to add the aroma components back to the reactor 101 according to the process requirements, thereby reducing flavor loss and enhancing the richness of the base aroma.

[0075] When the online monitoring system (temperature, pH, and viscosity sensors) determines that the flavor index has reached the preset optimal value, the PLC immediately stops the heat transfer medium supply and shuts down the heating system; at the same time, the cooling system is turned on, first activating the self-cooling function of the reactor 101, and then opening the cooling water passage to allow cooling water to enter the jacket 103. Through convection heat transfer, the material temperature is reduced to below 70-80℃ within ten to thirty seconds, terminating the Maillard reaction and avoiding excessive oxidation or deterioration of flavor due to residual heat.

[0076] As the control core, the PLC has a built-in formula management function, which can save multiple sets of process parameters (such as "classic spicy" and "strong aroma" formulas). The operator only needs to call up the corresponding formula on the touch screen, and the system can automatically execute the entire process of "feeding to heating to stirring to reaction to cooling" without manual intervention. At the same time, the PLC automatically records the key parameters of each batch of production (temperature curve, stirring speed, feeding time, etc.), and supports traceability by batch number, which is convenient for quality analysis and process optimization.

[0077] After cooling, the PLC commands add spices (such as Sichuan pepper) to activate the fresh aroma using the residual heat of the material. Then, the homogenizer is started to make the base material fine and uniform. Finally, the discharge valve at the bottom of the reactor 101 is opened, and the finished product is transported to the filling section by pumping or gravity flow to achieve continuous production.

[0078] After production is completed, the operator starts the cleaning system via the touch screen. The spray ball automatically sprays cleaning agent and water to thoroughly clean the inner wall of the reactor 101, the stirring shaft, the feeding port and other components. If the next batch of different flavor base materials needs to be produced, the sterilization (SIP) function can be activated to sterilize the system with steam, avoiding cross-contamination between batches and complying with food safety production standards.

[0079] In addition, the entire process of raw material pretreatment, Maillard reaction control, flavor recovery, cooling discharge and cleaning and maintenance is integrated in a single reaction vessel 101. The core is to achieve the targeted generation of hot pot base flavor by "precise temperature control, dynamic stirring and intelligent linkage".

[0080] When adding tallow to reactor 101, the central control system (PLC) instructs the weighing module 111, pneumatic ball valve, and front-end oil supply pump to work together. The oil supply pump first delivers the tallow to the inlet of reactor 101. The pneumatic ball valve adjusts its opening based on the weight data fed back in real time by the weighing module 111. When the weight reaches the preset value of the formula, the PLC immediately shuts off the pneumatic ball valve and the oil supply pump, achieving fully automatic and precise metering of "delivery-weighing-stopping" and avoiding dosage errors caused by manual oil addition.

[0081] In addition to the routine tare and zeroing (ensuring that there is no additional equipment or personnel leaning against the reactor 101), the PLC automatically activates the compressed air drainage function before weighing to remove any residual steam condensate or cooling water that may remain in the jacket 103. This uses compressed air to purge the pipes inside the jacket 103 and remove residual moisture, preventing moisture from adhering and causing measurement deviations in the weighing module 111. During the feeding process, the weighing module 111 not only automatically measures the fluid raw materials (grease), but also verifies the weight of powder materials (such as fragrance powder) fed through the manhole, transmitting the data to the touch screen in real time for the operator to confirm the accuracy of the feeding.

[0082] The stirring device is powered by a three-phase asynchronous motor 102. The output of the three-phase asynchronous motor 102 is rigidly connected to the input of a reducer 114. The output of the reducer 114 is vertically connected to a first rotating shaft 108. The end of the first rotating shaft 108 is coaxially connected to a transition shaft via a coupling 105. The top of the stirrer 106 is connected to the bottom of the transition shaft. The bottom of the stirrer 106 is fixed to a second rotating shaft 109. A low-speed scraping stirrer 112 is installed at the bottom of the second rotating shaft 109. This transmission path realizes "motor-reduction-multi-axis linkage," ensuring stable power transmission to the core stirring components.

