A pile-breaking and shifting process for producing sauce-flavor liquor

Abstract

The present invention belongs to the technical field of liquor brewing, and discloses a pile-breaking and shifting process for the production of sauce-flavor liquor, comprising the following steps: piling and saccharifying mash to form an initial saccharification pile; transferring the mash at the top of the initial saccharification pile to a target area as the center of a new saccharification pile; separating the mash remaining around the initial saccharification pile by peeling and surrounding it at the foot of the pile; transferring the mash at the foot of the pile in batches from the outside to the inside to the center of the saccharification pile covering the target area, and after multiple cycles, forming a shifted pile, and completing the pile-breaking and shifting. By adopting the "bottom-adjusting, peeling" pile-breaking and shifting method, mash with a lower temperature can be thoroughly saccharified and fermented. Compared with the current shifting technology, it can help the mash with a lower temperature in the saccharification pile to heat up better.

Description

Technical Field

[0001] The invention relates to the technical field of liquor brewing, in particular to a pile-breaking and shifting process for producing sauce-flavor liquor. Background Art

[0002] Maotai-flavor liquor belongs to the traditional manufacturing industry, characterized by long production cycles, unique and complex processes, and numerous uncontrollable factors. The stacking fermentation process plays a crucial role in baijiu production: it serves as a secondary koji-making step, saccharification and fermentation, secondary gelatinization, and aroma development. Direct cellaring without high-temperature stacking will result in no baijiu. Inadequate stacking time or temperature can affect the yield and quality of the base liquor.

[0003] In the process of making Maotai-flavor liquor, the following problems often occur during pile fermentation:

[0004] 1. The beneficial microorganisms and accumulated aroma substances in the saccharification pile that has not been piled at high temperature or the high temperature pile time is insufficient are few in variety and quantity, which affects the subsequent base wine production and quality;

[0005] Second, the center of the mash is tight and poorly oxygenated due to the weight of the mash, resulting in weak microbial growth and metabolic activity and low temperature, resulting in a "cold heart" (cold weather and slow heating of the mash will also cause a "cold heart"). The dextrin in this part of the mash shrinks and condenses, making it hard to the touch and less soft. The reaction between amylase and condensed dextrin is less effective, resulting in incomplete saccharification and fermentation and low fermentable sugar.

[0006] 3. The saccharification pile heats up quickly in summer, and the pile temperature is too high in a short period of time: (the mash clumps and changes from white to green), the starch loss is large, and the mash has a musty smell and is unpleasant to the nose.

[0007] The above problems will affect the high-temperature stacking fermentation effect of the mash and have an adverse impact on the subsequent base wine production and quality. Therefore, the method of "breaking the pile and shifting" is often used in the production process to avoid and remedy them.

[0008] The prior art document CN102994316B discloses a brewing process for a sauce-flavored liquor. The process adopts the method of breaking the pile before entering the cellar, and shifting the saccharification pile as a whole by turning the top over, the bottom over, and the center over, so as to control the uniform mixing of the upper, middle, and lower layers of mash. An exhaust fan is used to directly blow the mash to cool it down, thereby reducing the temperature of the mash, avoiding the death of microorganisms, and improving the wine yield.

[0009] The above method has the following defects: it ignores the temperature difference of the mash in different parts, lacks attention to the mash that has not been heated during the shifting process, and cannot ensure that the mash in the part with low stacking temperature is completely saccharified and fermented; in addition, the operation during the shifting process is not meticulous enough, resulting in unsatisfactory pile-breaking and shifting effects.

[0010] Therefore, it is necessary to propose a pile-breaking and shifting process for the production of sauce-flavor liquor to solve the above problems. Summary of the Invention

[0011] The invention provides a pile-breaking and shifting process for producing sauce-flavor liquor. By adopting a "bottom-adjusting and peeling" pile-breaking and shifting method, mash with a relatively low temperature can be completely saccharified and fermented, and the pile-breaking and shifting effect is good.

[0012] According to some embodiments, the present invention provides a pile-breaking and shifting process for the production of sauce-flavor liquor, comprising the following steps: piling and saccharifying the mash to form an initial saccharification pile; transferring the mash at the top of the initial saccharification pile to a target area as the center of a new saccharification pile; separating the mash remaining around the initial saccharification pile by peeling and surrounding it at the foot of the pile; transferring the mash at the foot of the pile in batches from the outside to the inside to the center of the saccharification pile covering the target area, and forming a shifted pile after multiple cycles, thereby completing the pile-breaking and shifting process.

