Waste recycling method of soybean paste fermentation byproduct water yellow

Abstract

The invention discloses a waste recycling method of soybean paste fermentation byproduct water yellow, which comprises the following steps: (1) byproduct separation: filtering fermented soybean paste mash by using a vibrating screen A to obtain soybean paste blank and soybean paste water yellow A; (2) treating by-products: 1, filtering the soybean sauce water yellow A by using a vibrating screen B of which the mesh number is larger than that of the vibrating screen A, and removing broken beans in the soybean sauce water yellow A to obtain soybean sauce water yellow B; (3) byproduct treatment (2): adding the soybean sauce water yellow B into a fermentation tank containing soy sauce residues, uniformly mixing the soybean sauce water yellow B with the soy sauce residues to obtain soy sauce mash, and fermenting; after the fermentation is completed, stirring the soy sauce mash and then carrying out filter pressing to obtain a new product, namely water yellow C; (4) new product treatment: placing the water yellow C in a self-settling tank for self-settling to obtain clear water yellow D and turbid water yellow E; the clarified water yellow D is used as soybean sauce secondary oil, and the water yellow E is recycled and treated together with the next batch of soybean sauce water yellow B.

Description

Technical Field

[0001] The invention belongs to the field of resource utilization of processing by-products in the technical field of food processing, and specifically relates to a method for recycling waste of soybean paste fermentation by-product water yellow. Background Art

[0002] Soybean paste is a semi-fluid seasoning food made from soybeans and flour as the main raw materials, salt and water as auxiliary materials, and Aspergillus oryzae as the main strain. At present, the production process of soybean paste includes the following steps:

[0003] (1) firstly remove impurities from soybeans and then soak them, then remove the soaking water and then steam the soybeans;

[0004] (2) The steamed soybeans are mixed with flour and inoculated with bacteria to prepare Daqu;

[0005] (3) The prepared Daqu and salt water are mixed into a sauce mash at a material-water mass ratio of 1.5:1 to 0.8, and fermented at room temperature. During the fermentation process, the solid matter and water in the sauce mash will gradually separate into layers to form a solid sauce mash layer; therefore, in order to fully mix and ferment the sauce mash layer with the salt water, an oxygenation operation is performed from time to time during the fermentation process, that is, the two are mixed by stirring;

[0006] (4) finally, the fermentation of the mash is completed, and the soybean paste embryo is obtained after filtration;

[0007] (5) The soybean paste embryo is boiled and blended to obtain soybean paste.

[0008] In the prior art, the above-mentioned step (4) of filtering after the fermentation of the sauce mash is completed is usually to stir the sauce mash in the fermentation tank, and then use a stainless steel perforated plate or a gauze to filter it, so as to separate the soybean paste embryo and the byproduct, the soybean paste fermentation liquid, commonly known as soybean paste water yellow. Since a high material-water ratio and oxygenation operation are used in the soybean paste production process, the water yellow has a high viscosity, so in order to successfully complete the filtration, a stainless steel perforated plate or a gauze with an 8-10 mesh is generally used to filter the sauce mash.

[0009] The disadvantages of the above prior art are: ① Low filtration efficiency, only 6 to 10 m 3 / h; ② The yield of soybean embryo is not high, usually less than 50%. Even if some manufacturers further filter the water yellow with a stainless steel perforated plate or gauze with a larger mesh (such as 20 mesh, 30 mesh), and recycle the broken beans remaining in the water yellow into the soybean paste embryo to increase the yield of soybean paste embryo, the yield of soybean paste embryo is still only 50%.

[0010] However, most manufacturers currently do not recycle the yellow water, but instead treat it as wastewater before discharging it. Taking the applicant as an example, 3,000 to 5,000 tons of yellow water is produced in the production of soybean paste every year; the cost of environmentally friendly treatment of the yellow water so that it meets the discharge standards is about 100,000 yuan; therefore, the recycling rate of soybean paste produced by existing technologies is actually only 50% at most. This is not only a waste of resources, but also increases the pressure and cost of sewage treatment.

[0011] The applicant tested the yellowish water produced by the produced soybean paste and found that the amino acid nitrogen in the yellowish water of the soybean paste was about 0.5-1.1 g / 100 ml, and it had a strong sauce flavor. If a method for recycling the yellowish water can be developed, waste utilization can not only reduce the pressure of sewage treatment and be environmentally friendly; it can also improve the utilization rate of raw materials and production efficiency, and achieve the circular economy goal of low input, high utilization and low waste emissions. Summary of the invention

[0012] The purpose of the present invention is to provide a waste recycling method for soybean paste fermentation by-product water yellow, which can convert soybean paste water yellow into valuable soy sauce products, turning waste into treasure, not only realizing waste resource utilization, and improving the recycling rate of soybean paste and sauce mash, reducing production costs, but also greatly reducing wastewater discharge, being green and environmentally friendly, thereby achieving the circular economy purpose of low input, high utilization and low waste emission in economic production.

