Process for brewing sake

Abstract

The invention discloses a brewing process of sake, and relates to the technical field of wine brewing, and the brewing process comprises the following steps: (1) checking and accepting raw materials; (2) soaking the rice; (3) steaming the rice; (4) cylinder falling; 5) diastatic fermentation; (6) squeezing and separating; (7) decocting the wine; (8) cleaning and sterilizing the wine tank; (9) aging and storing; (10) blending and blending; (11) filtering; (12) sterilizing the wine; (13) cleaning and disinfecting the container; (14) filling and sealing; and (15) warehousing finished products. By optimizing fermentation parameters and innovating a sterilization process, the flavor stability and the production efficiency of the sake are effectively improved, and the product quality reaches the domestic advanced level.

Description

Technical Field

[0001] The invention relates to the technical field of liquor brewing, and more specifically to a brewing process for sake. Background Art

[0002] Traditional sake brewing processes have problems such as long fermentation cycles, unstable alcohol content, and difficulty in regulating flavor substances. In the prior art, some processes use high-temperature sterilization, resulting in flavor loss, or inaccurate control of fermentation parameters, affecting the quality stability of products. Therefore, we propose a brewing process for sake. Summary of the Invention

[0003] Aiming at the deficiencies of the prior art, the invention provides a brewing process for sake, which solves the problems raised in the above background art.

[0004] To achieve the above object, the present invention provides a brewing process for sake, and the brewing process includes:

[0005] (1) Raw material acceptance: Select high-quality raw material rice that meets the standards, and do not use raw material rice that is moldy, deteriorated, contains toxic or harmful substances, or is contaminated by toxic or harmful substances. During acceptance, visually inspect, detect by smell, and conduct laboratory random inspections to ensure compliance with food safety standards. Immediately return unqualified raw materials, and record batch information for each raw material for traceability.

[0006] (2) Soaking rice: Place glutinous rice in water for soaking, and the water level should completely cover the rice layer. Regularly change the soaking water to prevent rancidity. After soaking, drain until there is no dripping water, and the surface is slightly sticky, providing a uniform moisture basis for subsequent steaming of rice.

[0007] (3) Steaming rice: Use a steam jacketed pan for steaming. After steaming, the rice grains should be cooked through, loose and non-sticky.

[0008] (4) Transfer to the fermentation tank: After the steamed rice is cooled, put the rice, water, and koji into the fermentation tank in a ratio of 100:100:0.4. After transferring to the tank, gently press and level it, and cover the tank mouth with a sterile gauze to maintain a micro-aerobic environment to activate the initial reproduction of yeast.

[0009] (5) Saccharification and fermentation: The fermentation time is required to be 15 - 28 days, and the fermentation is carried out at a normal temperature below 28°C.

[0010] (6) Pressing and separation: Press the fermented mash through a filter press to separate the liquor from the lees. After collecting the liquor, let it stand for 24 hours, and remove the bottom sediment by siphoning to ensure that the raw liquor is clear and free of suspended matter.

[0011] (7) Heating and clarifying sake: Treat the raw liquor with an ultra-high temperature instantaneous sterilizer to inactivate residual yeast and miscellaneous bacteria. After sterilization, quickly cool the liquor to below 25°C to avoid flavor loss due to high-temperature oxidation. During the heating and clarifying process of sake, volatile off-flavors are simultaneously removed, and the stability of the liquor body is significantly improved.

[0012] (8) Cleaning and sterilizing wine tanks: Before and after each batch of production, use clean water to blend with Ande disinfectant to clean and sterilize containers such as wine tanks in the fermentation area. Circulate and rinse for 30 minutes, then rinse with sterile water until there is no residue. After cleaning, seal and reserve to prevent secondary contamination.

[0013] (9) Aging and storage: After sterilization, the wine liquid is transferred to an aging tank and stored in a constant-temperature wine cellar at 15 - 20 °C. Keep it in the dark and static for 3 - 6 months. During this period, regularly detect the changes in alcohol content, total acid, and flavor substances.

[0014] (10) Blending and formulation: According to the actual needs of finished product production, use base wines with different precisions for blending, and control the alcohol degree within the range of ≤20 °C and ≥8 °C.

[0015] (11) Filtration: The blended wine liquid is filtered through a pre-filter and a micron filter in sequence to remove fine particles and colloids, avoid the growth of microorganisms, and ensure that the wine liquid is clear and transparent.

[0016] (12) Wine sterilization: Before filling each production batch, perform secondary sterilization on the wine liquid. The sterilization time is 20 minutes, and the temperature is 115 °C - 125 °C.

[0017] (13) Container cleaning and disinfection: Use sterile water to rinse and sterilize each empty filling bottle, then automatically dry it, and transfer the empty bottles to the filling workshop through a conveyor belt.

[0018] (14) Filling and sealing: Use a fully automatic filling machine for quantitative filling to ensure airtightness.

