Full-automatic baked egg roll and preparation method thereof

Abstract

The invention relates to a full-automatic baked egg roll and a preparation method thereof, and belongs to the technical field of baked food. The problems that traditional egg rolls are high in sugar and fat, extensive in process, low in production efficiency and the like are solved. According to the egg roll, wheat flour, white granulated sugar and vegetable oil are used as main materials, skim milk powder, whey powder and whole milk powder are innovatively introduced to construct a composite milk source system, and phospholipid and egg yolk powder are combined for synergistic emulsification, so that both sugar and lipid reduction and protein enhancement are realized. And precisely regulating and controlling in three stages through a gradient temperature control baking process: extending at 120 + / -5 DEG C to form a sheet of 0.2-0.3 mm, shaping a microporous structure at 160 + / -5 DEG C, dehydrating at 90 + / -3 DEG C until the water content is less than or equal to 3%, and rolling at a critical temperature of 60 + / -2 DEG C to form a 6-8-layer crisp structure. The full-automatic production line integrates the five-section temperature control module and the double-roller differential rolling technology, continuous production of 12 m / min is achieved, the reject ratio of products is smaller than 0.5%, and the labor cost is reduced by 60%. The multi-layer crisp biscuit has the advantages of being low in sugar and fat, multi-layer crisp, clean in formula and efficient in production, and meets the market requirements of healthy food.

Description

Technical Field

[0001] The invention relates to the technical field of baked food, in particular to a fully automatic baked egg roll and a preparation method thereof. Background Art

[0002] As a traditional snack food, egg rolls have long faced problems such as high sugar and fat, nutritional imbalance and processing technology defects.

[0003] 1. Formula technology: The main raw materials include flour, egg yolk powder, sugar, vegetable oil, etc. By adjusting the proportion of raw materials, the crispness and sweetness of the egg rolls can be controlled.

[0004] 2. Process technology: Spread the batter evenly on the baking tray and bake it at high temperature to form thin slices; stack multiple layers of slices and roll them into egg roll shape; ensure the crispness and color of the egg roll by controlling the baking temperature and time.

[0005] 3. Equipment technology: It requires multiple steps such as batter preparation, spreading, baking, stacking, rolling, cooling and packaging, and the process is relatively complicated.

[0006] The objective disadvantages include:

[0007] 1. The taste is single and lacks layering;

[0008] 2. High sugar and high fat content. The formula contains high sugar and fat content, which is not good for health;

[0009] 3. The production process is complicated and some links rely on manual operation, resulting in low production efficiency and high cost.

[0010] Therefore need a kind of fully automatic baking egg roll and preparation method thereof. Summary of the invention

[0011] In order to solve the problems of the prior art, the present invention provides a fully automatic baked egg roll and a preparation method thereof.

[0012] In order to solve the above technical problems, the present invention is implemented by the following technical solutions: In the first aspect, a fully automatic egg roll baking machine comprises the following raw materials in percentage by mass:

[0013] Wheat flour 40-60%, white sugar 20-30%, vegetable oil 15-19%, skim milk powder 0.4-1.2%, whey powder 0.4-0.8%, egg yolk powder 0.2-0.8%, lecithin 0.3-0.8%, edible salt 0.2-0.8%, whole milk powder 0.2-0.7%, sodium bicarbonate 0.01-0.03%, cinnamon 0.005-0.015%, vanilla 0.005-0.015%.

[0014] In this aspect, a "milk-derived protein complex system" (skim milk powder + whey powder + whole milk powder) is established to replace hydrogenated vegetable oils and artificial additives in traditional formulas. Through the synergistic emulsification of lecithin (0.3-0.8%) and egg yolk powder (0.2-0.8%), the amount of vegetable oil is reduced by 15% while maintaining a moist taste; through the compounding of "cinnamon + vanilla" natural flavors (total proportion 0.01-0.03%), the TRPV1 taste receptor is activated to enhance the perception of sweetness. The lactose in whey powder (0.4-0.8%) and white sugar form a stepped sweetness release.

[0015] In a specific embodiment of the first aspect, the wheat flour is 55%, the white sugar is 26%, the vegetable oil is 17%, the skim milk powder is 0.8%, the whey powder is 0.6%, the egg yolk powder is 0.5%, the lecithin is 0.5%, the edible salt is 0.4%, the whole milk powder is 0.4%, the sodium bicarbonate is 0.02%, the cinnamon is 0.01%, and the vanilla is 0.01%.

[0016] In a specific implementation of the first aspect, the egg roll has 6-8 crispy layers, a hollowness of ≥70%, a moisture content of ≤3%, and is free of trans fatty acids, artificial colors and preservatives.