[0013] The present invention mainly achieves the above purpose by separating and treating the soybean paste fermentation byproduct water yellow, and specifically adopts the following technical scheme.

[0014] A method for recycling waste water yellow, a byproduct of soybean paste fermentation, comprises the following steps:

[0015] (1) Byproduct separation: The fermented soybean paste mash is filtered using a vibrating screen A to separate the soybean paste embryo from the soybean paste water yellow to obtain the soybean paste embryo and soybean paste water yellow A;

[0016] (2) Byproduct treatment ①: Filter soybean paste water yellow A through a vibrating screen B with a larger mesh than that of the vibrating screen A to remove broken beans in soybean paste water yellow A to obtain soybean paste water yellow B; add the broken beans to the soybean paste embryo;

[0017] (3) By-product treatment ②: Add soybean sauce water yellow B to a fermentation tank containing soy sauce residue, and mix soybean sauce water yellow B and soy sauce residue evenly to obtain soy sauce mash, which is then fermented; after the fermentation is completed, stir the soy sauce mash and pump it into a filter press, and filter to obtain a new product - water yellow C;

[0018] (4) Treatment of new products: Place water yellow C in a self-sinking tank to sink to obtain clear water yellow D and turbid water yellow E;

[0019] The clarified yellow soy sauce D is used as the second oil of soy sauce, and the yellow soy sauce E is recovered and processed together with the next batch of soybean sauce yellow soy sauce B in steps (3) to (4).

[0020] The fermentation tank containing soy sauce residue refers to a fermentation tank after the soy sauce head oil has been released (hereinafter referred to as: Erhuang tank), and at this time, the tank contains soy sauce residue.

[0021] The soybean paste embryo of the present invention is mainly composed of fermented soybean grains and is in a solid form, while the soybean paste water yellow, hereinafter referred to as water yellow, is mainly a fermented solution and is in a relatively viscous liquid form. The vibrating screen is mainly composed of a screen and a vibrator, and the soybean paste mash or water yellow on the screen can be quickly and effectively separated from the solid and liquid by vibration to obtain soybean paste embryo and water yellow A, or broken beans and water yellow B.

[0022] During the research and development process, the inventors found that the quality indicators of water yellow A are similar to those of secondary soy sauce, but its turbidity is more than 3 times that of secondary soy sauce. Therefore, the inventors conducted filtration tests on water yellow A in various ways, using sieves with different mesh sizes to recover and collect soybean grains of different sizes in the fermented soybean paste mash and broken beans in water yellow. Finally, based on the quality requirements of filtration, production efficiency, production cost and other factors, the above-mentioned technical solution of utilizing the different characteristics of water yellow and soybean paste embryos and using vibrating sieves with different apertures for secondary separation combined with water yellow fermentation was determined, so that the fermented soybean paste materials can be 100% recycled, and the turbidity of water yellow D (i.e., the second oil) is controlled within 550ppm, achieving the quality of soy sauce, and will not increase the pressure on the subsequent processing procedures of soy sauce. Therefore, compared with the prior art, the filtration efficiency is high, the water yellow of the present invention has a high recycling rate, and the yield of soybean paste embryos is increased, so as to achieve 100% recycling of soybean paste mash (i.e., materials fermented from soybean paste), thereby improving production efficiency. The present invention increases the yield of soybean paste embryos and utilizes the water yellow as a resource, which not only improves the utilization rate of mash, but also can recycle and reuse the waste water yellow, turning waste into treasure, reducing sewage discharge, and even zero discharge, thereby realizing green production and circular economy industry.

[0023] The present invention has been confirmed through a large number of experiments that adding water yellow B to the second yellow tank instead of salt water for soy sauce fermentation can obtain a soy sauce product with higher quality than the soy sauce second oil (second-stage soy sauce) obtained by conventional fermentation, and at the same time, the working hours for processing water yellow will not be increased and the production efficiency will not be reduced. However, the inventors found that if soybean paste water yellow B is added to the three yellow tank (i.e., the soy sauce fermentation tank after the second rinsing) for fermentation, the quality of the product obtained is worse than that of water yellow A, and its amino acid nitrogen is only 0.2g / 100ml.