[0013] Preferably, the step of transferring the mash on the top of the initial saccharification pile to the target area as the center of the new saccharification pile includes: planning an open space in advance as the target area, the target area serving as the new accumulation point of the saccharification pile, and ensuring that the target area is dry, clean and free of debris.

[0014] Preferably, the transferring of the mash at the top of the initial saccharification pile to the target area as the center of the new saccharification pile further comprises: using a grab bucket of a bridge crane to grab the mash at a depth of 40-60 cm from the center of the top of the initial saccharification pile to the target area, and this portion of the mash serves as the center of the new saccharification pile.

[0015] Preferably, the peeling separation of the remaining mash around the initial saccharification pile and surrounding it at the foot of the pile includes: manually using a rake comb to peel the remaining mash from the top to the bottom and surrounding it at the foot of the pile to separate the mash with a better temperature from the mash with a lower temperature.

[0016] Preferably, when manually peeling the fermented grains with a higher temperature and those with a lower temperature, the horizontal digging depth is controlled to be 30 to 50 cm.

[0017] Preferably, the mash at the foot of the pile is transferred in batches from the outside to the inside to the center of the saccharification pile covering the target area, and a shift pile is formed after multiple cycles to complete the pile breaking and shifting, including: manually using a rake comb to pull and dig out the mash with a better temperature that has been separated by peeling; using the grab bucket of a bridge crane to grab half a bucket of the mash that has been pulled and dug out and has a better temperature to evenly cover the surface of the center of the saccharification pile.

[0018] Preferably, after the transfer of the mash with a better temperature is completed, the mash with a lower temperature that has been separated by peeling is manually stretched and scooped out using a rake comb; the stretched and scooped mash with a lower temperature is evenly covered on the surface of the center of the saccharification pile by grabbing half a bucket of the mash with the grab bucket of a bridge crane each time.

[0019] Preferably, when using a grab bucket to grab the mash, the grab opening of the grab bucket is controlled to retain a certain gap to prevent the scooped mash from being squeezed into clumps, which affects the dissolved oxygen effect.

[0020] Preferably, when using a grab bucket to grab the mash, the mash temperature is measured and screened one by one at the top, middle and bottom of the initial saccharification pile by touching with the skin of the hand or using a thermometer to ensure that the grab bucket is shifted in sequence according to the mash temperature.

[0021] The embodiments of the present disclosure have at least the following advantages:

[0022] The "bottom-adjusting and peeling" pile-breaking and shifting method is adopted, which can accurately peel out the mash with better fermentation temperature and pile it in the center of the new saccharification pile, and evenly disperse the mash with lower temperature on the surface of the new saccharification pile, effectively preventing the mash with higher temperature from agglomerating and losing too much starch. At the same time, it serves as a power source to start fermentation, allowing the mash with lower temperature to be thoroughly saccharified. This method requires meticulous operation during the shifting process and has a good pile-breaking and shifting effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the conventional technology, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0024] Figure 1 This is a schematic flow chart of a pile-breaking and shifting process for producing Maotai-flavor liquor in this embodiment;

[0025] Figure 2 Schematic diagram of the "flat top" stacking saccharification method in this embodiment;

[0026] Figure 3 Schematic diagram of the "top-type" stacking saccharification method in this embodiment;

[0027] Figure 4 Schematic diagram of the initial saccharification pile before pile breaking and displacement in this embodiment;

[0028] Figure 5 This is a schematic diagram of the top layer of the initial saccharification pile and the surrounding unfermented mash after stripping is completed;

[0029] Figure 6 Schematic diagram of the shifted saccharification pile after the pile breaking and shifting are completed in this embodiment. DETAILED DESCRIPTION

[0030] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, it will be understood by those skilled in the art that in the embodiments of the present invention, many technical details are provided to enable the reader to better understand the present invention. However, even without these technical details and the various changes and modifications based on the following embodiments, the technical solutions claimed in the present invention can be implemented. The division of the following embodiments is for convenience of description and should not constitute any limitation on the specific implementation of the present invention. The various embodiments can be combined with each other and referenced to each other under the premise that there is no contradiction.