[0083] When the mixing state needs to be switched, the PLC instructs the hydraulic telescopic rod to drive the mounting base 107 (which fixes the three-phase asynchronous motor 102 and the reducer 114) to rise and fall. During the rising process, the mounting base 107 drives the first rotating shaft 108, the agitator 106, the second rotating shaft 109, and the low-speed scraping agitator 112 to move upward synchronously until the outer side of the low-speed scraping agitator 112 is completely separated from the inner wall of the mixing cylinder 110 (determined by a displacement sensor or a preset stroke). During the falling process, the PLC receives the pressure signal from the pressure sensor 104 (installed on the inner circumferential wall of the lower section of the mixing cylinder 110) in real time. When the pressure between the outer side of the low-speed scraping agitator 112 and the inner wall of the mixing cylinder 110 reaches a preset value (such as 0.3MPa, the specific value needs to be preset according to the equipment parameters), the hydraulic telescopic rod action is stopped immediately to avoid excessive compression between the low-speed scraping agitator 112 and the mixing cylinder 110, which could lead to component wear.

[0084] The zoned temperature control thermal system uses a high-temperature thermal oil furnace as the heat source. The high-temperature heat transfer medium (thermal oil) is transported to the inlet of jacket 103 through pipelines. The high-precision pneumatic regulating valve at the inlet is controlled by the PLC through PID (proportional-integral-derivative) calculations. During the 105℃ aroma-making stage, the PLC sets the target temperature to 105℃. The PT100 temperature sensor (integrated in the upper section of reactor 101) collects the material temperature in real time. When the temperature is below 105℃, the opening of the pneumatic regulating valve is increased to increase the flow of the heat transfer medium. When the temperature approaches 105℃ (e.g., 104℃), the valve opening is decreased to avoid temperature overshoot. When entering the Maillard reaction stage (110-130℃) and the sauce-making stage (145-155℃), the PLC automatically switches the target temperature and repeats the above PID regulation logic to achieve precise and stable temperature control at each stage.

[0085] The relevant pipes and valves (including manual valves) connecting the reactor 101 and the jacket 103 are kept open during normal production to ensure smooth flow of heat medium or cooling water; the corresponding valves are only closed by the operator during equipment maintenance or cleaning to avoid temperature control failure due to accidental valve closure during production.

[0086] The water vapor and volatile flavor compounds (such as sulfides and furans) generated in reactor 101 are introduced into a shell-and-tube condenser through a top exhaust pipe. The mixture is cooled by circulating cooling water in the condenser. The water vapor condenses into liquid water and is discharged through a drain pipe. Because of their high boiling points, the volatile flavor components do not completely condense in the condenser and are carried by the airflow into a cold trap or oil circulation system (the cold trap liquefies the flavor components through a low-temperature environment, while the oil circulation system adsorbs the flavor components through oil) for recovery. When it is necessary to increase the flavor intensity of the base material, the PLC commands the return valve of the recovery system to open, returning the recovered flavor components to reactor 101 through a dedicated pipeline to mix with the material and reduce flavor loss.

[0087] When the online monitoring system (temperature, pH, and viscosity sensors) determines that the flavor indicators meet the standards, the PLC first stops the operation of the high-temperature thermal oil furnace, closes the heat medium supply valve, and activates the cooling function of the reactor 101 itself (such as keeping the stirring inside the reactor running at a low speed to accelerate heat diffusion). After a delay of 30-60 seconds, the cooling water system is then turned on, allowing cooling water to enter the jacket 103. The material temperature is reduced through heat exchange between the jacket 103 and the wall of the reactor 101. When the material temperature drops below 70-80℃, the PLC first turns off the cooling water system and then stops stirring to avoid prematurely turning off the cooling water, which could cause the material temperature to rise again and ensure the flavor "lock-in" effect.

[0088] The central control system uses a PLC with a touch screen and built-in recipe management function, which can save multiple sets of process parameter recipes (such as "classic spicy" and "strong aroma"). Each recipe includes parameters such as temperature setpoints for each stage, stirring speed switching timing, and feeding time. After the recipe is called, the PLC realizes multi-device linkage according to the preset sequence. For example, when the material temperature reaches 120℃ (the optimal temperature for Maillard reaction), the PLC synchronously triggers a continuous action from "the Maillard precursor feeding port opening to the three-phase asynchronous motor 102 switching from high speed to low speed after feeding is completed" without manual intervention.