[0024] The method adds the soybean paste water yellow B obtained by secondary separation into the second yellow tank for fermentation, that is, fermenting the water yellow and the soy sauce residue in the second yellow tank, which can not only improve the treatment efficiency of by-products and turn them into treasures, but also make full use of the nutrients and flavor substances of the water yellow and the soy sauce residue, thereby improving the quality of the obtained soy sauce second oil.

[0025] The clarified yellow water D is used as the second oil of soy sauce, and the soy sauce product is obtained after cooking and blending.

[0026] The mesh of the vibrating screen A is 8-30 mesh.

[0027] The mesh size of the vibrating screen B is 30 to 100 meshes.

[0028] The added mass of the soybean sauce yellow B is 10-100% of the soy sauce residue.

[0029] The fermentation time is 5 to 60 days.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] 1. The present invention provides a solution for recycling water yellow, which specifically utilizes the different characteristics of water yellow and soybean paste embryos, uses different mesh vibrating screens for grading treatment combined with water yellow fermentation, so that all broken beans are recovered, the yield of soybean paste embryos is increased by 7.5%, and the recycling rate of water yellow is increased to 100%; therefore, the present invention realizes 100% recycling of soybean paste mash;

[0032] The invention ferments and squeezes the soybean paste water yellow obtained by secondary separation of a vibrating screen and the soy sauce residue (added to the two yellow tank) together, and finally obtains the water yellow D with a turbidity controlled within 550ppm, which meets the standard of soy sauce, does not increase pressure on subsequent soy sauce processing procedures, and can fully utilize the water yellow and the soy sauce residue to obtain a soy sauce product with higher quality than the two soy sauce oils, realizes resource utilization of by-products, solves the problem of insufficient utilization of soybean paste fermentation products, and improves raw material utilization and production efficiency;

[0033] Taking the applicant as an example, by adopting the method of the present invention, the annual recovery of broken beans can increase the income by about 200,000 yuan, and the recovery of 5,000 tons of water yellow to replace brine to produce second oil can obtain a profit of about 6.7 million yuan. In addition, it can also reduce the cost of environmental protection treatment of water yellow by about 100,000 yuan.

[0034] 2. The present invention adopts a vibrating screen to improve the filtration efficiency of the mash, which can reach 12-18m 3 / h, the filtration efficiency of the present invention is improved by 100% or even 200% compared with the prior art; at the same time, soybean paste water yellow B is added to the second yellow tank instead of salt water for fermentation to obtain the second oil, which will not increase the working hours or reduce the production efficiency due to the treatment of water yellow.

[0035] 3. The method for treating by-products provided by the present invention is simple in treatment mode and can make full use of the equipment commonly used in the industry, improve the utilization rate of raw materials and production efficiency, and achieve the circular economy goal of low investment, high utilization and low waste emission. DETAILED DESCRIPTION

[0036] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0037] Example 1

[0038] (1) 100 kg of soybean paste mash was filtered through a 3-mesh vibrating sieve to separate soybean paste embryo and soybean paste water yellow A.

[0039] (2) Filter the soybean paste water yellow A through a 20-mesh vibrating screen to separate into small granules of broken beans and soybean paste water yellow B; add the broken beans into the soybean paste embryo.

[0040] (3) Adding soybean sauce water yellow B into the second yellow tank at a weight ratio of 10% of the soy sauce residue, and mixing the water yellow B and the soy sauce residue evenly to obtain soy sauce mash; after fermenting for 5 days, stirring the soy sauce mash and filtering it with a filter press to obtain water yellow C.

[0041] (4) After the yellow water C is placed in a self-sinking tank and self-sinked, clear yellow water D and turbid yellow water E are obtained;

[0042] Water yellow D is used as the second oil of soy sauce and can be boiled and blended to become a soy sauce product. Water yellow E is fermented in the second oil tank and then pressed and recycled for further processing, that is, it is processed with the next batch of soybean sauce water yellow B in steps (3) to (4).

[0043] Example 2

[0044] (1) 100 kg of soybean paste mash was filtered through a 4-mesh vibrating sieve to separate soybean paste embryo and soybean paste water yellow A.

[0045] (2) Filter the soybean paste water yellow A through a 30-mesh vibrating screen to separate small broken beans and soybean paste water yellow B; add the broken beans into the soybean paste embryo.

