Novel economic and environment-friendly comprehensive industrial production method of hydrolyzed vegetable protein

Abstract

The invention provides a brand-new comprehensive industrial production method of hydrolyzed vegetable protein, which comprises the following steps of: performing targeted separation on raw materials to obtain a solid part and a liquid part, respectively hydrolyzing by using a proper method to obtain two hydrolyzed semi-finished products, and blending and compounding. The whole process only needs one-stage heating, and the comprehensive average heating duration of the two parts is far shorter than that of a traditional method. In addition, additional dechlorination reaction is not needed, so that the use of other raw materials can be reduced, and the production energy consumption is reduced; product flavor can be improved, and sodium chloride content can be reduced; the method even has the effects of expanding product categories, reducing development cost, reducing industrial waste treatment difficulty and the like, and is an all-around comprehensive production method.

Description

Technical Field

[0001] The invention belongs to the technical field of hydrolyzed vegetable protein processing, and in particular relates to a novel economical and environmentally friendly comprehensive industrial production method of hydrolyzed vegetable protein. Background Art

[0002] Hydrolyzed vegetable protein is the product of hydrolysis of vegetable protein under the catalytic action of acid or alkali. Its main components are amino acids and small molecule peptides, so it is also called amino acid liquid. It is mainly used in the production of high-grade seasonings and base materials for fortified foods and raw materials for meat flavors. It is usually a light yellow liquid, paste, powder or granules, which has the effect of enhancing freshness and fragrance and giving food a mellow taste. When mixed with nucleotides and other flavor enhancers, it has a multiplying effect and has the function of reducing salt and covering odors. When seasoning, just adding a little can increase the deliciousness and improve the taste, thereby improving the product quality. It tastes extremely delicious and has a long aftertaste.

[0003] Although plant protein can be hydrolyzed by acid or alkali, and alkaline hydrolysis has advantages for specific amino acid groups, the flavor of the final product will be more prominent, but because its destructive effect on plant fiber is far less than that of acid, the yield of the final product is greatly reduced, and the waste in large-scale production is difficult to estimate. Therefore, most of the production processes of hydrolyzed plant protein now use acid hydrolysis, which improves the utilization rate of raw materials through high temperature, high pressure and long-term hydrolysis reaction. But at the same time, this currently widely used process will also lead to excessive energy consumption, excessive decomposition of some polypeptides, resulting in loss of flavor, and the most important 3-chloropropanol pollution problem. This harmful substance is very easy to produce during the long-term high-temperature acid hydrolysis process, and it has been closely watched. Manufacturers also have to carry out dechlorination treatment of subsequent products, which further increases the process and energy consumption, and also uses additional acid and alkali raw materials, and performs unnecessary neutralization processes. This will also cause another problem, that is, the sodium chloride content of acid-hydrolyzed plant protein is currently high, which greatly limits the development prospects of hydrolyzed plant protein under the current increasingly appealing concept of healthy and low-sodium diet. Summary of the invention

[0004] In view of the above-mentioned defects of the prior art, the technical problems to be solved by the present invention are the raw material utilization efficiency of hydrolyzed vegetable protein, the salt content of the final product, the difficulty of waste treatment, and the flavor and quality control of the final product.

[0005] In one aspect, the present invention provides an integrated industrial production process for hydrolyzed vegetable protein, comprising the following steps:

[0006] Step 1: Select production raw materials, perform solid-liquid separation, and obtain a liquid part and a solid part;

[0007] Step 2: The solid part is subjected to acid hydrolysis to obtain a crude acid hydrolysis product, the pH is adjusted to 3.5-4.2 with alkali, and then the product is heated, stirred, allowed to settle, and filtered to obtain a refined acid hydrolysis semi-finished product;

[0008] Step 3: performing alkaline hydrolysis on the liquid portion to obtain an alkaline hydrolysis crude product, adjusting the pH to 7-8 with an acid, and then heating, stirring, allowing to settle, and filtering to obtain a refined alkaline hydrolysis semi-finished product;

[0009] Step 4: The alkaline hydrolysis semi-finished product and the acid hydrolysis semi-finished product are mixed and refined to obtain a hydrolyzed vegetable protein product.