[0031] The following is a detailed description of a method for producing a Maotai-flavor liquor by breaking piles and shifting piles provided by this embodiment in conjunction with the accompanying drawings. Figure 1 As shown, the following steps are included:

[0032] S101, stacking and saccharifying the mash to form an initial saccharification pile;

[0033] S102, transferring the mash at the top of the initial saccharification pile to the target area as the center of a new saccharification pile;

[0034] S103, separating the remaining mash around the initial saccharification pile by peeling and surrounding it at the foot of the pile;

[0035] S104, transferring the mash at the foot of the pile from the outside to the inside in batches to the center of the saccharification pile within the target area, and forming a shifted saccharification pile after multiple cycles, thus completing the pile breaking and shifting.

[0036] In the present invention, the mash with a better temperature at the top of the initial saccharification pile is transferred to the target area as the center of the new saccharification pile, and then the remaining initial saccharification pile is separated by peeling and surrounded at the foot of the pile. The peeling separation can accurately separate the mash with a better fermentation temperature from the mash with a worse fermentation temperature. The mash with a better fermentation temperature is transferred in batches to the center of the saccharification pile covering the target area for stacking. After the mash with a better fermentation temperature in the outer layer is transferred, the mash with a worse fermentation temperature in the inner layer is transferred in batches to the surface layer uniformly dispersed in the center of the saccharification pile. This can prevent the mash with a higher temperature from agglomerating and losing too much starch, and at the same time serve as a power source for starting fermentation to allow the mash with a worse temperature to be thoroughly saccharified.

[0037] Each step in this embodiment is described in detail below.

[0038] Reference Figure 1 As shown, S101, the mash is piled up for saccharification to form an initial saccharification pile;

[0039] In this embodiment, stacking saccharification is a very unique and critical process in the brewing of Maotai-flavor liquor. The quality of stacking saccharification directly affects the fermentation effect in the cellar and determines the yield and quality of the base liquor. Figure 2 As shown, the "flat-top" stacking saccharification method is: the mash is manually shoveled into the grab bucket equipment of the bridge crane, the grab bucket is lifted to the top of the saccharification pile, and the mash in the grab bucket is slowly and evenly dropped clockwise or counterclockwise along the top outer edge of the saccharification pile. The mash slides down naturally and the top of the pile becomes a circular plane. Until the saccharification pile is completely dropped, the initial saccharification pile can be formed.

[0040] Reference Figure 3 As shown in the figure, the "top-type" stacking saccharification method: the mash is manually shoveled into the grab bucket of the bridge crane, the grab bucket is lifted to the top of the saccharification pile, and the mash in the grab bucket is slowly and evenly dropped from the center point of the pile top. The mash slides down naturally and the top of the pile becomes a pointed cone shape until the saccharification pile is completely dropped, and then the initial saccharification pile can be formed.

[0041] Reference Figure 1 As shown, S102, the mash at the top of the initial saccharification pile is transferred to the target area as the center of the new saccharification pile;

[0042] In this embodiment, it should be noted that after the mash is piled up to form an initial saccharification pile, since the fermentation temperature of the mash on the surface of the initial saccharification pile is higher and the fermentation temperature of the mash inside is lower, in order to avoid the mash with a higher internal temperature from agglomerating and wasting too much starch, the mash with a higher internal fermentation temperature is specially peeled off as the center of a new saccharification pile. The specific method is: plan enough open space in advance as a target area, and the target area is used as a new stacking point for the saccharification pile, and ensure that the target area is dry, clean and free of debris; Figure 4 As shown, the grab bucket of a bridge crane is used to grab the mash 40-60 cm from the top of the initial saccharification pile to the target area. This portion of mash serves as the center of the new saccharification pile. Preferably, the grab depth from the top of the initial saccharification pile is controlled to approximately 50 cm. The mash at this depth has better porosity and dissolved oxygen conditions, resulting in the best fermentation results and the highest temperature, typically ≥ 46°C. However, the actual grab depth can be adjusted appropriately based on the mash temperature and is not specifically limited in this embodiment. If the grab depth is too great, mash with a lower temperature is easily grabbed. Therefore, in this embodiment, the grab depth is controlled to approximately 50 cm.