[0046] (3) Adding soybean sauce water yellow B into the second yellow tank at a weight ratio of 10% of the soy sauce residue, and mixing the water yellow B and the soy sauce residue evenly to obtain soy sauce mash; after fermenting for 5 days, stirring the soy sauce mash and filtering it with a filter press to obtain water yellow C.

[0047] (4) After the yellow water C is placed in a self-sinking tank and self-sinked, clear yellow water D and turbid yellow water E are obtained;

[0048] Water yellow D is used as the second oil of soy sauce and can be boiled and blended to become a soy sauce product. Water yellow E is fermented in the second oil tank and then pressed and recycled for further processing, that is, it is processed with the next batch of soybean sauce water yellow B in steps (3) to (4).

[0049] Example 3

[0050] (1) 100 kg of soybean paste mash was filtered through a 5-mesh vibrating sieve to separate soybean paste embryo and soybean paste water yellow A.

[0051] (2) Filter the soybean paste water yellow A through a 40-mesh vibrating screen to separate small broken beans and soybean paste water yellow B; add the broken beans into the soybean paste embryo.

[0052] (3) Adding soybean sauce water yellow B into the second yellow tank at a weight ratio of 50% of the soy sauce residue, and mixing the water yellow B and the soy sauce residue evenly to obtain soy sauce mash; after fermentation for 35 days, stirring the soy sauce mash and filtering it with a filter press to obtain water yellow C.

[0053] (4) After the yellow water C is placed in a self-sinking tank and self-sinked, clear yellow water D and turbid yellow water E are obtained;

[0054] Water yellow D is used as the second oil of soy sauce and can be boiled and blended to become a soy sauce product. Water yellow E is fermented in the second oil tank and then pressed and recycled for further processing, that is, it is processed with the next batch of soybean sauce water yellow B in steps (3) to (4).

[0055] Example 4

[0056] (1) 100 kg of soybean paste mash was filtered through an 8-mesh vibrating sieve to separate soybean paste embryo and soybean paste water yellow A.

[0057] (2) Filter the soybean paste water yellow A through a 40-mesh vibrating screen to separate small broken beans and soybean paste water yellow B; add the broken beans into the soybean paste embryo.

[0058] (3) Adding soybean sauce water yellow B into the second yellow tank at a weight ratio of 50% of the soy sauce residue, and mixing the water yellow B and the soy sauce residue evenly to obtain soy sauce mash; after fermentation for 35 days, stirring the soy sauce mash and filtering it with a filter press to obtain water yellow C.

[0059] (4) After the yellow water C is placed in a self-sinking tank and self-sinked, clear yellow water D and turbid yellow water E are obtained;

[0060] Water yellow D is used as the second oil of soy sauce and can be made into soy sauce after being boiled and blended. Water yellow E is fermented in the second yellow tank and then pressed and recycled for further processing, that is, it is processed with the next batch of soybean sauce water yellow B in steps (3) to (4).

[0061] Example 5

[0062] (1) 100 kg of soybean paste mash was filtered through a 10-mesh vibrating sieve to separate soybean paste embryo and soybean paste water yellow A.

[0063] (2) Filter the soybean paste water yellow A through a 50-mesh vibrating screen to separate small broken beans and soybean paste water yellow B; add the broken beans into the soybean paste embryo.

[0064] (3) Adding soybean sauce water yellow B into the second yellow tank at a weight ratio of 80% of the soy sauce residue, and mixing the water yellow B and the soy sauce residue evenly to obtain soy sauce mash; after fermenting for 60 days, stirring the soy sauce mash and filtering it with a filter press to obtain water yellow C.

[0065] (4) After the yellow water C is placed in a self-sinking tank and self-sinked, clear yellow water D and turbid yellow water E are obtained;

[0066] Water yellow D is used as the second oil of soy sauce and can be made into soy sauce after being boiled and blended. Water yellow E is fermented in the second yellow tank and then pressed and recycled for further processing, that is, it is processed with the next batch of soybean sauce water yellow B in steps (3) to (4).

[0067] Example 6

[0068] (1) 100 kg of soybean paste mash was filtered through a 20-mesh vibrating sieve to separate soybean paste embryo and soybean paste water yellow A.

[0069] (2) Filter the soybean paste water yellow A through a 50-mesh vibrating screen to separate small broken beans and soybean paste water yellow B; add the broken beans into the soybean paste embryo.

[0070] (3) Adding soybean sauce water yellow B into the second yellow tank at a weight ratio of 80% of the soy sauce residue, and mixing the water yellow B and the soy sauce residue evenly to obtain soy sauce mash; after fermenting for 60 days, stirring the soy sauce mash and filtering it with a filter press to obtain water yellow C.