[0010] In some embodiments, in step 1, the types of production raw materials include corn steep liquor, corn protein liquid, flake soybean meal, powdered soybean meal, gluten, wheat protein, pea steep liquor, pea meal and other industrial plant protein sources, preferably corn steep liquor, gluten and powdered soybean meal.

[0011] Furthermore, when the production raw materials cannot be well separated into solid and liquid, the production raw materials need to be pretreated, and the pretreatment includes preliminary acid hydrolysis, preliminary enzymatic hydrolysis, sedimentation separation, etc.

[0012] In some embodiments, in step 1, the solid-liquid separation comprises filter pressing, pressing, centrifugation, sedimentation filtration and combinations thereof, preferably a combination of centrifugation and filter pressing.

[0013] Furthermore, the separation process can be assisted by adding an appropriate amount of water or a separation aid, wherein the separation aid is selected from glycerol, bentonite, quartz sand, etc. The separation process may also generate waste, and if any, the waste is removed.

[0014] Furthermore, the solid part is mainly composed of macromolecular proteins, plant fibers and polysaccharides; and the liquid part is mainly composed of small molecular proteins, polypeptides, soluble sugars and short fibers.

[0015] In some embodiments, the process further comprises adding water to the solid part and the liquid part respectively before acid hydrolysis and alkaline hydrolysis to adjust the crude protein content to 24%-30%.

[0016] In some embodiments, in step 2, the acid hydrolysis is carried out at 90-100° C. and normal pressure for 4-8 hours to match the binding properties of the protein in the solid raw material and reduce the risk of 3-chloropropanol generated during the production process.

[0017] In some embodiments, in step 2, flake sodium hydroxide or sodium hydroxide solution is used to adjust the pH of the acid hydrolysis crude product to protect subsequent equipment. Preferably, the concentration of the sodium hydroxide solution is 30%-50%.

[0018] In some embodiments, in step 3, the alkaline hydrolysis is performed at 102° C.-120° C. and 1-2 atmospheres for 2-4 hours to match the distribution characteristics of the protein in the liquid raw material to obtain the final desired flavor type.

[0019] In some embodiments, in step 3, a hydrochloric acid solution is used to adjust the pH of the crude alkaline hydrolysis product to protect subsequent equipment.

[0020] In some embodiments, in step 4, the compounding refers to mixing the alkaline hydrolysis semi-finished product and the acid hydrolysis semi-finished product in a mass ratio of 2:8-8:2. If necessary, hydrochloric acid solution or sodium hydroxide solution is additionally added for compounding.

[0021] In some embodiments, during the continuous production process, the acid hydrolysis semi-finished product and the alkaline hydrolysis semi-finished product in the compounding do not have to come from the same raw material batch, or even from the same raw material, and can be mixed and prepared in a variety of ways according to different needs.

[0022] In some embodiments, in step 4, the refining treatment includes heating, stirring, decolorization and deodorization, vacuum concentration, crystal precipitation, and combinations thereof.

[0023] In another aspect, the present invention also provides hydrolyzed vegetable protein obtained by the above integrated industrial production method.

[0024] In some embodiments, the 3-MCP content of the hydrolyzed vegetable protein is below 12 ppm, preferably below 5 ppm.

[0025] In some embodiments, the hydrolyzed vegetable protein has a total nitrogen content of 1.98%-2.4%, an ammonia nitrogen content of 0.8%-1.8%, a sodium chloride content of 9.3%-12%, and a solid content of 39%-42%.

[0026] Technical Effects

[0027] The present invention proposes a new comprehensive industrial production method for hydrolysis, which separates the raw materials in a targeted manner to obtain a solid part and a liquid part, and then hydrolyzes them separately using appropriate methods to obtain two hydrolysis semi-finished products, which are then modulated and compounded. The entire process only requires one stage of heating, and the average heating time of the two parts combined is much lower than that of the traditional method. In addition, since no additional dechlorination reaction is required, it can not only reduce the use of other raw materials and reduce production energy consumption; it can also improve product flavor and reduce sodium chloride content; it can even expand product categories, reduce development costs, and reduce the difficulty of industrial waste treatment. It is an all-round comprehensive production method. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1The present invention is a schematic flow diagram of the comprehensive industrial production method of hydrolyzed vegetable protein. DETAILED DESCRIPTION

[0029] The following describes several preferred embodiments of the present invention with reference to the drawings in the specification, so that the technical content is clearer and easier to understand. The present invention can be embodied in many different forms of embodiments, and the protection scope of the present invention is not limited to the embodiments mentioned in the text.