[0089] The PLC automatically records key parameters for each batch of production, including: temperature curves at each stage (time-temperature correspondence data), stirring speed switching points, feed weight, cooling time, and flavor index attainment time. All data is stored in a data set linked to the batch number. Operators can input the batch number via a touchscreen to query the complete production data for the corresponding batch, facilitating quality issue traceability and process parameter optimization. Simultaneously, the data can be exported to a host computer via the PLC's communication interface for long-term archiving.

[0090] After production is completed, the PLC receives a "cleaning start" command, first opening the discharge valve at the bottom of reactor 101 to drain residual material; then closing the discharge valve and activating the spray ball system (installed on the top inner wall of reactor 101), running in the sequence of "clean water rinsing to cleaning agent circulation cleaning to clean water secondary rinsing". The cleaning agent concentration and cleaning time are controlled by the PLC according to a preset program to ensure that there is no material residue on the inner wall of reactor 101, the stirring shaft, the feeding port, and the sensor surface.

[0091] When production batches are switched (e.g., from spicy broth to clear broth) or when aseptic production requirements need to be met, the PLC initiates the sterilization function after in-situ cleaning. High-temperature steam (121℃, 0.1MPa) is introduced into the reactor 101 and maintained for 15-20 minutes to sterilize the internal space and components in contact with materials. During sterilization, the PT100 temperature sensor monitors the internal temperature in real time to ensure sterilization parameters meet standards. After sterilization, the system cools the reactor to prepare for the next batch of production.

[0092] Example 2

[0093] Example 2 is based on Example 1 and is an integrated intelligent reaction vessel 101 system for hot pot base flavor regulation based on Maillard reaction. It includes a reaction vessel 101, a combined stirring system, a multi-channel precise feeding device, a zoned temperature control thermal system, an exhaust and condensation recovery system, a weighing system, and a central control system.

[0094] The reactor 101 body is made of 316L stainless steel and is a single-layer reactor body, and is equipped with a large surface area semi-pipe jacket 103 or a double spiral flow guide jacket 103.

[0095] The combined stirring system is a liftable structure, including an anchor-type wall scraper (i.e., low-speed side scraper 112) that rotates close to the vessel wall and bottom, and a high-speed dispersion homogenizing head (i.e., stirrer 106).

[0096] The multi-channel precision feeding device is integrated into the cover plate of the reactor 101, including a liquid / oil phase inlet for initial oil feeding, a solid feeding port with a quick-opening lid for feeding large materials, and a sauce feeding port for feeding sauces.

[0097] The zoned temperature control thermal system includes a high-temperature thermal oil furnace, a high-precision pneumatic regulating valve, and a PT100 temperature sensor. The high-temperature heat medium provided by the high-temperature thermal oil furnace enters the jacket 103 through the high-precision pneumatic regulating valve, and the PT100 temperature sensor monitors the material temperature in real time and feeds back the signal.

[0098] The exhaust and condensation recovery system includes a shell-and-tube condenser connected to the reactor 101 to remove water vapor and volatile flavor substances generated during the reaction. The system is also equipped with a cold trap or oil circulation system for recovering volatile aroma components, as well as a return path that can return the recovered aroma components to the reactor 101.

[0099] The weighing system is electrically connected to the central control system and is used to automatically measure the input fluid raw materials and to verify the weight of powder or materials input through the manhole.

[0100] The central control system is a PLC control system with a touch screen. The system has a built-in formula management function to save formulas with different process parameters, a time-series linkage control function to achieve precise linkage of temperature, stirring and feeding actions, and a data recording and traceability function to automatically record the key parameters of each batch of production and support query by batch number.

[0101] The above description is merely a preferred embodiment of this application and is not intended to limit this application. For those skilled in the art, this application can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An integrated intelligent control method for hot pot base flavor regulation based on Maillard reaction, characterized in that, Includes the following steps: Step 1: Heat the main oil in the preheating tank to the preset initial temperature. According to the selected flavor formula, the central control system instructs the actuator to pump the preheated oil into the reactor (101). Then, solid raw materials are added into the reactor (101) through the feed port (113) in the corresponding order and timing. Step 2: The jacket (103) of the reactor (101) is used for heating, and the stirring device is used for frequency conversion stirring. At the same time, the temperature sensor, pH sensor and viscosity sensor integrated in the upper section of the reactor (101) are used to collect material data in real time. The data is transmitted to the central control system and compared with the preset target flavor model curve. The heating power and stirring speed of the jacket (103) are dynamically adjusted according to the comparison results. If necessary, a trace amount of water or pH adjuster is added and the vacuum degree is adjusted. Step 3: When the online monitoring system determines that the flavor index has reached the preset optimal value, stop heating and turn on the cooling system to cool the material to below 70-80℃ within ten to thirty seconds. Step 4: Add the added spices, start the homogenizer, and then open the discharge valve at the bottom of the reactor (101) to pump the finished product to the filling section; Step 5: After production is completed, start the cleaning system.

