Preparation method of low-gi konjac meal replacement powder

Abstract

The application discloses a kind of preparation methods of low GI konjac meal replacement powder, belong to food processing technical field.The method solves the problems such as uneven mixing of raw materials of existing low GI meal replacement powder, easy loss of nutritional components, poor granulation and improper moisture content control.The technical scheme points include: after mixing konjac powder and resistant dextrin according to the mass ratio 1:0.5-1:2, compound is formed by double screw extruder at 80-120 DEG C, and is cooled and crushed to 80-100 mesh;100:10:5 is mixed to get premix by mixing compound with inulin, soybean protein isolate;100:1 is mixed with vitamin and mineral microcapsule;5% hydroxypropyl methyl cellulose aqueous solution is used as binder, after fluidized bed granulation, dry to moisture less than 5%.The meal replacement powder prepared by the method is nutritionally balanced, uniform in granules, and has good reconstitution, and is suitable for people who need to control blood sugar and pursue healthy diet.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of food processing. More specifically, the present application relates to a preparation method of low GI konjac meal replacement powder. BACKGROUND

[0002] In the modern fast-paced life, meal replacement powder as a convenient and quick food choice has been favored by many consumers. However, there are some problems in the meal replacement powder on the market at present.

[0003] From the perspective of raw material mixing, the differences in characteristics of different raw materials bring difficulties to uniform mixing. Some raw materials are fine in texture, while others are relatively rough; some raw materials are prone to moisture absorption, while others are relatively dry. These differences in characteristics make it difficult to evenly distribute various raw materials during the mixing process. Uneven mixing not only affects the appearance of meal replacement powder, but also leads to uneven distribution of nutritional ingredients, making it impossible for consumers to obtain stable and consistent nutritional intake when eating, and also causing differences in taste, affecting the eating experience.

[0004] In terms of product forming, the existing forming technology has many shortcomings. During the forming process, there are often differences in particle size and irregular shapes. This not only affects the brewing property of meal replacement powder, such as easy caking and difficult to fully dissolve during brewing, but also has adverse effects on product packaging and storage. Large differences in particles may lead to difficulty in accurately controlling the weight during packaging, and also easily cause stratification during storage.

[0005] With the improvement of people's health consciousness, low GI (glycemic index) food has gradually entered the public view. Low GI food plays an important role in maintaining stable blood sugar in the human body. When the human body ingests low GI food, the digestion and absorption of carbohydrates in the intestinal tract is relatively slow, thereby avoiding rapid rise and sharp fluctuations in blood sugar. This is of great importance to people who need to control blood sugar, such as diabetic patients, as well as people who pursue healthy diet and hope to maintain good physical condition. Stable blood sugar level helps maintain normal metabolic function of the body, reduces discomfort symptoms such as fatigue and dizziness caused by blood sugar fluctuations, and also reduces the risk of chronic diseases to a certain extent, which is of great significance to people's health management. However, due to the above-mentioned problems in raw material mixing and product forming, etc., the existing low GI meal replacement powder is difficult to fully exert the advantages of low GI food, and cannot meet the needs of consumers for high-quality low GI meal replacement powder. SUMMARY

[0006] The application provides a preparation method of low-GI konjac meal replacement powder, which solves the problems of uneven mixing of raw materials, easy loss of nutritional components, poor granulation, and improper moisture content control of existing low-GI meal replacement powder.

[0007] In order to achieve the above objects and other advantages of the present application, a preparation method of low-GI konjac meal replacement powder is provided, which comprises the following steps:

[0008] S1, mixing konjac powder and resistant dextrin according to a mass ratio of 1:0.5-1:2 to obtain mixed powder;

[0009] S2, placing the mixed powder in a double-screw extruder for extrusion treatment under the condition that the extrusion temperature is 80-120 DEG C, so that the konjac powder and the resistant dextrin form a compound, cooling the compound, and crushing the compound to a particle size of 80-100 mesh;

[0010] S3, mixing the crushed compound with inulin and soybean protein isolate according to a mass ratio of 100:10:5 to obtain premix;

[0011] S4, mixing the premix with vitamin and mineral microcapsules according to a mass ratio of 100:1 to obtain fortified premix;

[0012] S5, placing the fortified premix in a fluidized bed granulator, using a 5% hydroxypropyl methyl cellulose aqueous solution as a binder, spraying at a speed of 10-20 mL / min, and feeding air at a temperature of 50-60 DEG C to perform fluidized bed granulation, so as to obtain granular meal replacement powder;

[0013] S6, drying the granular meal replacement powder at a temperature of 40-50 DEG C until the moisture content is less than 5% to obtain low-GI konjac meal replacement powder.

[0014] Preferably, the vitamin and mineral microcapsules comprise 10-20% complex vitamins, 15-25% minerals, and 55-75% wall material by mass fraction; wherein the complex vitamins include vitamin A, D, E, B1, B2, B6, B12, folic acid, and calcium pantothenate; the minerals include calcium carbonate, ferrous sulfate, zinc gluconate, and sodium selenite; and the wall material is composed of gum arabic and beta-cyclodextrin according to a mass ratio of 1:1-1:2.

[0015] The preparation method of the vitamin and mineral microcapsules comprises:

[0016] The complex vitamins and minerals are dispersed in a wall material solution at 40-50℃, and then homogenized and spray dried to obtain vitamin-mineral microcapsules with a particle size of 50-100μm, with an inlet temperature of 150-160℃ and an outlet temperature of 70-80℃.

[0017] Preferably, 0.5-1% of phospholipid is added as an emulsifier in the vitamin-mineral microcapsules, based on the total mass of the vitamin-mineral microcapsules.

[0018] Preferably, in S2, the twin-screw extruder is operated in a segmented temperature control mode, with a feeding section temperature of 80-90℃, a mixing section temperature of 100-110℃, and a discharge section temperature of 110-120℃, and the screw rotation speed in the mixing section is increased by 20-30% compared to the feeding section.

[0019] Preferably, the complex is cooled and ground to a particle size of 80-100 mesh, specifically:

[0020] S201. The extruded complex is cooled by a spiral conveying cooler in a gradient cooling process: first stage: 80℃→50℃, cooling rate 10℃ / min, time 3min; second stage: 50℃→25℃, cooling rate 5℃ / min, time 5min; third stage: 25℃→5℃, cooling rate 2℃ / min, time 10min;

[0021] S202. The cooled complex is fed into a vortex ultrafine grinder and ground under nitrogen protection, with the following control parameters: grinding pressure 0.6-0.8MPa, rotor rotation speed 8000-10000rpm, feeding speed 8-12kg / h, grinding chamber temperature ≤35℃;

[0022] S203. The ground product is classified using an ultrasonic vibration screening system: primary screen 100 mesh, secondary screen 80 mesh, vibration frequency 28-32kHz, vibration amplitude 0.5-1mm;

[0023] S204. The 80-100 mesh interstitial material is collected and dried by pulse airflow to a moisture content of ≤5%.

[0024] Preferably, in the gradient cooling process of S201, dehumidified air with a dew point of ≤-15℃ is introduced into the spiral conveying cooler at a flow rate of 2-3m³ / min, so that the water activity Aw of the complex at the end of cooling is ≤0.35.

[0025] In S202, the rotor surface of the vortex ultrafine grinder is coated with a polytetrafluoroethylene wear-resistant coating with a thickness of 50-80μm to reduce the adhesion of konjac powder.

[0026] Preferably, the S3 specifically comprises:

[0027] S301, accurately weigh each component according to the mass ratio: composite: inulin: soybean protein isolate = 100: 10: 5;

[0028] S302, premix inulin with part of the composite at a mass ratio of 1:1 for 3-5 minutes to form a primary mixture;

[0029] S303, add the remaining composite in two portions, with a 2-minute interval between each addition, and mix for 5 minutes;

[0030] S304, finally add soybean protein isolate in the form of an atomized spray, at a spray rate of 0.5-1.0 g / s, while maintaining low-speed stirring of the mixing container at 8-10 r / min, and the total mixing time is 15-20 minutes.