[0030] Example 1

[0031] Corn syrup as raw material

[0032] Step 1: Place sufficient amount of industrial corn pulp production raw materials in reactor A and let it settle for 24 hours.

[0033] Step 2: Extract the liquid with better fluidity from the upper layer, pass it through a centrifugal device and flush it with an appropriate amount of water to finally separate the liquid and solid raw materials. Add the liquid part to reactor B and pour the solid part back into reactor A.

[0034] Step 3: Add appropriate amount of water to reactors A and B respectively to adjust the crude protein content to 24%-25%.

[0035] Step 4: Add 30% hydrochloric acid to reactor A and 50% sodium hydroxide solution to reactor B, so that the concentrations of hydrochloric acid and sodium hydroxide solution in the whole raw materials reach 9.6%.

[0036] Step 5: Close the lids of the two reactors, stir and heat them, and react separately. The set conditions are: Reactor A: 94°C for 8 hours; Reactor B: 108°C for 3 hours.

[0037] Step 6: After the reaction is completed, turn on the cooling water and stir to cool down to 40°C. Add hydrochloric acid and sodium hydroxide solution to the two reactors respectively, adjust the pH in reactor A to 4.0, and adjust the pH in reactor B to 7.8. Continue stirring to complete the reaction and keep the pH reading stable.

[0038] Step 7: filter the feed liquids in the two reaction kettles respectively to obtain intermediate product A and intermediate product B, which are placed in two concentration kettles.

[0039] Step 8: Add 2% activated carbon to each of the two concentration kettles, and then vacuum concentrate the two intermediate products, decolorize and deodorize them until the solid content reaches 42%, and then cool and place them.

[0040] Step 9: Filter the two concentrated intermediate products to remove the activated carbon and precipitated crystals to obtain the refined intermediate products.

[0041] Step 10: Mix the two refined intermediates to make the pH reach 5.0, and then filter and purify again to obtain the final product. The final indicators of the three batches are as follows.

[0042] Table 1

[0043] Total nitrogen / % Ammonia nitrogen / % Sodium chloride / % Solid content / % 3-Chloropropanol / ppm 2.20 0.85 10.7 41.3 7 2.15 0.88 9.9 41.7 <5 2.15 0.90 10.2 40.8 <5

[0044] Example 2

[0045] Gluten as raw material

[0046] Step 1: Place gluten powder, water and sulfuric acid in reactor A, so that the overall crude protein content of the feed reaches 32%, and the sulfuric acid addition amount is 2%, then heat and stir, react at 96°C for 2 hours, then cool, and add slaked lime to adjust the pH to 4.5.

[0047] Step 2: filter the liquid from the previous step to finally separate the liquid and solid parts of the raw materials. The liquid part is added to reactor B, and the solid part is returned to reactor A.

[0048] Step 3: Add appropriate amount of water to reactors A and B respectively to adjust the crude protein content to 28%-29%.

[0049] Step 4: Add 30% hydrochloric acid to reactor A and 50% sodium hydroxide solution to reactor B, so that the concentrations of hydrochloric acid and sodium hydroxide solution in the whole raw materials reach 8.8% and 7.2% respectively.

[0050] Step 5: Close the lids of the two reactors, stir and heat them, and react separately. The set conditions are: Reactor A: 98°C for 5 hours; Reactor B: 102°C for 2 hours.

[0051] Step 6: After the reaction is completed, turn on the cooling water and stir to cool down to 40°C. Add hydrochloric acid and sodium hydroxide solution to the two reactors respectively, adjust the pH in reactor A to 3.8, and adjust the pH in reactor B to 7.4. Continue stirring to complete the reaction and keep the pH reading stable.

[0052] Step 7: filter the feed liquids in the two reaction kettles respectively to obtain intermediate product A and intermediate product B, which are placed in two concentration kettles.

[0053] Step 8: Add 2% activated carbon to each of the two concentration kettles, and then vacuum concentrate the two intermediate products, decolorize and deodorize them until the solid content reaches 40%, and then cool and place them.

