Method for preparing fermented feed through synergistic fermentation of bacteria and enzymes

Abstract

The invention belongs to the technical field of fermented feeds, and discloses a method for preparing a fermented feed through synergistic fermentation of bacteria and enzymes, and the method for preparing the fermented feed comprises the following steps: step 1, raw material selection and pretreatment; step 2, constructing a bacterium-enzyme synergistic system; step 3, performing a three-stage dynamic fermentation process; step 4, intelligent dynamic regulation and control; step 5, drying; and step 6, post-treatment and storage. According to the invention, a'dynamic regulation and control-multistage cooperation 'fermentation system is constructed, a traditional fermentation process is comprehensively optimized, and an intelligent control system is innovatively introduced. By implementing the system, the fermentation period is remarkably shortened, the fermentation efficiency is improved, and the production process is more efficient and quicker; meanwhile, agricultural and sideline products are ingeniously used as raw materials of the fermented feed, so that the production cost is effectively reduced, and the economic benefit is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of fermented feed, and in particular is a method for preparing fermented feed by bacterial and enzyme coordinated fermentation. Background Art

[0002] With the continuous development and progress of animal husbandry, the demand for feed grains is also growing sharply, which has led to increasingly tight feed grain resources. In order to meet this challenge, it is crucial to improve the utilization rate of feed and its nutritional value. Although traditional feed preparation methods have met the basic needs of animal husbandry to a certain extent, their problems are becoming increasingly prominent. The content of anti-nutritional factors in feeds prepared by these traditional methods is relatively high, which not only affects the nutritional value of the feed, but may also have an adverse effect on the digestion and absorption of animals. Furthermore, the palatability of traditional feeds is generally poor, which makes animals less willing to consume them, further affecting the utilization rate of feeds. More critically, the nutrient conversion rate of traditional feeds is low, which means that even if the animal ingests the feed, its body cannot fully absorb and utilize the nutrients in it; In order to improve the above problems, the bacterial enzyme synergistic fermentation technology came into being. This technology combines the two major processes of microbial fermentation and enzymatic hydrolysis, giving full play to the advantages of both. Through microbial fermentation, the anti-nutritional factors in feed raw materials can be effectively degraded, making them easier for animals to digest and absorb. At the same time, enzymatic hydrolysis can further improve the nutritional value of the feed and enhance its palatability, making animals more willing to ingest it.

[0003] But it is worth noting that although the bacterial enzyme synergistic fermentation technology has brought significant improvements, the existing technical solutions still have some problems that need to be solved. Among them, low fermentation efficiency is a prominent problem, which not only affects the production efficiency of feed, but also increases production costs. In addition, the quality of products produced using the current technical solutions is not stable, which may pose a potential risk to the health of animals; the existing bacterial enzyme synergistic technology has several core defects: first, the combination of bacterial enzymes is too rough and has not been finely adjusted according to the characteristics of different raw materials; second, the process parameters lack dynamic regulation and cannot be adjusted in real time according to the actual situation during the fermentation process, which affects the fermentation effect; finally, the evaluation standards in this field are not unified, which leads to unstable product quality and market chaos, so improvements are needed. Summary of the invention

[0004] The object of the present invention is to provide a method for preparing fermented feed by bacterial enzyme synergistic fermentation, so as to solve the problems raised in the above background technology.

[0005] In order to achieve the above object, the present invention provides the following technical solution: a method for preparing fermented feed by bacterial enzyme synergistic fermentation, the method for preparing fermented feed comprising: Step 1: Raw material selection and pretreatment: strictly select plant raw materials without mildew and pesticide residue according to national standards; crush the raw materials to 40 mesh, steam sterilize or ultraviolet disinfect, and adjust the moisture to improve the efficiency of enzymatic hydrolysis and kill bacteria; Step 2: constructing a bacterial enzyme synergistic system; selecting three bacterial species, namely lactic acid bacteria, bacillus, and yeast; activating the freeze-dried bacterial powder with 30°C, 5% brown sugar water for 2 hours; preparing an enzyme preparation using a certain proportion of cellulase, acid protease, and xylanase; and mixing the enzyme preparation and bacterial species evenly; Step 3, three-stage dynamic fermentation process: add the bacterial enzyme synergistic system to the raw materials, adjust the water content to an appropriate level, ferment under an appropriate fermentation environment, and turn the raw materials over in time; the fermentation is divided into three stages, namely: primary fermentation dominated by enzymatic hydrolysis, secondary fermentation of bacterial proliferation, and tertiary fermentation of product optimization; Step 4: Intelligent dynamic control: Introduce an intelligent dynamic control system to monitor and control pH control, temperature gradient and dissolved oxygen management during the fermentation process in real time; Step 5: Drying: Use a tube bundle dryer to dry the product, control the temperature to ≤60°C, and the moisture content to ≤12%; Step six, post-processing and storage: perform post-processing operations such as dehydration, crushing, mixing, etc. on the fermented feed, and store it in a suitable environment.