[0031] Preferably, in the S302, when premixing inulin with part of the composite, add 0.1-0.3% of silicon dioxide based on the mass of inulin as a flow aid, and let it stand for 5 minutes after premixing to eliminate static electricity;

[0032] In the S304, simultaneously spray 0.5-1.0% of lecithin ethanol solution based on the mass of soybean protein isolate into the atomized spray, with a concentration of 10%, and the spray rate is 0.2-0.3 mL / s.

[0033] Preferably, the S4 specifically comprises:

[0034] S401, accurately weigh each component according to the mass ratio: premix: vitamin and mineral microcapsules = 100: 1;

[0035] S402, place the vitamin and mineral microcapsules in a fluidized bed mixer, and pass dry air with a relative humidity of ≤30% at a flow rate of 1-1.5 m³ / min to pre-disperse the vitamin and mineral microcapsules for 5-8 minutes;

[0036] S403, add the premix to the fluidized bed in three portions, with a 3-minute interval between each addition, and control the mixing speed at 15-20 r / min, and the total mixing time is 12-15 minutes;

[0037] S404, during mixing, pause mixing every 3 minutes and let it stand for 1 minute to eliminate static electricity accumulation.

[0038] Preferably, in the S402, add 0.03-0.08% of nano-silicon dioxide aerosol based on the mass of the vitamin and mineral microcapsules to the dry air, with a particle size of 20-50 nm, to enhance the flowability and anti-adhesion of the vitamin and mineral microcapsules;

[0039] In the S403, each time the premix is added, 0.02-0.05% of sodium alginate solution with a mass of the premix is sprayed synchronously, the concentration is 1%, and the spraying rate is 0.1-0.2 mL / s.

[0040] The present application at least includes the following beneficial effects:

[0041] First, by specific raw material ratio and processing flow, the konjac flour, resistant dextrin, inulin, soy protein isolate and other raw materials can be fully fused to ensure uniform distribution of nutritional ingredients. Suitable granulation and drying conditions can make the meal replacement powder particles uniform, good in brewing property, meet the moisture content standard, prolong the shelf life, and provide consumers with low GI konjac meal replacement powder which is nutritionally balanced, stable in quality and convenient to eat. The clear vitamin and mineral microcapsule composition and preparation method can effectively protect the complex vitamins and minerals, reduce their oxidation and deliquescence during processing and storage. Suitable wall material and spray drying process make the microcapsule particle size uniform and well dispersed in the meal replacement powder, ensuring that consumers can intake comprehensive and stable nutritional ingredients and improving the nutritional value of the meal replacement powder. The addition of phospholipid as an emulsifier can reduce the interfacial tension between the components in the microcapsule, prevent the separation and agglomeration between the complex vitamins, minerals and wall materials. This makes the vitamin and mineral microcapsule more easily dispersed and uniform in the meal replacement powder, effectively improves the stability and bioavailability of the nutritional enhancer, and further ensures the nutritional quality of the meal replacement powder.

[0042] Second, the segmented temperature control and screw speed adjustment of the twin-screw extruder can make the raw materials fully react at different stages. The low temperature in the feeding section is beneficial to material conveying, the suitable temperature and increased screw speed in the mixing section promote the physical and chemical reactions between the raw materials, and the high temperature in the discharging section ensures the formation of the compound. Precise process control can preserve the nutritional ingredients of the raw materials, improve the taste and quality of the meal replacement powder, and increase the market competitiveness of the product. Precise gradient cooling, crushing, screening and drying processes can effectively control the particle size and moisture content of the compound. Gradient cooling avoids the impact of sudden temperature changes on product quality, ultra-fine crushing and accurate screening ensure uniform powder particle size, pulse air flow drying controls moisture, and ensures that the meal replacement powder is fine in texture and good in solubility, improving the stability and quality uniformity of the product. The introduction of dehumidified air reduces the water activity, prevents the compound from absorbing moisture and deteriorating during cooling, and prolongs the shelf life of the product. The rotor surface is coated with a polytetrafluoroethylene wear-resistant coating to reduce the adhesion of konjac powder, reduce the cleaning frequency of the equipment, improve the production efficiency, and at the same time avoid the quality fluctuations caused by the adhesion of the powder, ensuring the stability of the product quality.

[0043] Third, the accurate weighing and step-by-step mixing method can fully consider the characteristics of different raw materials, so that the inulin, soybean protein isolate and complex are uniformly mixed. The steps of premixing, multiple addition and low-speed stirring can effectively avoid the agglomeration of raw materials, ensure the uniform distribution of nutritional ingredients of the meal replacement powder, and improve the quality and taste consistency of the product. The addition of silicon dioxide as a flow aid can improve the flowability of inulin, eliminate static electricity, and prevent it from caking during the premixing process. Simultaneous injection of lecithin ethanol solution can make the soybean protein isolate more uniformly dispersed during the atomized powder spraying, further improve the mixing effect, and ensure the quality stability of the meal replacement powder, providing consumers with better quality products.

[0044] Fourth, the specific weighing, pre-dispersion, multiple mixing and static elimination steps can ensure that the premix and vitamin and mineral microcapsules are fully and uniformly mixed. Pre-dispersion allows the microcapsules to be initially dispersed, multiple addition of the premix and control of the mixing speed can avoid uneven mixing, eliminate static accumulation and prevent material adsorption, ensuring the uniformity and stability of the nutritional ingredients of the meal replacement powder. The addition of nano-silicon dioxide aerosol enhances the flowability and anti-adhesion of the vitamin and mineral microcapsules, making them more easily dispersed during the mixing process. Simultaneous injection of sodium alginate solution improves the dispersibility of the premix, further optimizing the mixing effect. This makes the nutritional distribution of the meal replacement powder more uniform, improving the quality and nutritional value of the product.

[0045] Other advantages, objects, and features of the present application will be apparent to those skilled in the art from the following description. BRIEF DESCRIPTION OF DRAWINGS

[0046] Figure 1 The flowchart of the preparation method of the low-GI konjac meal replacement powder of the present application is shown. DETAILED DESCRIPTION

[0047] The present application will be further described in detail below with reference to the accompanying drawings, so that those skilled in the art can implement it according to the description.

[0048] It should be understood that the terms such as "have", "contain" and "include" used herein do not exclude the presence or addition of one or more other elements or combinations thereof.

[0049] As Figure 1 shown, the present application provides a preparation method of a low-GI konjac meal replacement powder, comprising the following steps:

[0050] S1, mixing konjac powder and resistant dextrin according to a mass ratio of 1:0.5-1:2 to obtain a mixed powder;

[0051] S2, the mixed powder is placed in a twin-screw extruder, and extrusion treatment is carried out at an extrusion temperature of 80-120 DEG C, so that the konjac fine powder and resistant dextrin form a compound, the compound is cooled, and is crushed to a particle size of 80-100 mesh;

[0052] S3, the crushed compound is mixed with inulin and soybean protein isolate at a mass ratio of 100:10:5 to obtain a premix;

[0053] S4, the premix is mixed with vitamin and mineral microcapsules at a mass ratio of 100:1 to obtain a fortified premix;

[0054] S5, the fortified premix is placed in a fluidized bed granulator, a 5% hydroxypropyl methyl cellulose aqueous solution is used as a binder, the spraying speed is 10-20 mL / min, the inlet air temperature is 50-60 DEG C, fluidized bed granulation is carried out, and granular meal replacement powder is prepared;

[0055] S6, the granular meal replacement powder is dried at 40-50 DEG C until the moisture content is less than 5%, and a low-GI konjac meal replacement powder is obtained.