[0043] Reference Figure 1 As shown, S103, the mash remaining around the initial saccharification pile is separated by peeling and surrounded at the foot of the pile;

[0044] In this embodiment, it should be noted that Figure 5As shown, after the mash with a higher fermentation temperature inside the initial saccharification pile is separated, the remaining mash around the initial saccharification pile is manually pulled down from top to bottom in a peeling manner and wrapped around the foot of the pile, and processed carefully and loosely to separate the mash with a higher temperature from the mash with a lower temperature. In this process, the horizontal digging depth is controlled at 30 to 50 cm. The mash at this horizontal depth has a better fermentation effect and a higher temperature, usually between 35-46°C.

[0045] Reference Figure 1 As shown, S104, the mash at the base of the pile is transferred in batches to the center of the saccharification pile within the target area, and after multiple cycles, a shifted saccharification pile is formed, completing the pile breaking and shifting:

[0046] In this embodiment, it should be noted that, after the remaining mash around the initial saccharification pile is separated by peeling and surrounded at the foot of the pile, a rake comb is used to manually pull and dig out the mash with a better temperature that was separated by peeling, and the mash that was pulled and dug out and has a better temperature is evenly covered on the center surface of the new saccharification pile by grabbing half a bucket of mash each time with a grab bucket, as the "middle layer" of the shifted saccharification pile. Subsequently, after the mash with a better temperature is transferred, about half a pile of mash is left in a circle from the outside to the inside. At this time, a rake comb is continued to be used to pull and dig out the mash with a lower temperature that was separated by peeling, and the mash that was pulled and dug out and has a lower temperature is evenly covered on the new saccharification pile by grabbing half a bucket of mash each time with a grab bucket, and the shifted saccharification pile is formed after multiple cycles (such as Figure 6 As shown), the stack breaking and shifting are completed.

[0047] In addition, in the above-mentioned peeling separation operation, manual operation can ensure that the mash with a higher temperature is accurately peeled and separated from the mash with a lower temperature, while direct use of a forklift and a grab bucket cannot guarantee the operation accuracy.

[0048] In this embodiment, it should also be noted that when using a grab bucket to grab the mash, the grip should be avoided from being completely closed, and a certain gap should be maintained in the grip to prevent the scooped mash from being squeezed and formed into clumps, which would affect the dissolved oxygen effect. At the same time, when the grab bucket is grabbing the material, the operator needs to use the skin of the hand or a thermometer to measure and screen the mash temperature at the top, middle, and bottom of the initial saccharification pile one by one, and direct the grab bucket to shift in sequence according to the temperature of the mash, ensuring that the temperature gradient of the mash decreases from the inside to the outside of the shifted saccharification pile. Then, the mash with a lower temperature in the initial saccharification pile can be placed on the surface of the shifted saccharification pile, allowing it to better dissolve oxygen and trap microorganisms, ensuring its thorough saccharification and fermentation.

[0049] The pile-breaking and shifting process adopted in the embodiment of the present invention can accurately separate the mash with a better fermentation temperature and pile it in the center of a new saccharification pile, and evenly disperse the mash with a lower temperature on the surface of the new saccharification pile. In hot weather, the mash with a higher temperature can be effectively prevented from agglomerating and wasting too much starch when the stacking time is extended. At the same time, it serves as a power source for starting fermentation, allowing the mash with a lower temperature to be thoroughly saccharified, and can also solve the problem of "slow start-up and heating" of the saccharification pile in low temperature weather.

[0050] The following examples demonstrate the effects of the stack breaking and shifting process in this embodiment:

[0051] Table 1

[0052]