2. The control method according to claim 1, characterized in that, In step 1, the main oil is at least one of butter, vegetable oil, and salad oil; the solid raw materials are added in the following order: ginger, garlic, and broad bean paste are added first, followed by chili peppers and Sichuan peppercorns.

3. The control method according to claim 1, characterized in that, In step 2, the stirring device includes a three-phase asynchronous motor (102), a pressure sensor (104), a coupling (105), a stirrer (106), a mounting base (107), a first rotating shaft (108), a second rotating shaft (109), a mixing cylinder (110), a low-speed scraping stirrer (112), and a reducer (114). The top of the reaction vessel (101) is equipped with a mounting base (107) via a hydraulic telescopic rod. The three-phase asynchronous motor (102) and the reducer (114) are fixedly connected to the mounting base (107). The output end of the three-phase asynchronous motor (102) is connected to the reducer (114). The input end of the reducer (114) is connected to the first rotating shaft (108), and the output end of the first rotating shaft (108) extends into the mixing cylinder (110) inside the reactor (101). The end of the first rotating shaft (108) is connected to the top of the agitator (106) through a coupling (105) and a transition shaft. The bottom of the agitator (106) is connected to the top of the second rotating shaft (109). A low-speed scraping agitator (112) is provided at the bottom of the second rotating shaft (109). A pressure sensor (104) is provided on the inner circumferential wall of the lower section of the mixing cylinder (110). When the Maillard reaction precursor is added, the hydraulic telescopic rod is activated, causing the agitator (106) and the low-speed scraper agitator (112) to move upward until the outer side of the low-speed scraper agitator (112) disengages from the inner wall of the mixing cylinder (110). The three-phase asynchronous motor (102) is then activated, causing the agitator (106) to run at a high speed of 800-1500 r / min for 1-3 minutes. Then, the hydraulic telescopic rod is activated again, causing the agitator (106) and the low-speed scraper agitator (112) to move upward. The low-speed scraping agitator (112) moves down until its outer side is in contact with and abuts against the inner wall of the mixing cylinder (110). When the pressure signal collected by the pressure sensor (104) is transmitted to the central control system and is equal to the preset pressure value of 0.3MPa in the central control system, the component driven by the hydraulic telescopic rod stops moving down, and then the three-phase asynchronous motor (102) is started again, so that the low-speed scraping agitator (112) scrapes the wall at a low speed of 15-45r / min.

4. The control method according to claim 1, characterized in that, In step 2, the jacket (103) heating uses a high-temperature thermal oil furnace as the heat source. The high-temperature heat medium enters the jacket (103) through a high-precision pneumatic regulating valve. The temperature sensor is a PT100 sensor. The central control system dynamically adjusts the valve opening through PID calculation to achieve segmented program temperature control for 105℃ for sautéing, 110-130℃ for Maillard reaction, and 145-155℃ for stir-frying sauce. That is, the jacket (103) heating uses a high-temperature thermal oil furnace as the heat source. The high-temperature heat medium enters the jacket (103) through a high-precision pneumatic regulating valve. The temperature sensor is a PT100 sensor. The central control system dynamically adjusts the valve opening through PID calculation to achieve segmented program temperature control. 1) Sautéing stage: Maintain temperature at 105℃ for 10-15 minutes; during this stage, until the ginger and garlic turn golden yellow, the viscosity sensor will detect a 5%-8% increase in material viscosity and trigger a switch. 2) Maillard reaction stage: Heat to 110-130℃ and maintain for 20-25 minutes; during this period, the pH sensor monitors the pH value and triggers a switch when it drops to 5.5-6.0; 3) Stir-frying stage: Heat to 145-155℃ and continue for 8-12 minutes; during this stage, the concentration of flavor substances is monitored by an online near-infrared sensor and the switch is triggered when it reaches a preset threshold.