[0006] Preferably, the plant raw materials in the raw material selection and pretreatment of step 1 include but are not limited to corn stalks, soybean meal, and cottonseed meal; the steam sterilization conditions are a temperature of 121° C. and a time of 20 minutes; and the moisture adjustment comprises adding deep well water or boiled cooling water to control the moisture content of the raw materials to 65-70%.

[0007] Preferably, the step 1 of raw material selection and pretreatment further comprises adopting high temperature cooking or acid-base soaking process for the anti-nutritional factors of cottonpol and tannin in the miscellaneous meal to ensure that their content is reduced to a safe range.

[0008] Preferably, the three-stage dynamic fermentation process in step 3 specifically includes: Primary fermentation: Conditions: temperature 45°C, pH 6.0, aeration 0.5 vvm, for 12 hours.

[0009] Target: Crude fiber degradation rate ≥ 60% and starch gelatinization degree increased by 30%.

[0010] Secondary fermentation: Conditions: temperature 37°C, pH 5.0, anaerobic environment, inoculation of lactic acid bacteria + Bacillus, for 24 hours.

[0011] Target: lactic acid content ≥3.5%, small peptide production ≥25%.

[0012] Tertiary fermentation: Conditions: temperature 30°C, pH 4.5, micro-aerobic environment, supplementation of yeast, for 12 hours.

[0013] Target: ethyl hexanoate ≥120 mg / kg, mycotoxins <5 μg / kg.

[0014] Preferably, the intelligent dynamic control in step 4 includes: pH control: Real-time monitoring is performed using a carbon nanotube flexible sensor, and the pH fluctuation range is maintained by automatically adding lactic acid or sodium bicarbonate.

[0015] Temperature gradient: segmented temperature control, combined with jacket circulating water system; Dissolved oxygen management: The dissolved oxygen level is adjusted by stirring rate, and intermittent compost turning is used in solid-state fermentation.

[0016] Preferably, the mixing equipment for constructing the bacterial-enzyme synergistic system in step 2 adopts a horizontal double-blade mixer; the fermentation container is divided into two types, the solid-state fermentation adopts a 0.12 mm thick PE film breathing bag or a 304 stainless steel fermentation tank with a temperature control interlayer; the liquid fermentation adopts a 50 m³ gas-lift fermenter with a pH / DO online monitoring module.

[0017] Preferably, the post-processing and storage in step 5 specifically include: After fermentation, the fermented feed is dehydrated to reduce the moisture content for storage and use; The dehydrated fermented feed is crushed and mixed to prepare a complete fermented feed product; Store fermented feed in a dry, ventilated, light-proof environment to avoid contamination and mildew.

[0018] Preferably, the intelligent dynamic control of step 4 further includes: deploying Internet of Things sensors, predicting metabolic trends through LSTM neural networks, automatically adjusting stirring speed and ventilation volume, and maintaining pH 4.5-6.0 and humidity 65%-70%.

[0019] Preferably, the method for preparing fermented feed also includes post-processing technology upgrade, specifically including: Low temperature vacuum drying: Dry at 50℃ with vacuum degree -0.08MPa to a moisture content of ≤12%, retaining more than 90% of active bacteria; Microecological stabilization: Adding 2% trehalose + 1% ascorbic acid as a protective agent, the survival rate of the bacteria increased to 95%.

[0020] Preferably, in the raw material selection and pretreatment of step 1, the raw material crushing uses 50kHz high-frequency ultrasound to promote cell wall rupture, thereby increasing the fiber degradation rate by 40%.

[0021] The beneficial effects of the present invention are as follows: 1. The present invention comprehensively optimizes the traditional fermentation process by constructing a "dynamic regulation-multi-level coordination" fermentation system, and innovatively introduces an intelligent control system. The implementation of this system not only significantly shortens the fermentation cycle, improves the fermentation efficiency, and makes the production process more efficient and fast; at the same time, it also cleverly uses agricultural and sideline products as raw materials for fermented feed, effectively reducing production costs and improving economic benefits. This innovation not only brings new vitality to the fermentation industry, but also provides strong support for promoting the development of animal husbandry, helps to improve the growth performance and meat quality of farmed animals, and meets the market demand for high-quality livestock products.