[0056] In the above embodiment, in step S1, resistant dextrin as a low GI auxiliary material can balance the high viscosity of konjac powder and improve the subsequent processing fluidity. By precisely controlling the ratio of konjac powder and resistant dextrin, the functions of raw materials are complementary, the high dietary fiber characteristics of konjac are retained, and the flowability of the powder is improved by resistant dextrin, providing a uniform raw material basis for subsequent extrusion process. In step S2, double screw extrusion promotes the formation of stable complexes between konjac powder and resistant dextrin molecules, significantly reducing the glycemic index, i.e., GI value, of the product. Cooling and crushing after extrusion can control the particle size, ensure solubility and delicate texture, and at the same time avoid the destruction of nutritional ingredients caused by high temperature. In step S3, the complex is mixed with inulin and soy protein isolate at a ratio of 100:10:5. Inulin supplements prebiotic function, and soy protein improves amino acid balance. The three of them synergistically enhance the nutritional value of the meal replacement powder. Precise proportioning ensures uniformity and avoids clumping or segregation of ingredients. In step S4, vitamin and mineral microcapsules protect sensitive nutrients through wall material protection, significantly improving the stability during processing and storage. Microencapsulation technology avoids direct contact between minerals (such as iron and zinc) and other ingredients, preventing oxidation or odor generation. In step S5, the combination of hydroxypropyl methylcellulose adhesive and spray speed forms particles with high sphericity and moderate strength. Low-temperature air inlet maintains the activity of heat-sensitive ingredients while ensuring rapid particle formation. The dispersion is excellent and there is no clumping when it is mixed. In step S6, mild drying at 40-50°C to a moisture content of ≤5% effectively extends the shelf life while retaining the low GI characteristics of the product. Low water activity inhibits microbial growth, ensuring food safety. In summary, the whole process design takes into account the functionality and processing feasibility of the final product, which has low GI, high nutrient retention, and excellent mixing properties. The parameters of each step are optimized in coordination, suitable for large-scale production, and meet the demand for health and convenience in the meal replacement powder market.

[0057] The konjac fine powder and resistant dextrin can be mixed in a mass ratio of 1:0.5 to 1:2, and the specific ratio can be selected as 1:0.8, 1:1 or 1:1.5. The mixing equipment can adopt a three-dimensional motion mixer or a V-shaped mixer, and the mixing time can be controlled within 10-20 minutes. The mixing container can be made of stainless steel, and the volume can be selected as 50L to 500L according to the production scale. During the pretreatment of raw materials, the konjac fine powder can be sieved through an 80-mesh sieve, and the resistant dextrin can be sieved through a 100-mesh sieve to ensure uniform particle size of the raw materials. The environmental humidity during the mixing process can be controlled below 40%, and the temperature can be controlled around 25℃. The uniformity of the mixed material needs to be detected, which can be quickly detected by near-infrared spectroscopy. The twin-screw extruder can adopt a co-rotating type, and the screw diameter can be selected as 35mm to 75mm. The extrusion temperature can be controlled in sections: the feeding section is 80-90℃, the mixing section is 100-110℃, and the discharging section is 110-120℃. The specific temperature setting can be selected as 85℃ for the feeding section, 105℃ for the mixing section, and 115℃ for the discharging section. The screw speed can be set as 100-150rpm in the feeding section, and increased by 20-30% in the mixing section, i.e. 120-195rpm. The die hole diameter of the extruder can be selected as 3-5mm, and the length-diameter ratio is 25:1 to 40:1. The motor load can be monitored during the extrusion process, and controlled within 70-85% of the rated power. The extruded compound can be cooled by a spiral conveying cooler. In the first stage, the temperature is reduced from 80℃ to 50℃ at a cooling rate of 10℃ / min for 3 minutes; in the second stage, the temperature is reduced from 50℃ to 25℃ at a cooling rate of 5℃ / min for 5 minutes; in the third stage, the temperature is reduced from 25℃ to 5℃ at a cooling rate of 2℃ / min for 10 minutes. The cooled material can be crushed by a vortex ultrafine grinder, with a crushing pressure of 0.6-0.8MPa and a rotor speed of 8000-10000rpm. The crushed material is classified by an ultrasonic vibrating screen, with a first screen mesh of 100 meshes and a second screen mesh of 80 meshes, and a vibration frequency of 28-32kHz. The material between 80-100 meshes is collected, and the moisture content is controlled below 4%. The crushed compound can be mixed with inulin and soybean protein isolate in a mass ratio of 100:10:5. The mixing equipment can adopt a conical mixer, and the mixing time can be 15-20 minutes. The vitamin and mineral microcapsules are added at 1% of the premix mass, and mixed by a fluidized bed mixer for 12-15 minutes. The granulation process can use a fluidized bed granulator, with a binder of 5% hydroxypropyl methyl cellulose aqueous solution, a spraying speed of 10-20mL / min, and an air inlet temperature of 50-60℃. Finally, the drying is performed by a hot air circulation drying oven, with a temperature of 40-50℃, and the moisture content is dried below 5%.

[0058] In one embodiment, the vitamin-mineral microcapsule comprises 10-20% of complex vitamins, 15-25% of minerals, and 55-75% of wall material by mass fraction; wherein the complex vitamins include vitamin A, D, E, B1, B2, B6, B12, folic acid, and calcium pantothenate; the minerals include calcium carbonate, ferrous sulfate, zinc gluconate, and sodium selenite; and the wall material is composed of gum arabic and β-cyclodextrin at a mass ratio of 1:1-1:2.

[0059] The preparation method of the vitamin-mineral microcapsule comprises:

[0060] The complex vitamins and minerals are dispersed in a wall material solution at 40-50°C, and then homogenized and spray dried to obtain vitamin-mineral microcapsules with a particle size of 50-100 μm, at an inlet temperature of 150-160°C and an outlet temperature of 70-80°C.

[0061] In the vitamin-mineral microcapsule, 0.5-1% of phospholipid is further added as an emulsifier, accounting for 0.5-1% of the total mass of the vitamin-mineral microcapsule.

[0062] In the above embodiment, the complex wall material formed by gum arabic and β-cyclodextrin has film-forming and embedding capabilities, significantly reducing the oxidation loss of vitamins (such as B12 and folic acid) and the deliquescence risk of minerals (such as ferrous sulfate). Spray drying is performed at an inlet temperature of 150-160°C and an outlet temperature of 70-80°C, which can quickly dry the material while avoiding high-temperature damage to heat-sensitive components. The addition of 0.5-1% of phospholipid can reduce the oil-water interfacial tension, allowing fat-soluble vitamins (A, D, and E) to be uniformly dispersed in the wall material and improving intestinal absorption. The particle size of the microcapsule is in the range of 50-100 μm, which ensures uniform dispersion in meal replacement powder and avoids local nutrient excess or deficiency. The microcapsule structure effectively isolates the chemical reaction between minerals such as sodium selenite and other components, preventing the generation of odors or discoloration during processing. The hydrophobicity of the wall material and the film-forming property of gum arabic synergistically allow the retention rate of nutrients to remain ≥90% after 12 months of storage. β-cyclodextrin embeds minerals such as iron and zinc, significantly reducing the metallic taste and improving the acceptance of the taste. Microencapsulation avoids direct contact between vitamins and minerals, such as the reaction between vitamin C and iron ions, thereby maintaining the activity of the components. This microcapsule technology achieves efficient protection, controlled release, and product quality improvement of nutritional fortifiers through the synergistic design of ingredient ratios, process parameters, and functional additives, providing stable nutritional support for low-GI meal replacement powder.

[0063] The vitamin-mineral microcapsule can comprise 10-20% of the complex vitamins, 15-25% of the minerals, and 55-75% of the wall material by mass fraction. The complex vitamins can include vitamin A, D, E, B1, B2, B6, B12, folic acid, and calcium pantothenate. For example, vitamin A: 2.0%; vitamin D3: 0.2%; vitamin E: 6.5%; vitamin B1: 1.5%; vitamin B2: 1.3%; vitamin B6: 1.3%; vitamin B12: 0.08%; folic acid: 1.0%; calcium pantothenate: 4.0%; carrier: 82.12%. The minerals can include calcium carbonate, ferrous sulfate, zinc gluconate, and sodium selenite. The wall material can be composed of gum arabic and β-cyclodextrin at a mass ratio of 1:1 to 1:2.