[0017] In a second aspect, a method for preparing fully automatic baked egg rolls comprises the following steps:

[0018] Step 1: Gradient temperature controlled baking:

[0019] Stage 1: The batter is stretched into 0.2-0.3 mm thin sheets at 120±5℃ for 30-45 seconds;

[0020] The second stage: heating to 160±5℃ to form a microporous structure, lasting for 20-30 seconds;

[0021] The third stage: cooling to 90±3℃ for slow release dehydration, lasting 40-60 seconds;

[0022] Step 2: Rolling: At a critical temperature of 60±2°C, the baked sheets are stacked and rolled into a cylinder with a diameter of 12±0.5 mm.

[0023] In this aspect, gradient temperature controlled baking and critical rolling process achieve precise control of taste and texture.

[0024] Gradient temperature controlled baking:

[0025] The first stage (120℃): The low-temperature extension stage allows the batter to be evenly spread into an ultra-thin layer of 0.2-0.3mm to form an initial crispy base;

[0026] The second stage (160℃): High temperature setting causes the water to evaporate instantly, forming a dense microporous structure (hollowness ≥ 70%), which significantly improves the crispness;

[0027] The third stage (90℃): The slow-release dehydration stage avoids burning through precise temperature control, ensures the final moisture content is ≤3%, and extends the shelf life.

[0028] Critical roll forming:

[0029] At a critical temperature of 60°C, the plasticity and elasticity of the baked slices are superimposed and curled to form a cylinder with a diameter of 12 mm. This temperature ensures structural stability and avoids excessive oil penetration.

[0030] The multi-layer stacking process (6-8 layers) further reduces the density through air cavities between layers, while enhancing the sense of bite and layering.

[0031] Process advantages: The fully automatic production line achieves precise control of temperature, time and pressure parameters, ensuring product batch consistency while reducing the risk of contamination caused by manual intervention.

[0032] The beneficial effects of the present invention are:

[0033] 1. The present invention achieves a double breakthrough in health attributes and sensory quality through the synergistic effect of formula system reconstruction and gradient temperature control process: low sugar, low fat and high protein: the proportion of white sugar is compressed to 20-30%, and the amount of vegetable oil is ≤19%. At the same time, through the composite addition of skim milk powder, whey powder and whole milk powder, the protein content is increased to 5.6g / 100g, meeting 17% of the daily protein requirement of adults. Natural flavor enhancement: The innovative use of "cinnamon + vanilla" natural spice combination still maintains the sweetness intensity equivalent to the traditional high-sugar formula under the condition of 30% sugar reduction, and the aftertaste persistence is improved by 23%. Combined with the 6-8 layers of crispy structure formed by gradient temperature control baking, an "airy" texture and layered flavor release are achieved. Blind test data show that the crispness score reaches 8.9 / 10;

[0034] 2. Through the fully automatic temperature control system and thermoplastic rolling technology, the pain points of the traditional process that relies on manual labor and has unstable quality are solved: precise temperature control and dehydration: three-stage gradient baking (120℃→160℃→90℃) makes the moisture content ≤3%, the hollowness ≥70%, and the shelf life is extended to 9 months; the five-section independent temperature control module (±1.5℃) ensures that the thickness error of the dough sheet is ≤±0.02mm, and the product defect rate is reduced; efficient continuous production: the integrated coating-baking-rolling equipment achieves a line speed of 12m / min (traditional production line 4m / min), the frequency of manual intervention is less than 1 time / hour, and the unit energy consumption is reduced by 40% (2.1kW·h / kg vs3.5kW·h / kg). Through 60±2℃ critical temperature rolling and double-roller differential system (line speed difference 15%), the diameter accuracy reaches 12±0.3mm, the breakage rate is reduced by 42%, and the comprehensive production cost is reduced by 28%. DETAILED DESCRIPTION

[0035] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in 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 making creative work are within the scope of protection of the present invention.

[0036] A fully automatic egg roll baking method, comprising the following raw materials in percentage by mass:

[0037] Wheat flour 55%, white sugar 26%, vegetable oil 17%, skim milk powder 0.8%, whey powder 0.6%, egg yolk powder 0.5%, lecithin 0.5%, edible salt 0.4%, whole milk powder 0.4%, sodium bicarbonate 0.02%, cinnamon 0.01%, vanilla 0.01%.

[0038] Raw material mixing

[0039] Premixing of dry materials: put wheat flour, white sugar, skim milk powder, whey powder, whole milk powder, sodium bicarbonate, cinnamon powder and vanilla powder into a planetary mixer and mix at 120r / min for 5 minutes until uniform.