[0022] 2. The present invention achieves effective degradation of anti-nutritional factors in feed raw materials through a carefully designed bacterial enzyme synergistic system, thereby significantly improving the nutritional value and palatability of the feed. The uniqueness of this system is that it can optimize the action targets of bacterial enzymes in stages, and through the "three-level dynamic fermentation" mode, enzymatic hydrolysis, acid production and flavor synthesis are carried out in sequence, making the fermentation process more precise and controllable, and the product more standardized. This innovation not only improves the quality of feed, but also provides a healthier and more nutritious feed source for farmed animals, which helps promote the sustainable development of animal husbandry.

[0023] 3. The present invention has also made important breakthroughs in equipment innovation. By integrating flexible pH sensors with PLC control systems, precise control of key parameters in the fermentation process is achieved. The response time of this system is extremely short, and the adjustment can be completed in only 15 seconds, which greatly improves the stability and reliability of the production process. At the same time, this innovation also shortens the fermentation cycle from the traditional 10 days to 48 hours, increases the crude fiber degradation rate by 28%, and significantly improves production efficiency and product quality. In addition, the integration of flexible pH chips and metabolic models provides the industry with a full-chain solution from laboratory to industrialization, providing strong technical support for the further development of the fermentation industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 The present invention is a simplified flow chart of the preparation process of the fermented feed. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in 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 creative work are within the scope of protection of the present invention.

[0026] like Figure 1 As shown, the embodiment of the present invention provides a method for preparing fermented feed by bacterial enzyme synergistic fermentation, and the method for preparing fermented feed includes: Step 1: Raw material selection and pretreatment: strictly select plant raw materials without mildew and pesticide residue according to national standards; crush the raw materials to 40 mesh, steam sterilize or ultraviolet disinfect, and adjust the moisture to improve the efficiency of enzymatic hydrolysis and kill bacteria; Step 2: constructing a bacterial enzyme synergistic system; selecting three bacterial species, namely lactic acid bacteria, bacillus, and yeast; activating the freeze-dried bacterial powder with 30°C, 5% brown sugar water for 2 hours; preparing an enzyme preparation using a certain proportion of cellulase, acid protease, and xylanase; and mixing the enzyme preparation and bacterial species evenly; Strain selection Core enzyme system The optimal ratio was determined by orthogonal test (cellulase 1.0% + acid protease 0.4% + xylanase 0.5%) Step 3, three-stage dynamic fermentation process: add the bacterial enzyme synergistic system to the raw materials, adjust the water content to an appropriate level, ferment under an appropriate fermentation environment, and turn the raw materials over in time; the fermentation is divided into three stages, namely: primary fermentation dominated by enzymatic hydrolysis, secondary fermentation of bacterial proliferation, and tertiary fermentation of product optimization; Step 4: Intelligent dynamic control: Introduce an intelligent dynamic control system to monitor and control pH control, temperature gradient and dissolved oxygen management during the fermentation process in real time; Step 5: Drying: Use a tube bundle dryer to dry the product, control the temperature to ≤60°C, and the moisture content to ≤12%; Step six, post-processing and storage: perform post-processing operations such as dehydration, crushing, mixing, etc. on the fermented feed, and store it in a suitable environment.

[0027] Among them, the plant raw materials in the raw material selection and pretreatment of step 1 include but are not limited to corn stalks, soybean meal, and cottonseed meal; the steam sterilization conditions are temperature 121° C. and time 20 minutes; the moisture adjustment includes adding deep well water or boiled cooling water to control the moisture content of the raw materials to 65-70%.

[0028] Among them, the raw material selection and pretreatment in step 1 also includes adopting high temperature cooking or acid-base soaking process for the anti-nutritional factors of cottonpol and tannin in the miscellaneous meal to ensure that their content is reduced to a safe range.

[0029] Among them, the three-stage dynamic fermentation process of step three specifically includes: Primary fermentation (enzymatic hydrolysis dominated): Conditions: temperature 45°C, pH 6.0, aeration 0.5 vvm (aerobic phase), duration 12 h.

[0030] Target: Crude fiber degradation rate ≥ 60% and starch gelatinization degree increased by 30%.

[0031] Secondary fermentation (bacterial proliferation): Conditions: temperature 37°C, pH 5.0, anaerobic environment, inoculation of lactic acid bacteria + Bacillus (inoculation amount 5%), for 24 hours.

[0032] Target: lactic acid content ≥3.5%, small peptide production ≥25%.