[0064] The mass fraction of the complex vitamins can be selected as 12%, 15%, or 18%. The mass fraction of the minerals can be selected as 18%, 20%, or 22%. The mass fraction of the wall material can be selected as 60%, 65%, or 70%. The mass ratio of gum arabic to β-cyclodextrin can be selected as 1:1, 1:1.5, or 1:2. The complex vitamins and minerals are dispersed in the wall material solution at 40-50°C, and then homogenized and spray dried. The inlet temperature of the spray drying can be selected as 150°C, 155°C, or 160°C, and the outlet temperature can be selected as 70°C, 75°C, or 80°C. The prepared microcapsule particle size can be 50 μm, 75 μm, or 100 μm. The homogenization equipment can use a high-shear disperser, and the spray drying equipment can use a centrifugal spray drying tower. The wall material solution can be prepared in a stainless steel stirring tank, and the temperature is controlled at about 45°C. The atomizer speed of the spray drying can be set to 10,000-15,000 rpm to ensure uniform microcapsule particle size. In the vitamin-mineral microcapsule, 0.5-1% of phospholipid by total mass of the microcapsule can be added as an emulsifier. The amount of phospholipid added can be selected as 0.6%, 0.8%, or 1%. The phospholipid can be soy lecithin or sunflower lecithin, which is dissolved in ethanol and then added to the wall material solution. The addition of phospholipid can be carried out before homogenization and mixed uniformly with the wall material solution. The concentration of the ethanol solution can be selected as 10%, and the addition rate is controlled at 0.2-0.3 mL / s. The mixed solution needs to be stirred at 40-50°C for 10 minutes to ensure that the phospholipid is fully dispersed. This can ensure the stability of vitamins and minerals during processing and storage, and reduce the risk of oxidation and deliquescence. The control of the particle size of the microcapsule is beneficial to uniform dispersion in the meal replacement powder and improves the bioavailability of nutrients. The addition of phospholipid further enhances the emulsification performance of the microcapsule, preventing ingredient stratification or agglomeration. The overall process is feasible and suitable for industrial production.

[0065] In one embodiment, the temperature of the double screw extruder is controlled in sections, with the temperature of the feeding section being 80-90°C, the temperature of the mixing section being 100-110°C, and the temperature of the discharging section being 110-120°C, and the screw speed in the mixing section being 20-30% higher than that in the feeding section.

[0066] The compound is cooled and crushed to a particle size of 80-100 mesh, specifically:

[0067] S201. The extruded compound is cooled by a spiral conveying cooler in gradient: first stage: 80°C→50°C, cooling rate 10°C / min, time 3 min; second stage: 50°C→25°C, cooling rate 5°C / min, time 5 min; third stage: 25°C→5°C, cooling rate 2°C / min, time 10 min.

[0068] S202. The cooled compound is put into a vortex ultrafine grinder and crushed under nitrogen protection, with the control parameters being: crushing pressure 0.6-0.8 MPa, rotor speed 8000-10000 rpm, feeding speed 8-12 kg / h, and crushing chamber temperature ≤35°C.

[0069] S203. The crushed product is classified by an ultrasonic vibration screening system: first screen 100 mesh, second screen 80 mesh, vibration frequency 28-32 kHz, and vibration amplitude 0.5-1 mm.

[0070] S204. The 80-100 mesh product is collected and dried by pulse airflow to make the moisture content ≤5%.

[0071] Further, in the gradient cooling process of S201, dehumidified air with a dew point ≤-15°C is introduced into the spiral conveying cooler at a flow rate of 2-3 m³ / min, so that the water activity Aw of the compound at the end of cooling is ≤0.35.

[0072] In S202, the rotor surface of the vortex ultrafine grinder is coated with a polytetrafluoroethylene wear-resistant coating with a thickness of 50-80 μm to reduce the adhesion of konjac powder.

[0073] In the above embodiment, by gradient heating through the feeding section (80-90°C) → mixing section (100-110°C) → discharging section (110-120°C), the molecular cross-linking of konjac glucomannan and resistant dextrin is promoted, forming a stable complex structure, which reduces the GI value of the final product by 15-20%. The increase of 20-30% in the rotation speed of the mixing section enhances the shear force, making the raw materials mix more uniformly, while avoiding the destruction of nutrients caused by local overheating. Three-stage gradient cooling (80°C→50°C→25°C→5°C) is adopted, with the cooling rate gradually decreasing from 10°C / min to 2°C / min, preventing the breaking of konjac polysaccharide molecular chains caused by sudden temperature changes and preserving its hydration capacity. Through three-stage precise temperature control (80°C→5°C), the complex is prevented from absorbing moisture and caking due to sudden cooling, while the gel properties of resistant dextrin are preserved. Combined with dehumidified air with a dew point of ≤-15°C, the water activity Aw at the cooling endpoint is ≤0.35, inhibiting microbial activity and extending the shelf life of the raw material semi-finished product. By controlling the water activity with dehumidified air, the wall sticking problem during subsequent pulverization is inhibited from the source. Pulverization is carried out in a nitrogen environment, effectively preventing the oxidation of polyphenolic substances in the konjac powder. Vortex pulverization combined with inert gas environment prevents the oxidation and degradation of konjac polysaccharide, and the particle size distribution is concentrated. Through a pulverization pressure of 0.6-0.8 MPa and a rotor speed of 8000-10000 rpm, uniform powder of 80-100 mesh is obtained, ensuring the process stability of subsequent mixing and granulation. Special collection of 80-100 mesh (100 mesh ≈ 150 μm, 80 mesh ≈ 180 μm) screen inter-material, 150-180 μm particles have the best specific surface area. If the particle size is too fine, such as less than 150 μm, it is easy to cause clumping, such as konjac glucomannan swelling into a glue block when encountering water. If the particle size is too coarse, such as greater than 180 μm, it settles too quickly, and 80-100 mesh particles can be uniformly dispersed in water for 5-10 minutes. This particle size range maximizes the slow-release effect of konjac fiber and resistant dextrin. And particles larger than 180 μm have a rough texture in the oral cavity, and 150-180 μm particles continuously release flavor substances in a saliva environment, such as added mineral ions, and the sensory quality can be improved. 80 mesh screening uses 28 kHz, 100 mesh screening uses 30 kHz, and the amplitude is adjusted by 0.5-1 mm accordingly.

[0074] In one specific embodiment, S3 specifically includes:

[0075] S301, accurately weigh each component according to the mass ratio: complex: inulin: soybean protein isolate = 100:10:5;

[0076] S302, pre-mix inulin and part of the complex at a mass ratio of 1:1 for 3-5 minutes to form a primary mixture;

[0077] S303, add the remaining complex in two portions, with a 2-minute interval between each addition, and mix for 5 minutes;

[0078] S304, finally, the soybean protein isolate is added in the form of atomized powder, the powder spraying rate is 0.5-1.0 g / s, and the mixing container is kept at low speed stirring at the same time, 8-10 r / min, the total mixing time is 15-20 minutes.

[0079] Further, in the S302, when the inulin is premixed with part of the complex, 0.1-0.3% of silicon dioxide based on the mass of inulin is added as a flow aid, and the premixed product is left for 5 minutes to eliminate static electricity;

[0080] In the S304, when the atomized powder is sprayed, 0.5-1.0% of lecithin ethanol solution based on the mass of soybean protein isolate is sprayed synchronously, the concentration is 10%, and the spraying rate is 0.2-0.3 mL / s.

[0081] In the above embodiment, by designing a step-by-step mixing process, the inulin is first premixed with part of the complex, then the remaining complex is added in several times, and finally the soybean protein is added by atomization. This effectively solves the mixing problem of raw materials with different densities and particle sizes. This gradual mixing method significantly improves the uniformity of each component and avoids the segregation problem commonly seen in traditional mixing processes. Adding an appropriate amount of flow aid during the premixing stage and setting a standing period effectively eliminates the electrostatic adsorption phenomenon between the raw materials. This measure significantly reduces the tendency of powder agglomeration, ensuring good flowability of the material in subsequent processes, creating favorable conditions for uniform mixing. Using atomized powder spraying technology with a surfactant solution allows the soybean protein isolate to be uniformly dispersed in the mixing system. This method not only avoids the aggregation of protein particles, but also improves the compatibility of protein with other components, enhancing the solubility of the final product. The step-by-step mixing process avoids direct contact between heat-sensitive components (such as inulin) and high-temperature materials, effectively protecting the activity of functional components. At the same time, the mild mixing conditions maximize the preservation of the natural structure and functional properties of soybean protein. Standardized process parameters and step-by-step operation design ensure consistency between different production batches. This controllable mixing method provides reliable protection for large-scale production, reducing the risk of product quality fluctuations. Compared with traditional mixing processes, this step-by-step mixing method optimizes the process design, ensuring mixing quality while improving production efficiency, achieving reasonable control of energy consumption, and demonstrating good economic benefits. This mixing process exhibits significant advantages in the uniformization of multi-component systems through the synergistic effect of physical and chemical means, providing an ideal material basis for subsequent processing procedures, ultimately ensuring the excellent quality and stable performance of the product.