[0053] In order to verify the technical effect of the pile-breaking and shifting process, 30 saccharification piles in the same production room were selected for experimental comparison during the first and fifth rounds of Maotai-flavor liquor production, respectively. Among them, 10 saccharification piles were not shifted, the current pile-breaking and shifting method was used, and the new technology shifted method was used. When all saccharification piles met the cellar entry standards (a layer of white microbial colonies was generated on the surface of the saccharification pile, and the shells were slightly peeled but not clumped), the top, middle and bottom temperatures of the piles were measured. The measurement method was as follows: after the pile fermentation was completed, 3 points were selected on the top, middle and bottom sides of the pile, and the temperature of the mash was measured with a thermometer. The top temperature was measured at the position with the highest temperature, and the thermometer was inserted 10 cm parallel to the ground; the middle temperature was measured at 80-100 cm above the ground (high in winter and low in summer), and the thermometer was inserted 100 cm parallel to the ground; the bottom temperature was measured at 30-40 cm above the ground (high in winter and low in summer), and the thermometer was inserted 100 cm parallel to the ground; the average temperature of the pile top, middle and bottom was recorded, and the average value of the obtained data is shown in Table 1 above. It can be seen that both the new shifting technology of the present invention and the current shifting technology are beneficial for improving the high-temperature stacking effect. In winter, they can effectively accelerate the heating rate of the saccharification pile and increase the fermentation temperature of the mash. In summer, they can extend the stacking time and improve the fermentation effect. In particular, the new shifting technology of the present invention, namely the broken pile shifting process scheme, has higher temperatures at the middle and bottom of the saccharification pile than the current shifting technology in both winter and summer. It can be judged that it is more effective in helping to heat the mash with a lower temperature in the saccharification pile.

[0054] It should be understood that the above-described specific embodiments of the present invention are merely illustrative or illustrative of the principles of the present invention and do not constitute limitations of the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc. made without departing from the spirit and scope of the present invention should be included within the scope of protection of the present invention. In addition, the appended claims are intended to cover all variations and modifications that fall within the scope and metes and bounds of the appended claims or their equivalents.

Claims

1. A pile breaking and shifting process for producing Maotai-flavor liquor, characterized in that: The steps include: The mash is piled up for saccharification to form an initial saccharification pile; Transfer the mash from the top of the initial mash pile to the target area as the center of the new mash pile; The remaining mash around the initial saccharification pile is separated by peeling and placed at the foot of the pile; The mash at the foot of the pile is transferred in batches from the outside to the inside to the center of the saccharification pile covering the target area. After multiple cycles, a shift pile is formed, completing the pile breaking and shifting. The method of transferring the mash at the top of the initial saccharification pile to the target area as the center of the new saccharification pile further includes: Use the grab bucket of the bridge crane to grab the mash at a depth of 40-60 cm from the top of the initial saccharification pile to the target area, and this part of the mash will serve as the center of the new saccharification pile; The method of separating the remaining mash around the initial saccharification pile by peeling and surrounding it at the foot of the pile includes: Manually use a rake comb to peel the remaining initial saccharification pile from top to bottom and pull the mash down to the bottom of the pile to separate the mash with better temperature from the mash with lower temperature; The method of transferring the mash at the foot of the pile from the outside to the inside in batches to the center of the saccharification pile within the target area is repeated multiple times to form a displacement pile, thereby completing the pile breaking and displacement, including: Manually use rake combs to separate and dig out the fermented mash with a better temperature after peeling; Use the grab bucket of a bridge crane to grab half a bucket of the loosened, finely dug, and high-temperature mash each time and evenly cover the surface of the saccharification pile; After the transfer of the fermented mash with a better temperature is completed, the fermented mash with a lower temperature separated by peeling is manually separated and scooped out with a rake comb. The loosened, finely dug and low-temperature mash is evenly covered on the surface of the saccharification pile by using the grab bucket of a bridge crane to grab half a bucket of mash each time.

2. The process for breaking piles and shifting the production of Maotai-flavor liquor according to claim 1, characterized in that: The step of transferring the mash at the top of the initial saccharification pile to the target area as the center of the new saccharification pile comprises: Plan an open space in advance as a target area, which will serve as a new accumulation point for the saccharification pile, and ensure that the target area is dry, clean, and free of debris.

3. The process for breaking piles and shifting the production of Maotai-flavor liquor according to claim 1, characterized in that: When manually peeling the mash with a higher temperature and the mash with a lower temperature, the horizontal digging depth is controlled at 30 to 50 cm.

4. The process for breaking piles and shifting the production of Maotai-flavor liquor according to claim 1, characterized in that: When using a grab bucket to grab the mash, control the grab mouth to keep a certain gap to prevent the scooped mash from being squeezed into clumps, which will affect the dissolved oxygen effect.

5. The process for breaking piles and shifting the production of Maotai-flavor liquor according to claim 4, characterized in that: When using a grab bucket to grab the mash, the temperature of the mash is measured and screened one by one at the top, middle and bottom of the initial saccharification pile by touching with the skin of the hand or using a thermometer to ensure that the grab bucket is shifted in sequence according to the temperature of the mash.

Images