[0033] Tertiary fermentation (product optimization): Conditions: temperature 30°C, pH 4.5, microaerobic environment (dissolved oxygen 5-10%), supplementation of yeast (2%), for 12 hours.

[0034] Target: ethyl hexanoate ≥120 mg / kg, mycotoxin (aflatoxin B1) <5 μg / kg.

[0035] The intelligent dynamic control in step 4 includes: pH control: Real-time monitoring is carried out by deploying carbon nanotube flexible sensors, and the pH fluctuation range is maintained at ±0.3 by automatically adding lactic acid or sodium bicarbonate.

[0036] Temperature gradient: segmented temperature control (45℃ (bacterial proliferation) → 37℃ (enzyme activity peak) → 30℃ (metabolite accumulation)) combined with jacketed circulating water system, accuracy ±1℃.

[0037] Dissolved oxygen management: The dissolved oxygen level is adjusted by stirring rate (50-150 rpm), and intermittent compost turning (once every 8 hours) is used for solid-state fermentation. The stirring rate is adjusted to maintain 5-30% saturation; Among them, the mixing equipment for constructing the bacterial-enzyme synergistic system in step 2 adopts a horizontal double-blade mixer; the fermentation container is divided into two types, solid-state fermentation adopts a 0.12 mm thick PE film breathing bag or a 304 stainless steel fermentation tank with a temperature control interlayer; liquid fermentation adopts a 50 m³ airlift fermenter with a pH / DO online monitoring module.

[0038] Among them, the post-processing and storage of step 5 specifically include: After fermentation, the fermented feed is dehydrated to reduce the moisture content for storage and use; The dehydrated fermented feed is crushed and mixed to prepare a complete fermented feed product; Store fermented feed in a dry, ventilated, light-proof environment to avoid contamination and mildew.

[0039] The intelligent dynamic control of step 4 also includes: deploying IoT sensors (pH, temperature, CO 2 concentration), predict metabolic trends through LSTM neural network, automatically adjust stirring speed and ventilation volume, maintain pH 4.5-6.0 and humidity 65%-70%.

[0040] Among them, the method for preparing fermented feed also includes post-processing technology upgrades, specifically including: Low temperature vacuum drying: Dry at 50℃ with vacuum degree -0.08MPa to a moisture content of ≤12%, retaining more than 90% of active bacteria; Microecological stabilization: Adding 2% trehalose + 1% ascorbic acid as a protective agent, the survival rate of the bacteria is increased to 95% (stored at room temperature for 6 months).

[0041] Among them, the raw material crushing in the step 1 of raw material selection and pretreatment adopts 50kHz high-frequency ultrasound to promote cell wall rupture, so that the fiber degradation rate is increased by 40%.

[0042] Quality testing and evaluation: core testing indicators Animal testing verification Broiler feeding trial: feed-to-weight ratio decreased by 12-15%, diarrhea rate decreased by 40-50%. Expected results and technical advantages; Efficiency improvement: The fermentation cycle was shortened from 72 hours to 48 hours, and the raw material utilization rate was increased by 35%.

[0043] Cost Control: The amount of enzyme preparations used was reduced by 20% (orthogonal optimization result). Energy consumption was reduced by 18% (dynamic regulation reduced over-sterilization).

[0044] Product quality: Small peptide content ≥25% (traditional process ≤15%). The number of aroma substances increased by 5-8 (GC-MS detection).

[0045] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0046] 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 method for preparing fermented feed by bacterial enzyme synergistic fermentation, characterized in that: The method for preparing fermented feed comprises: Step 1: Raw material selection and pretreatment: strictly select plant raw materials without mildew and pesticide residue according to national standards; crush the raw materials to 40 mesh, steam sterilize or ultraviolet disinfect, and adjust the moisture to improve the efficiency of enzymatic hydrolysis and kill bacteria; Step 2: constructing a bacterial enzyme synergistic system; selecting three bacterial species, namely lactic acid bacteria, bacillus, and yeast; activating the freeze-dried bacterial powder with 30°C, 5% brown sugar water for 2 hours; preparing an enzyme preparation using a certain proportion of cellulase, acid protease, and xylanase; and mixing the enzyme preparation and bacterial species evenly; Step 3, three-stage dynamic fermentation process: add the bacterial enzyme synergistic system to the raw materials, adjust the water content to an appropriate level, ferment under an appropriate fermentation environment, and turn the raw materials over in time; the fermentation is divided into three stages, namely: primary fermentation dominated by enzymatic hydrolysis, secondary fermentation of bacterial proliferation, and tertiary fermentation of product optimization; Step 4: Intelligent dynamic control: Introduce an intelligent dynamic control system to monitor and control pH control, temperature gradient and dissolved oxygen management during the fermentation process in real time; Step 5: Drying: Use a tube bundle dryer to dry the product, control the temperature to ≤60°C, and the moisture content to ≤12%; Step six, post-processing and storage: perform post-processing operations such as dehydration, crushing, mixing, etc. on the fermented feed, and store it in a suitable environment.