[0082] In one specific embodiment, the S4 specifically includes:

[0083] S401, accurately weigh each component according to the mass ratio: premix: vitamin and mineral microcapsule = 100:1;

[0084] S402, the vitamin and mineral microcapsules are placed in a fluidized bed mixer, dry air with relative humidity ≤ 30% is introduced at a flow rate of 1-1.5 m³ / min, and the vitamin and mineral microcapsules are pre-dispersed for 5-8 minutes;

[0085] S403, the premix is added to the fluidized bed in three times, each time with an interval of 3 minutes, the mixing speed is controlled at 15-20 r / min, and the total mixing time is 12-15 minutes;

[0086] S404, during the mixing process, the mixing is paused every 3 minutes and is placed for 1 minute to eliminate static accumulation.

[0087] Further, in the S402, the dry air is added with nano-silicon dioxide aerosol accounting for 0.03-0.08% of the mass of the vitamin and mineral microcapsules, and the particle size is 20-50 nm to enhance the flowability and anti-adhesion of the vitamin and mineral microcapsules; in specific implementation, the nano-silicon dioxide can be premixed with anhydrous glucose at a ratio of 1:10, then added to the dry air (flow rate 1.2 m³ / min) accounting for 0.3% of the total mass of the vitamin and mineral microcapsules, dispersed by an ultrasonic atomizer, and then introduced into the fluidized bed mixer.

[0088] In the S403, when the premix is added each time, 0.02-0.05% of sodium alginate solution accounting for the mass of the premix is sprayed synchronously, the concentration is 1%, and the spraying rate is 0.1-0.2 mL / s.

[0089] In the above embodiments, the pre-dispersion of microcapsules by the fluidized bed mixer, combined with low humidity drying air, effectively prevents moisture absorption and caking of microcapsules, ensuring their initial dispersion state in the mixing system. The addition of nano-sized silicon dioxide in the drying air significantly improves the surface flowability of microcapsules, reducing inter-particle adhesion and agglomeration. Using a three-batch addition method for the premix, combined with precise control of the mixing speed, achieves gradual and uniform mixing of microcapsules and premix, avoiding local over-concentration or stratification. Regularly pausing the mixing and allowing it to stand effectively eliminates particle aggregation caused by static electricity, ensuring uniform mixing. Simultaneous injection of sodium alginate solution during each addition of the premix forms a protective film, preventing microcapsule damage and promoting the combination of different components. The formation of a hydrophilic layer on the particle surface by sodium alginate improves the wettability and dispersion stability of the overall system. Strict control of air humidity, flow rate, and mixing parameters ensures consistency of different batches of products, reducing the impact of environmental factors on mixing results. The dual action of nano-sized silicon dioxide and sodium alginate significantly reduces material adhesion to the inner wall of the equipment, improving production efficiency and product yield. Mild mixing conditions and precise parameter control minimize mechanical damage to the microcapsule structure, ensuring the stability of vitamins and minerals. Ensuring uniform distribution of micronutrients in the final product avoids local excess or deficiency. In summary, through the synergistic effect of physical dispersion, chemical modification, and precise control, the perfect combination of micronutrient fortifiers and main ingredients is achieved, providing a uniform and stable material basis for subsequent granulation processes, while ensuring the integrity of nutrients and product quality.

[0090] Specific examples will be given below to illustrate the application.

[0091] Example 1:

[0092] Raw material preparation: 10 kg of konjac powder; 10 kg of resistant dextrin; 1 kg of inulin; 0.5 kg of soybean protein isolate; 0.1 kg of vitamin and mineral microcapsules; and an appropriate amount of hydroxypropyl methylcellulose (prepared into a 5% aqueous solution).

[0093] Preparation steps:

[0094] S110, basic mixing: 10 kg of konjac powder and 10 kg of resistant dextrin are mixed in a mixer at a mass ratio of 1:1 for 15 minutes until uniform;

[0095] S120, double screw extrusion: the mixed powder is added to a double screw extruder, and the extrusion temperature is set to 100°C. The konjac-resistant dextrin compound is obtained by extrusion treatment.

[0096] S130, cooling and crushing: the extrusion product is cooled to room temperature and crushed to a fineness of 80-100 mesh.

[0097] S140, premix preparation: take 10 kg of pulverized compound and mix with 1 kg of inulin and 0.5 kg of soybean protein, stir for 15 minutes until uniform.

[0098] S150, nutrition fortification: mix the premix with 0.1 kg of vitamin and mineral microcapsules, stir for 10 minutes until uniformly dispersed.

[0099] S160, fluidized bed granulation: add the fortified premix to the fluidized bed granulator, spray in 5% hydroxypropyl methylcellulose solution (15 mL / min), control the inlet air temperature to 55°C for granulation.

[0100] S170, drying and packaging: dry the granular product at 45°C until the moisture content is ≤5%.

[0101] Product properties: uniform granules, good brewing properties, low GI characteristics, uniform distribution of nutrients, shelf life up to 12 months.

[0102] Example 1 data analysis:

[0103] 1. Basic physical property testing:

[0104] Particle size distribution: 92% of 80-100 mesh, using a laser particle size analyzer. Moisture content: 4.8%, using the constant weight method at 105°C (GB 5009.3). Brewing time: 35±3 seconds, observed under stirring in 200 mL of 60°C water. Bulk density: 0.52 g / cm³. Standard measuring cylinder method.

[0105] 2. Nutrient analysis:

[0106] Per 100 g: dietary fiber: 28.6 g, using enzymatic method (GB 5009.88); protein: 15.2 g, using Kjeldahl method. Vitamin B12 retention rate: 89%, using HPLC method (GB 5009.217).

[0107] 3. Functional property testing: GI value (glucose = 100): 48±2; water absorption expansion rate (20°C): 5.8 times; shelf life (room temperature), 12 months without caking.

[0108] Example 2:

[0109] Raw material preparation: konjac powder: 10 kg; resistant dextrin: 10 kg; inulin: 1 kg; soybean protein isolate: 0.5 kg; vitamin and mineral microcapsules: 0.1 kg, specifically: multivitamin: 15% (including A, D, E, B vitamins, etc.), minerals: 20% (calcium carbonate, ferrous sulfate, etc.), wall material: 65% (arabic gum: β-cyclodextrin = 1:1), phospholipid: 0.8%; hydroxypropyl methylcellulose: appropriate amount (prepared into 5% aqueous solution).

[0110] Preparation steps:

[0111] S210, base mixing: 10 kg of konjac powder and 10 kg of resistant dextrin were put into a three-dimensional mixer and mixed for 15 minutes at a mass ratio of 1:1 until uniform.

[0112] S220, twin-screw extrusion: the mixed powder was added to a twin-screw extruder, and the extrusion temperature was set to 100°C to form a konjac-resistant dextrin compound.

[0113] S230, cooling and crushing: the extrusion product was cooled to room temperature and crushed to 80-100 mesh,

[0114] S240, preparation of premix: 10 kg of crushed compound was mixed with 1 kg of inulin and 0.5 kg of soybean protein,

[0115] at a mass ratio of 100:10:5, and stirred for 15 minutes.

[0116] S250, nutrition fortification: the premix was mixed with 0.1 kg of vitamin and mineral microcapsules at a mass ratio of 100:1 and stirred for 10 minutes.

[0117] Microcapsule preparation method: the vitamins and minerals were dispersed in a 45°C wall material solution, homogenized, and spray dried (inlet temperature 155°C, outlet temperature 75°C) to obtain 80μm microcapsules, with 0.8% phospholipid as an emulsifier.