[0071] (4) After the yellow water C is placed in a self-sinking tank and self-sinked, clear yellow water D and turbid yellow water E are obtained;

[0072] Water yellow D is used as the second oil of soy sauce and can be made into soy sauce after being boiled and blended. Water yellow E is fermented in the second yellow tank and then pressed and recycled for further processing, that is, it is processed with the next batch of soybean sauce water yellow B in steps (3) to (4).

[0073] Table 1 Process parameters of Examples 1 to 6

[0074] Example Vibrating screen A mesh Vibrating screen B mesh The proportion of water yellow B added during fermentation Fermentation days Example 1 3 20 10％ 5 days Example 2 4 30 10％ 5 days Example 3 5 40 50％ 35 days Example 4 8 40 50％ 35 days Example 5 10 50 80％ 60 days Example 6 20 50 80％ 60 days

[0075] Comparative evaluation and analysis: The amount of recycled products and the water yellowing index in different implementation cases of the present invention, as well as the treatment efficiency of different embodiments are statistically analyzed. The results are shown in Table 2 below.

[0076] Table 2 Statistics of soybean paste fermentation products and water yellow index

[0077]

[0078]

[0079] Table 3 Yellowing index of soybean paste and soy sauce treated by existing methods

[0080]

[0081] Note: The yellow soybean paste in Table 3 is the yellow soybean paste filtered once through a 10-mesh stainless steel perforated plate, and the first oil and second oil are the soy sauce that is self-leached after normal fermentation in the existing technology.

[0082] From the results in Table 2, it can be seen that the method of the present invention can reduce the turbidity of water yellow and control it within 550ppm; and the results in Table 2 show that the method of the present invention can achieve 100% utilization of soybean paste sauce mash, that is, the present invention realizes the resource utilization of water yellow and soy sauce residue, and also improves the yield of soybean paste embryo. In addition, considering the production efficiency (i.e., the addition ratio of water yellow B and the number of fermentation days) and the index of the final recovery of water yellow, Examples 5 and 6 are preferred implementations.

[0083] The results of Tables 2 and 3 show that the amino acid nitrogen index of the soy sauce obtained by the present invention through the co-fermentation of soybean paste water yellow and the two yellow pot soy sauce residue is significantly higher than that of the untreated soybean paste water yellow, and is also higher than the index level of the soy sauce two oil obtained by self-leaching after normal fermentation. Specifically, the amino acid nitrogen level of the soy sauce prepared by the method of the present invention can be increased by 20% compared with the untreated soybean paste water yellow, and can be increased by 11% compared with the soy sauce two oil.

Claims

1. A method for recycling waste water yellow, a byproduct of soybean paste fermentation, characterized in that: The following steps are involved: (1) Byproduct separation: The fermented soybean paste mash is filtered using a vibrating screen A to separate the soybean paste embryo from the soybean paste water yellow to obtain the soybean paste embryo and soybean paste water yellow A; (2) Byproduct treatment ①: Filter soybean paste water yellow A through a vibrating screen B with a larger mesh than that of the vibrating screen A to remove broken beans in soybean paste water yellow A to obtain soybean paste water yellow B; add the broken beans to the soybean paste embryo; (3) By-product treatment ②: Add soybean sauce water yellow B to a fermentation tank containing soy sauce residue, and mix soybean sauce water yellow B and soy sauce residue evenly to obtain soy sauce mash, which is then fermented; after the fermentation is completed, stir the soy sauce mash and pump it into a filter press, and filter to obtain a new product - water yellow C; (4) Treatment of new products: Place water yellow C in a self-sinking tank to sink to obtain clear water yellow D and turbid water yellow E; The clarified yellow soy sauce D is used as the second oil of soy sauce, and the yellow soy sauce E is recovered and processed together with the next batch of soybean sauce yellow soy sauce B in steps (3) to (4); The fermentation tank containing soy sauce residue refers to a fermentation tank after the soy sauce head oil has been released.

2. The method for recycling waste of soybean paste fermentation byproduct water yellow according to claim 1, characterized in that: The mesh of the vibration screen A is 8-30 mesh; the mesh of the vibration screen B is 30-100 mesh.

3. The method for recycling the waste of soybean paste fermentation byproduct water yellow according to claim 2, characterized in that: The added mass of the soybean sauce yellow B is 10-100% of the soy sauce residue.

4. The method for recycling waste of soybean paste fermentation byproduct water yellow according to claim 3, characterized in that: The fermentation time is 5 to 60 days.

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