[0054] Step 9: Filter the two concentrated intermediate products to remove the activated carbon and precipitated crystals to obtain the refined intermediate products.

[0055] Step 10: Mix the two refined intermediates according to A:B=3:1, and add a small amount of sodium hydroxide solution again to make the pH reach 4.8. After filtering and refining again, the final product is obtained. The final indicators of the three batches are as follows.

[0056] Table 2

[0057]

[0058]

[0059] Example 3

[0060] Made from powdered soybean meal

[0061] Step 1: Place powdered soybean meal, water and 30% hydrochloric acid in a ratio of 3:5:1 in reactor A, heat and stir, react at 110°C for 3 hours, then cool and add 50% sodium hydroxide solution to adjust the pH to 4.2.

[0062] Step 2: Press the liquid from the previous step to finally separate the liquid and solid parts of the raw materials. Add the liquid part to reactor B, and pour the solid part back into reactor A.

[0063] Step 3: Add appropriate amount of water to reactors A and B respectively to adjust the crude protein content to 25%-27%.

[0064] Step 4: Add 30% hydrochloric acid to reactor A and 50% sodium hydroxide solution to reactor B, so that the concentrations of hydrochloric acid and sodium hydroxide solution in the whole raw materials reach 10% and 6.4% respectively.

[0065] Step 5: Close the lids of the two reactors, stir and heat them, and react separately. The set conditions are: Reactor A: 100°C for 4 hours; Reactor B: 105°C for 2 hours.

[0066] Step 6: After the reaction is completed, turn on the cooling water and stir to cool down to 40°C. Add hydrochloric acid and sodium hydroxide solution to the two reactors respectively, adjust the pH in reactor A to 3.8, and adjust the pH in reactor B to 7.4. Continue stirring to complete the reaction and keep the pH reading stable.

[0067] Step 7: filter the feed liquids in the two reaction kettles respectively to obtain intermediate product A and intermediate product B, which are placed in two concentration kettles.

[0068] Step 8: Add 2% activated carbon to each of the two concentration kettles, and then vacuum concentrate the two intermediate products, and decolorize and deodorize them until the solid content reaches 44%, and then cool and place them.

[0069] Step 9: Filter the two concentrated intermediate products to remove the activated carbon and precipitated crystals to obtain the refined intermediate products.

[0070] Step 10: Mix the two refined intermediates to make the pH reach 4.7, and then filter and purify again to obtain the final product. The final indicators of the three batches are as follows.

[0071] Table 3

[0072] Total nitrogen / % Ammonia nitrogen / % Sodium chloride / % Solid content / % 3-Chloropropanol / ppm 2.00 1.30 12.0 42.3 12 1.98 1.25 11.8 42.0 7 2.02 1.27 11.7 42.2 9

[0073] Comparative Example 1

[0074] The conventional industrial acid hydrolysis plant protein production process, taking soybean meal as raw material as an example, generally includes the following steps:

[0075] Soybean meal, concentrated hydrochloric acid and water are used in a ratio of about 1:1:1, heated to 110°C-120°C in a reactor, and hydrolyzed under 1-2 atmospheres for about 8-12 hours.

[0076] After the reaction is completed, about 32%-36% sodium hydroxide (based on the dry mass of the raw soybean meal) needs to be added to adjust the pH to above 10, reheat to about 120°C, and perform a dechlorination reaction under 2 atmospheres for about 2 hours. Finally, add about 5%-10% hydrochloric acid to readjust the pH to between 4.8 and 5.4, and finally add activated carbon for decolorization and deodorization before filtering. The concentrated hydrochloric acid and sodium hydroxide added in the whole process are about 105%-110% and 32%-36% (based on the dry mass of the raw soybean meal). The whole reaction heating process takes about 12-14 hours, and two stages of heating need to be repeated.

[0077] The total nitrogen content of the hydrolyzed vegetable protein liquid obtained by conventional industrial acid hydrolysis process is generally 1.7-1.8%, the ammonia nitrogen content is 1.0-1.1%, the sodium chloride content is 15-17%, the solid content is 35-37%, and the 3-chloropropanol content is 20-40ppm.

[0078] When corn steep liquor and gluten powder are used as raw materials respectively, and the above conventional acid hydrolyzed vegetable protein production process is adopted, the 3-MCPA content in the obtained hydrolyzed vegetable protein liquid is 15-30 ppm and 10-15 ppm respectively.