[0118] S260, fluidized bed granulation: the fortified premix was added to a fluidized bed granulator, 5% hydroxypropyl methylcellulose solution (15mL / min) was sprayed, and the inlet temperature was controlled at 55°C for granulation.

[0119] S270, drying and packaging: the granular product was dried at 45°C to a moisture content of ≤5%,

[0120] Product properties: granule uniformity: passed through 80-100 mesh screen; infusion property: completely dispersed within 30 seconds; microcapsule integrity: no damage observed under microscope; GI value: ≤45 (glucose reference).

[0121] Example 2 data analysis:

[0122] 1. Microcapsule performance test:

[0123] Microcapsule embedding rate: 93.5%, UV spectrophotometry; particle size distribution: D50=82μm (90% within 50-100μm), laser diffraction method; iron element oxidation rate (3 months): 8.2%, atomic absorption spectrometry.

[0124] 2. Product property comparison, as shown in Table 1:

[0125] Table 1

[0126] Properties Example 2 Conventional meal replacement powder Vitamin E retention rate (after processing) 91% 68% Mineral dissolution rate (2h) 35% 62% Sensory score (0-10) 8.7 6.2

[0127] 3. Accelerated stability test:

[0128] Changes after one month: 12% loss of vitamin C; water activity Aw from 0.28→0.31; no visible caking.

[0129] Achievements: microencapsulation improves the process retention rate of heat-sensitive nutrients (vitamin B group) by more than 25%; through in vitro digestion experiments, the glucose release rate of the product of Example 2 is reduced by 42% (compared with ordinary konjac powder); electron microscope observation shows that the microcapsules still maintain the complete structure after 3 months of storage.

[0130] Example 3:

[0131] Raw material preparation: 10 kg of konjac powder; 10 kg of resistant dextrin; 1 kg of inulin; 0.5 kg of soybean protein isolate; 0.1 kg of vitamin and mineral microcapsules; and an appropriate amount of hydroxypropyl methyl cellulose (to prepare a 5% water solution)

[0132] Preparation steps:

[0133] S310, basic mixing: mix 10 kg of konjac powder with 10 kg of resistant dextrin at a mass ratio of 1:1, and use a three-dimensional mixer to mix for 15 minutes until uniform.

[0134] S320, twin-screw extrusion: A, set the segmented temperature control mode: feeding section: 85°C, mixing section: 105°C, discharge section: 115°C; B, screw speed control: feeding section: 120 rpm, mixing section: 150 rpm, continuous extrusion treatment to form a composite.

[0135] S330, gradient cooling and crushing: three-stage cooling of the spiral conveying cooler: first stage: 80°C→50°C (10°C / min, 3 min) second stage: 50°C→25°C (5°C / min, 5 min), third stage: 25°C→5°C (2°C / min, 10 min); pass in dehumidified air at dew point -25°C (flow rate 2.5 m³ / min), vortex type ultrafine crushing: nitrogen protection environment, crushing pressure 0.7 MPa, rotor speed 9000 rpm, feeding speed 10 kg / h, polytetrafluoroethylene coated rotor, ultrasonic screening (100 / 80 mesh), pulse airflow drying to moisture ≤5%.

[0136] S340, preparation of premix: mix 10 kg of crushed composite with 1 kg of inulin and 0.5 kg of soybean protein, and stir at a mass ratio of 100:10:5 for 15 minutes.

[0137] S350, Nutrient fortification: Mix the premix with 0.1 kg of vitamin and mineral microcapsules, stirring for 10 minutes at a mass ratio of 100:1.

[0138] S360, Fluidized bed granulation: Add the fortified premix to the fluidized bed granulator, spray in 5% hydroxypropyl methylcellulose solution (15 mL / min), control the inlet air temperature at 55°C for granulation.

[0139] S370, Drying and packaging: Dry the granular product at 45°C until the moisture content is ≤5%

[0140] Process features: Temperature control by segmented extrusion ensures molecular crosslinking; gradient cooling maintains material properties; nitrogen protection during pulverization prevents oxidation; dehumidified air controls water activity to ≤0.3; wear-resistant coating reduces equipment adhesion.

[0141] Example 3 data analysis:

[0142] 1. Verification of extrusion process parameters:

[0143] Actual temperature in the mixing section of the extruder: 106.2 ± 0.8°C, technical standard 100-110°C; screw speed increase ratio 27.5%, technical standard 20-30%; change in molecular weight distribution of the composite: peak shift to the right by 15%, using gel permeation chromatography.

[0144] 2. Cooling and pulverization effect:

[0145] Final temperature of gradient cooling: 4.8 ± 0.3°C, measured by infrared temperature measurement; qualified rate of particle size after pulverization: 95.3%, using sieve method (80-100 mesh); oxygen content in nitrogen environment: 0.4%, using gas analyzer; maximum temperature in the pulverization chamber: 33.7°C, monitored by thermocouple.

[0146] 3. Product performance testing, as shown in Table 2:

[0147] Table 2

[0148] Item Example 3 Uncontrolled temperature control group Konjac glucomannan retention rate 97.2% 83.5% Rinsing sedimentation rate (10min) 8% 22% Water activity Aw 0.28 0.41

[0149] Conclusion: The gradient cooling process increases the intrinsic viscosity retention rate of konjac polysaccharide by 16.3% (p<0.05).

[0150] Example 4:

[0151] Raw material preparation: Konjac powder: 10 kg; resistant dextrin: 10 kg; inulin: 1 kg; soybean protein isolate: 0.5 kg; vitamin and mineral microcapsules: 0.1 kg; hydroxypropyl methylcellulose: appropriate amount (prepared into a 5% aqueous solution); silicon dioxide (flow aid): 3 g (0.3% of the mass of inulin); lecithin ethanol solution: 4 mL (10% concentration, 0.8% of the mass of soybean protein).

[0152] Preparation steps:

[0153] S410, Base mixing: 10kg of konjac powder and 10kg of resistant dextrin were mixed in a 1:1 mass ratio, and a V-shaped mixer was used for mixing for 15 minutes until uniform.

[0154] S420, Twin-screw extrusion: The mixed powder was added to a twin-screw extruder, and the extrusion temperature was set to 100°C to form a konjac-resistant dextrin compound.

[0155] S430, Cooling and crushing: The extrusion product was cooled to room temperature and crushed to 80-100 mesh.

[0156] S440, Preparation of premix: A, accurate weighing: crushed compound: 10kg; inulin: 1kg; soybean protein isolate: 0.5kg. B, primary premix: mix 5kg of compound with 1kg of inulin, add 3g of silicon dioxide, premix for 4 minutes, and stand for 5 minutes to eliminate static electricity. C, stepwise mixing: add the remaining 5kg of compound (in two times, with an interval of 2 minutes), and mix for 5 minutes each time. D, protein addition: spray 0.5kg of soybean protein at a rate of 0.8g / s, and simultaneously spray 4mL of lecithin ethanol solution (10% concentration, 0.25mL / s), low-speed stirring (9r / min) for a total mixing time of 18 minutes.

[0157] S450, Nutrient fortification: Mix the premix with 0.1kg of vitamin and mineral microcapsules, and stir for 10 minutes at a mass ratio of 100:1.

[0158] S460, Fluidized bed granulation: Add the fortified premix to the fluidized bed granulator, spray 5% hydroxypropyl methylcellulose solution (15mL / min), and control the inlet air temperature to 55°C for granulation.

[0159] S470, Drying and packaging: Dry the granular product at 45°C until the moisture content is ≤5%.

[0160] Process features: 1. Stepwise mixing ensures uniformity: inulin is premixed with part of the compound, and the remaining compound is added in two times. 2. Anti-caking treatment: silicon dioxide eliminates static electricity, and lecithin improves protein dispersibility. 3. Atomized powder spraying technology:

[0161] Precise control of powder spraying rate (0.5-1.0g / s), and simultaneous liquid spraying to ensure coating effect.

[0162] Example 4 data analysis:

[0163] 1. Key data of mixing process:

[0164] Silica addition: 0.28%, control range 0.1-0.3%; lecithin solution spray uniformity: CV=4.2%, using high-speed camera analysis; mixing uniformity (CV value): 3.8%, near-infrared spectral imaging.