[0040] Wet material preparation: Heat the vegetable oil to 45±2°C, add phospholipids and egg yolk powder, and shear emulsify (8000r / min, 3 minutes) to form a stable emulsion.

[0041] Final mixing: put the dry material, wet material and edible salt into a double-screw mixer, inject 25-30℃ pure water (addition amount 18%) simultaneously, mix at 60r / min for 8 minutes to form a batter with a viscosity of 4500±200mPa·s.

[0042] A method for preparing fully automatic baked egg rolls comprises the following steps:

[0043] Step 1: Gradient temperature controlled baking:

[0044] Stage 1: The batter is stretched into 0.2-0.3 mm thin sheets at 120±5℃ for 30-45 seconds;

[0045] The second stage: heating to 160±5℃ to form a microporous structure, lasting for 20-30 seconds;

[0046] The third stage: cooling to 90±3℃ for slow release dehydration, lasting 40-60 seconds;

[0047] Step 2: Rolling: At a critical temperature of 60±2°C, the baked sheets are stacked and rolled into a cylinder with a diameter of 12±0.5 mm.

[0048] Preparation process of this recipe: Gradient temperature controlled baking parameters:

[0049] The first stage: infrared radiation heating (wavelength 2-5μm) is used, and the roller speed is controlled at 0.8-1.2rpm to ensure that the batter extension thickness is uniform (0.2-0.3mm), and real-time monitoring is carried out through a laser thickness gauge.

[0050] The second stage: use hot air circulation (wind speed 8-12m / s), the heating rate needs to be controlled at 3.5-4℃ / second, and the CO2 release amount needs to be monitored during the microporous structure formation stage (≥20mL / min).

[0051] The third stage: dehumidification and drying (dew point ≤ -20°C) is adopted, the dehydration rate is controlled at 0.5-0.8% / minute, and the final moisture is detected by Karl Fischer method (≤3%).

[0052] Roll forming process:

[0053] Critical temperature control: The surface temperature of the sheet is monitored in real time by a contact infrared thermometer (60±2℃), and the cooling air volume is automatically adjusted when the temperature deviation is greater than 2℃.

[0054] Rolling parameters: A double-roller spiral rolling mechanism is used, the pitch is set to 1.5-2mm, the rolling pressure is controlled at 0.3-0.5MPa, and the CCD visual inspection system is used to ensure the consistency of the number of layers (6-8 layers) and diameter (12±0.5mm).

[0055] Key control of production line:

[0056] Batter delivery: quantitative delivery by gear pump (accuracy ±1.5%), pipeline temperature maintained at 35±2℃ to prevent premature denaturation of protein.

[0057] Finished product testing: 10 samples are taken every 30 minutes to test crispness (breaking force ≥ 3N), hollowness (CT scanning method) and microbial indicators (total colony count ≤ 1000 CFU / g, coliform group ≤ 3MPN / g)

[0058]

[0059]

[0060] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A fully automatic egg roll baking machine, characterized in that: The following raw materials are included in mass percentage: Wheat flour 40-60%, white sugar 20-30%, vegetable oil 15-19%, skim milk powder 0.4-1.2%, whey powder 0.4-0.8%, egg yolk powder 0.2-0.8%, lecithin 0.3-0.8%, edible salt 0.2-0.8%, whole milk powder 0.2-0.7%, sodium bicarbonate 0.01-0.03%, cinnamon 0.005-0.015%, vanilla 0.005-0.015%.

2. The fully automatic egg roll baking machine according to claim 1, characterized in that: Wheat flour 55%, white sugar 26%, vegetable oil 17%, skim milk powder 0.8%, whey powder 0.6%, egg yolk powder 0.5%, lecithin 0.5%, edible salt 0.4%, whole milk powder 0.4%, sodium bicarbonate 0.02%, cinnamon 0.01%, vanilla 0.01%.

3. The fully automatic egg roll baking machine according to claim 1, characterized in that: The egg roll has 6 to 8 crispy layers, a hollowness of ≥70%, a moisture content of ≤3%, and is free of trans fatty acids, artificial colors and preservatives.

4. A method for preparing fully automatic baked egg rolls, characterized in that: The following steps are involved: Step 1: Gradient temperature controlled baking: Stage 1: The batter is stretched into 0.2-0.3 mm thin sheets at 120±5℃ for 30-45 seconds; The second stage: heating to 160±5℃ to form a microporous structure, lasting for 20-30 seconds; The third stage: cooling to 90±3℃ for slow release dehydration, lasting 40-60 seconds; Step 2: Rolling: At a critical temperature of 60±2°C, the baked sheets are stacked and rolled into a cylinder with a diameter of 12±0.5 mm.

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