2. The method for preparing fermented feed by bacterial-enzyme cooperative fermentation according to claim 1, characterized in that: The plant raw materials in the raw material selection and pretreatment of step 1 include but are not limited to corn stalks, soybean meal, and cottonseed meal; the steam sterilization conditions are a temperature of 121° C. and a time of 20 minutes; and the moisture adjustment includes adding deep well water or boiled cooling water to control the moisture content of the raw materials to 65-70%.

3. The method for preparing fermented feed by bacterial-enzyme cooperative fermentation according to claim 1, characterized in that: The step 1 of raw material selection and pretreatment also includes high temperature cooking or acid-base soaking process for the anti-nutritional factors of cottonpol and tannin in the miscellaneous meal to ensure that their content is reduced to a safe range.

4. The method for preparing fermented feed by bacterial-enzyme cooperative fermentation according to claim 1, characterized in that: The three-stage dynamic fermentation process of step 3 specifically includes: Primary fermentation: Conditions: temperature 45°C, pH 6.0, aeration 0.5 vvm, for 12 h; Target: Crude fiber degradation rate ≥ 60%, starch gelatinization degree increased by 30%; Secondary fermentation: Conditions: temperature 37°C, pH 5.0, anaerobic environment, inoculation of lactic acid bacteria + Bacillus, for 24 hours; Target: lactic acid content ≥3.5%, small peptide production ≥25%; Tertiary fermentation: Conditions: temperature 30°C, pH 4.5, microaerobic environment, supplemented with yeast, for 12 hours; Target: ethyl hexanoate ≥120 mg / kg, mycotoxins <5 μg / kg.

5. The method for preparing fermented feed by bacterial-enzyme cooperative fermentation according to claim 1, characterized in that: The intelligent dynamic control of step 4 includes: pH control: Real-time monitoring using carbon nanotube flexible sensors, maintaining the pH fluctuation range by automatically adding lactic acid or sodium bicarbonate; Temperature gradient: segmented temperature control, combined with jacket circulating water system; Dissolved oxygen management: The dissolved oxygen level is adjusted by stirring rate, and intermittent compost turning is used in solid-state fermentation.

6. The method for preparing fermented feed by bacterial enzyme cooperative fermentation according to claim 1, characterized in that: The mixing equipment for constructing the bacterial-enzyme synergistic system in step 2 adopts a horizontal double-blade mixer; the fermentation container is divided into two types, the solid-state fermentation adopts a 0.12 mm thick PE film breathing bag or a 304 stainless steel fermentation tank with a temperature control interlayer; the liquid fermentation adopts a 50 m³ airlift fermenter with a pH / DO online monitoring module.

7. The method for preparing fermented feed by bacterial-enzyme cooperative fermentation according to claim 1, characterized in that: The post-processing and storage of step 5 specifically include: After fermentation, the fermented feed is dehydrated to reduce the moisture content for storage and use; The dehydrated fermented feed is crushed and mixed to prepare a complete fermented feed product; Store fermented feed in a dry, ventilated, light-proof environment to avoid contamination and mildew.

8. The method for preparing fermented feed by bacterial-enzyme cooperative fermentation according to claim 1, characterized in that: The intelligent dynamic control of step 4 also includes: deploying IoT sensors, predicting metabolic trends through LSTM neural networks, automatically adjusting stirring speed and ventilation volume, maintaining pH 4.5-6.0 and humidity 65%-70%.

9. The method for preparing fermented feed by bacterial-enzyme cooperative fermentation according to claim 1, characterized in that: The method for preparing fermented feed also includes post-processing technology upgrades, specifically including: Low temperature vacuum drying: Dry at 50℃ with vacuum degree -0.08MPa to a moisture content of ≤12%, retaining more than 90% of active bacteria; Microecological stabilization: Adding 2% trehalose + 1% ascorbic acid as a protective agent, the survival rate of the bacteria increased to 95%.

10. The method for preparing fermented feed by bacterial enzyme cooperative fermentation according to claim 1, characterized in that: In the step 1, raw material selection and pretreatment, the raw material pulverization uses 50kHz high-frequency ultrasound to promote cell wall rupture, thereby increasing the fiber degradation rate by 40%.

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