[0165] 2. Protein dispersion effect, as shown in Table 3:

[0166] Table 3

[0167] Test item Example 4 Direct mixing group Soy protein dispersion index 0.88 0.52 Dissolution time (complete dispersion) 28 seconds 51 seconds Particle size distribution span 1.15 1.87

[0168] 3. Static control effect, as shown in Table 4:

[0169] Table 4

[0170] Index Before treatment After treatment Powder surface static voltage 5.6kV 0.3kV Equipment adhesion loss rate 0.8% 5.2% Difference between mixed batches ±1.2% ±6.5%

[0171] It can be obtained that lecithin coating increases the solubility near the isoelectric point of soybean protein by 42%; the step-by-step mixing process reduces energy consumption by 35% and increases production capacity by 28% (compared with traditional mixing); and static control reduces raw material loss rate by 84%.

[0172] Example 5:

[0173] Raw material preparation: konjac powder: 10 kg; resistant dextrin: 10 kg; inulin: 1 kg; soybean protein isolate: 0.5 kg;

[0174] Vitamin and mineral microcapsules: 0.1 kg; hydroxypropyl methylcellulose: appropriate amount (prepared into a 5% aqueous solution); nano-silicon dioxide aerosol: 0.075 g (0.075% of the mass of the microcapsules); sodium alginate solution: 1% concentration, 30 mL (0.03% of the total mass of the premix).

[0175] Preparation steps:

[0176] Step S510, basic mixing: mix 10 kg of konjac powder with 10 kg of resistant dextrin at a mass ratio of 1:1; use a three-dimensional mixer to mix for 15 minutes until uniform.

[0177] Step S520, double screw extrusion: add the mixed powder to a double screw extruder, set the extrusion temperature to 100°C, and form a konjac-resistant dextrin compound.

[0178] Step S530, cooling and crushing: cool the extrusion product to room temperature and crush it to 80-100 mesh.

[0179] Step S540, preparation of premix: mix 10 kg of crushed compound with 1 kg of inulin and 0.5 kg of soybean protein, and stir for 15 minutes at a mass ratio of 100:10:5.

[0180] Step S550, fortification: A, accurate weighing: premix: 10 kg; vitamin and mineral microcapsules: 0.1 kg

[0181] B, microcapsule pre-dispersion: place the microcapsules in a fluidized bed mixer, introduce dry air (1.2 m³ / min) with RH≤30%, add 0.075 g of nano-silica aerosol, and pre-disperse for 7 minutes; C, stepwise mixing: add the premix in three portions (with 3 minutes interval); mixing speed: 18 r / min; synchronously spray 10 mL of sodium alginate solution (from the right 10) for each addition; D, electrostatic control: pause for 1 minute every 3 minutes of mixing, and the total mixing time is 14 minutes.

[0182] S560, fluidized bed granulation: add the fortified premix into a fluidized bed granulator, spray 5% hydroxypropyl methylcellulose solution (15 mL / min), and control the inlet air temperature to 55°C for granulation.

[0183] S570, drying and packaging: dry the granular product at 45°C until the moisture content is ≤5%.

[0184] Process features: 1, fluidized bed pre-dispersion technology: control the humidity to ≤30% to prevent moisture absorption, and use nano-silica to enhance the flowability.

[0185] 2. Progressive mixing: add the premix in three portions, and accurately control the mixing speed (15-20 r / min); 3, antistatic treatment: intermittent mixing to eliminate charge accumulation. 4. Surface modification: sodium alginate solution improves the wettability of the particles, and synchronous spraying ensures uniform coating.

[0186] Example 5 data analysis:

[0187] 1, microcapsule dispersion performance test, as shown in Table 5:

[0188] Table 5

[0189] Test item Example 5 Conventional mixing process Pre-dispersion uniformity (CV value) 4.1% 12.6% Nano-silica adsorption efficiency 92.3% - Microcapsule breakage rate after mixing 1.8% 7.5%

[0190] 1, fluidized bed mixing effect: control the air relative humidity to 28.5±1.2% RH using a humidity sensor; sodium alginate coating coverage: 89.7% using fluorescence labeling method; ingredient segregation index after mixing: 0.05 using near-infrared imaging.

[0191]

[0192] 2, nutrient retention comparison, as shown in Table 6:

[0193] Table 6

[0194] Ingredients Example 5 retention rate Traditional process retention rate Vitamin B12 (3 months) 94.2% 76.8% Ferrous ion oxidation rate 9.5% 34.2% Folic acid bioavailability 82.1% 63.4%

[0195] Example 6: ​

[0196] Raw material preparation: Konjac powder: 10 kg (moisture content ≤8%, glucosan ≥85%); resistant dextrin: 10 kg (DE value ≤10%); inulin: 1 kg (DP ≥10); soybean protein isolate: 0.5 kg (protein content ≥90%); vitamin and mineral microcapsules: 0.1 kg: 15% (containing A, D, E, B group, etc.), 20% (calcium carbonate, ferrous sulfate, etc.), wall material: 64.2% (arabic gum: β-cyclodextrin = 1:1), phospholipid: 0.8%, hydroxypropyl methyl cellulose: 500 g (prepared into 5% aqueous solution), silicon dioxide: 3 g (0.3% of inulin); lecithin ethanol solution: 4 mL (10% concentration, 0.8% of soybean protein), nanometer silicon dioxide aerosol: 0.075 g (0.075% of microcapsules), sodium alginate solution: 30 mL (1% concentration, 0.03% of premix).

[0197] Preparation steps:

[0198] S610: Basic mixing: 10 kg of konjac powder and 10 kg of resistant dextrin are put into a three-dimensional mixer and mixed at a mass ratio of 1:1 for 15 minutes until uniform.

[0199] S620: Twin-screw extrusion: A, set the temperature control in sections: feeding section: 85°C; mixing section: 105°C, screw rotation speed 150 rpm (increase by 25%); discharging section: 115°C. B, continuously extrude to form a composite.

[0200] S630: Gradient cooling and crushing: A, three-stage spiral cooling: 80°C→50°C (10°C / min, 3 min), 50°C→25°C (5°C / min, 5 min), 25°C→5°C (2°C / min, 10 min); B, pass in dew point-25°C dehumidified air (2.5 m³ / min); C, vortex crushing under nitrogen protection: polytetrafluoroethylene coated rotor, pressure 0.7 MPa, rotation speed 9000 rpm; D, ultrasonic sieving (100 / 80 mesh); E, pulse airflow drying to moisture content ≤5%.

[0201] S640: Preparation of premix: A, stepwise mixing: primary premix: 5 kg of composite + 1 kg of inulin + 3 g of silicon dioxide, premix for 4 minutes; stand for 5 minutes to dissipate static electricity; add the remaining 5 kg of composite in two times (interval 2 minutes, mix for 5 minutes each time); B, atomized powder spraying: soybean protein is sprayed at a rate of 0.8 g / s; 4 mL of lecithin ethanol solution is sprayed synchronously (0.25 mL / s)

[0202] C, low-speed stirring (9 r / min) for a total of 18 minutes

[0203] S650: Nutrient fortification: A, fluidized bed pre-dispersion: microcapsule + nano-silica aerosol, RH < 30% dry air pre-dispersion for 7 minutes; B, add pre-mix (such as 30% + 30% + 40%) in three times: each time interval 3 minutes, synchronously spray 10 mL sodium alginate solution, mixing speed 18 r / min, C, rest for 1 minute to dissipate static electricity every 3 minutes of mixing, D, total mixing time 14 minutes.

[0204] S660: Fluidized bed granulation: spray 5% hydroxypropyl methylcellulose (15 mL / min), inlet air temperature 55°C granulation (granules 0.4-0.6 mm).

[0205] S670: Drying and packaging: hot air drying at 45°C to moisture < 5%, nitrogen-filled packaging.

[0206] The integrated process advantages are: 1. double protection of microcapsules; 2. precise temperature control extrusion; 3. inert environment treatment; 4. intelligent mixing system; 5. nutrient synergistic effect.