[0079] Since the entire process requires repeated adjustment of pH, the salt content of the final product is relatively high; in order to obtain a higher product yield, the entire reaction time is relatively long and an additional high-temperature dechlorination step is required, so the energy consumption during the reaction process is relatively high; in addition, high-temperature dechlorination reactions will lead to the loss of flavor, and the overall reaction time is relatively long, there are too many processing steps and many other defects, all of which indicate that there is huge room for improvement.

[0080] At the same time, there are many reports on the method of alkaline hydrolysis. The raw materials are usually hydrolyzed with 4%-10% sodium hydroxide solution, the temperature is controlled between 90-120°C, the time ranges from 4-8 hours, and hydrochloric acid is added to neutralize after the reaction is completed, and finally activated carbon is added for filtration. Compared with the above-mentioned acid hydrolysis method, it has the advantages of less salt content, more distinct flavor, and greatly reduced risk of 3-chloropropanol pollution. However, since the destructive effect of alkali on plant fibers is weaker than that of acid, in actual application, the final yield does not exceed 70%, which is much lower than the 85%-88% of the conventional acid hydrolysis method, and the amino acid conversion rate is also low, often less than half, so there is no example of large-scale industrialization.

[0081] The preferred specific embodiments of the present invention are described in detail above. It should be understood that ordinary technicians in the field can make many modifications and changes based on the concept of the present invention without creative work. Therefore, all technical solutions that can be obtained by technicians in the technical field based on the concept of the present invention through logical analysis, reasoning or limited experiments on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. A comprehensive industrial production method for hydrolyzed vegetable protein, comprising the following steps: Step 1: Select production raw materials, perform solid-liquid separation, and obtain a liquid part and a solid part; Step 2: The solid part is subjected to acid hydrolysis to obtain a crude acid hydrolysis product, the pH is adjusted to 3.5-4.2 with alkali, and then the product is heated, stirred, allowed to settle, and filtered to obtain a refined acid hydrolysis semi-finished product; Step 3: performing alkaline hydrolysis on the liquid portion to obtain an alkaline hydrolysis crude product, adjusting the pH to 7-8 with an acid, and then heating, stirring, allowing to settle, and filtering to obtain a refined alkaline hydrolysis semi-finished product; Step 4: The alkaline hydrolysis semi-finished product and the acid hydrolysis semi-finished product are mixed and refined to obtain a hydrolyzed vegetable protein product.

2. The integrated industrial production method according to claim 1, wherein: In step 1, the types of production raw materials include corn steep liquor, corn protein liquid, flaked soybean meal, powdered soybean meal, gluten, wheat protein, pea milk, and pea meal.

3. The integrated industrial production method according to claim 1, wherein: In step 1, the solid-liquid separation includes filter pressing, pressing, centrifugation, sedimentation filtration and their combination.

4. The integrated industrial production method according to claim 1, wherein: In step 2, the acid hydrolysis is carried out at 90-100° C. and normal pressure for 4-8 hours.

5. The integrated industrial production method according to claim 4, wherein: In step 2, the pH of the acid hydrolysis crude product is adjusted using sodium hydroxide flakes or sodium hydroxide solution.

6. The integrated industrial production method according to claim 1, wherein: In step 3, the alkaline hydrolysis is carried out at 102-120° C. and 1-2 atmospheres for 2-4 hours.

7. The integrated industrial production method according to claim 6, wherein: In step 3, the pH of the crude alkaline hydrolysis product is adjusted using a hydrochloric acid solution.

8. The integrated industrial production method according to claim 1, wherein: In step 4, the modulation and compounding refers to mixing the alkaline hydrolysis semi-finished product and the acid hydrolysis semi-finished product in a mass ratio of 2:8-8:

2.

9. The integrated industrial production method according to claim 1, wherein: In step 4, the refining treatment includes heating, stirring, decolorization and deodorization, vacuum concentration, crystal precipitation and their combinations.

10. The hydrolyzed vegetable protein obtained by the integrated industrial production process according to any one of claims 1 to 9, wherein The 3-chloropropanol content of the hydrolyzed vegetable protein is below 12 ppm.

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