5. The control method according to claim 1, characterized in that, In step 2, the Maillard reaction precursor is added after the aromatic vegetables are stir-fried and removed, and before the water-containing materials such as broad bean paste are added. It is automatically added through a special feeding port integrated on the cover of the reactor (101). After stir-frying the aromatic vegetables and removing them, the vegetables can avoid side reactions with the precursor to generate bitter substances. Adding the precursor before the water-containing material ensures that the precursor dissolves and disperses rapidly in an anhydrous hot oil environment. When the water content is <1%, the Maillard reaction efficiency is increased by more than 30%. The Maillard reaction precursor includes amino acids, reducing sugars, and vitamin B1 complexes, wherein the amino acid is at least one of cysteine, methionine, glycine, and alanine, and the reducing sugar is at least one of xylose, glucose, and D-allulose.

6. The control method according to claim 1, characterized in that, In step 1, when raw materials are added into the reactor (101), the added fluid raw materials are automatically measured by the weighing module (111), and the weight of powder or materials added through the manhole is checked. Before weighing, the tare and zeroing operation is performed through the touch screen. When tare and zeroing, it is ensured that there are no additional equipment on the reactor (101) and that personnel do not lean against the equipment. The compressed air drainage function is activated to remove residual moisture from the jacket (103).

7. The control method according to claim 1, characterized in that, In step 1, when adding tallow to the reactor (101), precise quantitative oiling is achieved through the cooperation of the weighing module (111), pneumatic ball valve, and front-end oil supply pump.

8. The control method according to claim 1, characterized in that, In step 3, when the cooling system is turned on, the cooling function of the reactor (101) is turned on first, and then the cooling water system is turned on. After all the cooling processes are completed, the cooling water system is turned off. The corresponding pipes and valves connecting the reactor (101) and the jacket (103) are in the open state when they are working normally.

9. The control method according to claim 1, characterized in that, In step 2, during the intelligent reaction process, the water vapor and volatile flavor substances generated in the reactor (101) are exported to the shell-and-tube condenser. The water vapor is condensed and separated and discharged. The volatile aroma components are recovered through a cold trap or oil circulation system. The recovered aroma components can be added back into the reactor (101). The central control system is a PLC control system with a touch screen. The PLC control system has a built-in formula management function, which can save formulas with different process parameters and automatically record the key parameters of each batch of production, supporting traceability by batch number.

10. An integrated intelligent reaction vessel system for hot pot base seasoning based on Maillard reaction flavor regulation, characterized in that, It includes a reaction vessel (101), a combined stirring system, a multi-channel precision feeding device, a zoned temperature control thermal system, an exhaust and condensation recovery system, a weighing system, and a central control system; The reactor (101) body is made of 316L stainless steel and is equipped with a large surface area semi-pipe jacket (103) or a double spiral flow guide jacket (103). The combined stirring system is a liftable structure, including an anchor-type wall scraper that rotates close to the vessel wall and bottom, and an independently driven high-speed dispersion and homogenization head; The multi-channel precision feeding device is integrated into the cover plate of the reactor (101), including a liquid / oil phase inlet for initial oil feeding, a solid feeding port with a quick-opening lid for feeding large materials, and a sauce feeding port for feeding sauces. The zoned temperature control thermal system includes a high-temperature thermal oil furnace, a high-precision pneumatic regulating valve, and a PT100 temperature sensor. The high-temperature heat medium provided by the high-temperature thermal oil furnace enters the jacket (103) through the high-precision pneumatic regulating valve. The PT100 temperature sensor monitors the material temperature in real time and feeds back the signal. The exhaust and condensation recovery system includes a shell-and-tube condenser connected to the reactor (101) to exhaust water vapor and volatile flavor substances generated by the reaction. The system is also equipped with a cold trap or oil circulation system for recovering volatile aroma components, and a return path for returning the recovered aroma components to the reactor (101). The weighing system is electrically connected to the central control system and is used to automatically measure the input fluid raw materials and to verify the weight of powder or materials input through the manhole. The central control system is a PLC control system with a touch screen. The system has a built-in formula management function to save formulas with different process parameters, a time-series linkage control function to achieve precise linkage of temperature, stirring and feeding actions, and a data recording and traceability function to automatically record the key parameters of each batch of production and support query by batch number.

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