[0207] Example 6 data analysis:

[0208] 1. Comprehensive process verification data:

[0209] Extrusion composite GI value reduction: 46.3 (control 58.7), in vitro digestion method; microcapsule slow-release effect (2h): release rate 62%, dialysis membrane method; total mixing energy consumption: reduced by 41%, electric energy monitoring.

[0210] 2. Product quality analysis

[0211] Particle sphericity: 93.5%, industry standard > 80%; infusion stability (2h): no stratification; total vitamin retention rate: 91.4%, industry standard > 75%.

[0212] 3. Accelerated stability test (40°C / 75%RH), as shown in Table 7:

[0213] Table 7

[0214] Time Water activity Aw Clumping area ratio Vitamin C retention 0 months 0.29 0% 100% 3 months 0.32 1.2% 88.5% 6 months 0.35 3.7% 76.2%

[0215] From the above, the integrated process increases the nutrient retention rate at room temperature by 25-40%; nitrogen protection pulverization makes the polyphenol oxidation inhibition rate reach 92.4%; the composite wall material microcapsule shows a stepwise release characteristic in simulated gastrointestinal fluid.

[0216] The number of devices and processing scale described herein are used to simplify the description of the present application. Applications, modifications and variations of the present application will be apparent to those skilled in the art.

[0217] While embodiments of the application have been disclosed in connection with the above specification and drawings this description is not intended to limit the scope of the application and many modifications, enhancements, alternatives, and variations will become apparent to those skilled in the art from this disclosure. Accordingly, it is intended that the application not be limited to the described embodiments, but that it include all variations falling within the scope of the claims, and their equivalents.

Claims

1. A method for preparing a low-GI konjac meal replacement powder, characterized by, Includes the following steps: S1. Mix konjac flour and resistant dextrin at a mass ratio of 1:0.5-1:2 to obtain a mixed powder; S2. Place the mixed powder in a twin-screw extruder and extrude it at an extrusion temperature of 80℃-120℃ to form a complex with konjac flour and resistant dextrin. Cool the complex and pulverize it to a particle size of 80-100 mesh. S3. Mix the pulverized complex with inulin and soy protein isolate at a mass ratio of 100:10:5 to obtain a premix. S4. Mix the premix with vitamin and mineral microcapsules at a mass ratio of 100:1 to obtain the fortified premix; S5. Place the reinforced premix in a fluidized bed granulator, use a 5% (w / w) aqueous solution of hydroxypropyl methylcellulose as a binder, spray at a speed of 10 mL / min-20 mL / min, and inlet air temperature of 50℃-60℃ to perform fluidized bed granulation and obtain granular meal replacement powder. S6. Dry the granular meal replacement powder at 40℃-50℃ until the moisture content is less than 5% to obtain low-GI konjac meal replacement powder. Specifically, the cooling and pulverizing of the composite to a particle size of 80-100 mesh involves: S201. The extruded composite is subjected to gradient cooling through a screw conveyor cooler: First stage: 80℃→50℃, cooling rate 10℃ / min, time 3min; Second stage: 50℃→25℃, cooling rate 5℃ / min, time 5min; Third stage: 25℃→5℃, cooling rate 2℃ / min, time 10min. S202. The cooled composite material is fed into a vortex ultrafine pulverizer and pulverized under nitrogen protection. The control parameters are: pulverization pressure 0.6-0.8MPa, rotor speed 8000-10000rpm, feeding speed 8-12kg / h, and pulverization chamber temperature ≤35℃. S203. The pulverized products are classified using an ultrasonic vibration sieving system: 100 mesh for the first-stage sieve, 80 mesh for the second-stage sieve, vibration frequency 28-32kHz, and amplitude 0.5-1mm. S204. Collect the material between 80-100 mesh sieves and dry it using pulsed airflow to achieve a moisture content of ≤5%. S4 specifically includes: S401. Weigh each component precisely according to the mass ratio: premix: vitamin and mineral microcapsules = 100:1; S402. Place the vitamin and mineral microcapsules in a fluidized bed mixer and introduce dry air with a relative humidity ≤30% at a flow rate of 1-1.5 m. 3 / min, pre-disperse the vitamin and mineral microcapsules for 5-8 minutes; S403. Add the premix to the fluidized bed in three portions, with a 3-minute interval between each addition. Control the mixing speed at 15-20 r / min and the total mixing time at 12-15 minutes. S404. During the mixing process, pause mixing every 3 minutes and let it stand for 1 minute to eliminate static electricity buildup. In step S402, nano-silica aerosol with a particle size of 20-50 nm, accounting for 0.03-0.08% of the mass of the vitamin and mineral microcapsules, is added to the dry air to enhance the flowability and anti-adhesion of the vitamin and mineral microcapsules. In step S403, each time the premix is ​​added, a sodium alginate solution accounting for 0.02-0.05% of the mass of the premix is ​​sprayed simultaneously at a concentration of 1% and a spraying rate of 0.1-0.2 mL / s.

2. The preparation method of low-GI konjac meal replacement powder as described in claim 1, characterized in that, The vitamin and mineral microcapsules comprise: 10%-20% by mass of compound vitamins, 15%-25% by mass of minerals, and 55%-75% by mass of wall material; wherein the compound vitamins include: vitamins A, D, E, B1, B2, B6, B12, folic acid, and calcium pantothenate; the minerals include calcium carbonate, ferrous sulfate, zinc gluconate, and sodium selenite; and the wall material is composed of gum arabic and β-cyclodextrin in a mass ratio of 1:1 to 1:

2. The method for preparing the vitamin and mineral microcapsules includes: Complex vitamins and minerals were dispersed in a wall material solution at 40℃-50℃, homogenized, and then spray-dried with an inlet air temperature of 150℃-160℃ and an outlet air temperature of 70℃-80℃ to obtain vitamin and mineral microcapsules with a particle size of 50μm-100μm.

3. The preparation method of low-GI konjac meal replacement powder as described in claim 2, characterized in that, In the vitamin and mineral microcapsules, 0.5%-1% of phospholipids as emulsifiers are also added.

4. The preparation method of low-GI konjac meal replacement powder as described in claim 1, characterized in that, In S2, the twin-screw extruder adopts a segmented temperature control mode, wherein the temperature of the feeding section is 80℃-90℃, the temperature of the mixing section is 100℃-110℃, the temperature of the discharge section is 110℃-120℃, and the screw speed in the mixing section is 20%-30% higher than that in the feeding section.

5. The method for preparing low-GI konjac meal replacement powder as described in claim 4, characterized in that, In the gradient cooling process of S201, dehumidified air with dew point ≤-15℃ is introduced into the spiral conveying cooler at a flow rate of 2-3 m 3 / min, so that the moisture activity Aw of the composite at the cooling endpoint is ≤0.

35. In S202, the rotor surface of the vortex ultrafine pulverizer is coated with a polytetrafluoroethylene wear-resistant coating with a thickness of 50-80μm to reduce the adhesion of konjac powder.

6. The method for preparing low-GI konjac meal replacement powder as described in claim 1, characterized in that, S3 specifically includes: S301. Weigh each component precisely according to the mass ratio: complex: inulin: soy protein isolate = 100:10:5; S302. Mix inulin with a portion of the complex at a mass ratio of 1:1 for 3-5 minutes to form a primary mixture. S303. Add the remaining complex in two portions, with a 2-minute interval between each portion, and mix for 5 minutes each time. S304. Finally, add the soy protein isolate in the form of atomized spray powder at a spray rate of 0.5-1.0 g / s, while keeping the mixing container stirring at a low speed of 8-10 r / min. The total mixing time is 15-20 minutes.

7. The method for preparing low-GI konjac meal replacement powder as described in claim 6, characterized in that, In S302, when inulin is premixed with part of the complex, 0.1-0.3% of silica by mass of inulin is added as a flow aid, and the mixture is allowed to stand for 5 minutes after premixing to eliminate static electricity. In S304, during atomized powder spraying, a lecithin ethanol solution accounting for 0.5-1.0% of the soybean protein isolate is simultaneously sprayed in, with a concentration of 10% and a spraying rate of 0.2-0.3 mL / s.

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