[0019] (15) Finished product warehousing: After the finished products are labeled and boxed, they should be stored in a warehouse that is cool, dry, well-ventilated, and at a room temperature of 5 °C - 35 °C. Do not stack them outdoors, expose them to sunlight, rain, or place them near heat sources. Do not store them in the same warehouse with toxic, harmful, corrosive, volatile, or odorous items. The bottom of the packaging box in contact with the ground is padded with a spacer material of 100 mm.

[0020] Preferably, in step (3), the steaming rice temperature is 100 - 105 °C, and the duration is 40 - 50 minutes.

[0021] Preferably, in step (5), for the first 7 days before saccharification and fermentation, promote the activity of saccharifying enzymes at 28 °C, and then lower the temperature to 20 °C in the following 18 days to inhibit miscellaneous bacteria and slowly produce wine. Stir 1 - 2 times a day to ensure uniform distribution of oxygen.

[0022] Preferably, in step (8), the blending ratio of clean water and Ande disinfectant is 1 L of clean water : 20 ml of disinfectant.

[0023] Based on traditional techniques, this sake realizes an overall improvement in safety, quality, and efficiency through technological innovation. Its core advantages are as follows: First, it strictly controls raw materials and production processes. High-quality glutinous rice and compliant auxiliary materials are selected, combined with double sterilization processes and full-chain cleaning management to ensure that there are no additive residues in the product and the microbial indicators far exceed national standards, guaranteeing drinking safety from the source. Second, it adopts segmented temperature-controlled fermentation technology to optimize the balance between saccharification and wine production, and cooperates with precise blending and aging processes to endow the wine body with a mellow and harmonious flavor characteristics, retaining the delicate taste of traditional sake while improving quality stability. Third, it flexibly adapts to market demands. By adjusting fermentation parameters and blending ratios, it can produce low-alcohol refreshing types, high-alcohol aged types, and fruit-flavored innovative products to meet the consumption needs of multiple scenarios such as healthy light drinking and high-end collection. In addition, the process integrates environmental protection concepts, has a high resource recycling rate, low energy consumption in the production process, and combines the efficiency of industrial mass production with sustainability. Overall, this process breaks through in inheritance, creates sake products that are safe, reliable, have unique flavors, and are highly adaptable to the market with a scientific and standardized production system, providing a model for the modernization upgrade of the traditional brewing industry. Description of the Drawings

[0024] Figure 1 The attached drawing is a flow chart of the invention. Detailed Description of the Invention

[0025] Unless otherwise defined, the technical terms used in the following embodiments have the same meanings as commonly understood by those skilled in the art to which this invention belongs. The test reagents used in the following embodiments are all conventional biochemical reagents unless otherwise specified; the experimental methods are all conventional methods unless otherwise specified.

[0026] The technical solutions provided by the present invention will be described in detail below in conjunction with the embodiments, but they should not be construed as limiting the protection scope of the present invention.

[0027] First Embodiment

[0028] (1) Raw material acceptance: Select high-quality raw material rice that meets the standards. Do not use raw material rice that is moldy, deteriorated, contains toxic or harmful substances, or is contaminated by toxic or harmful substances. During acceptance, visual inspection, odor detection, and laboratory random inspections are carried out to ensure compliance with food safety standards. Unqualified raw materials are immediately returned, and batch information of each raw material is recorded for traceability.

[0029] (2) Soaking rice: Place glutinous rice in water for soaking. The water level needs to completely cover the rice layer. The soaking water is changed regularly to prevent rancidity. After soaking, drain it until there is no dripping water and the surface is slightly sticky, providing a uniform moisture basis for subsequent rice steaming.

[0030] (3) Rice steaming: Use a steam jacketed kettle for steaming. The steaming temperature is 100°C and the duration is 40 minutes. After steaming, the rice grains need to be fully cooked, loose and non-sticky.

[0031] (4) Placing into the vat: After the cooked rice has cooled, it is put into the fermentation vat at a ratio of 100 parts glutinous rice, 100 parts water, and 0.4 parts distiller's yeast. After placing it into the vat, it is gently pressed and leveled, and the vat mouth is covered with a sterile gauze to maintain a micro-oxygen environment to activate the initial reproduction of yeast.

[0032] (5) Saccharification and fermentation: Fermentation is carried out at an initial temperature of 28°C for 7 days, and then the temperature is lowered to 20°C for 18 days, with a total cycle of 25 days.

[0033] (6) Pressing and separation: The fermented mash is pressed by a filter press to separate the liquor from the distillers' grains. After the liquor is collected, it is left to stand for 24 hours, and the bottom sediment is removed by siphoning to ensure that the raw liquor is clear and free of suspended matter.

[0034] (7) Wine frying: The raw liquor is treated by an ultra-high temperature instantaneous sterilizer to inactivate the residual yeast and miscellaneous bacteria. After sterilization, the liquor is quickly cooled to below 25°C to avoid flavor loss due to high-temperature oxidation. During the wine frying process, volatile odors are simultaneously removed, and the stability of the wine body is significantly improved.

[0035] (8) Cleaning and sterilizing of wine tanks: Before and after each batch of production, the wine tanks and other containers in the fermentation area are cleaned and sterilized using a mixture of clean water and Ande disinfectant. The mixing ratio of clean water and Ande disinfectant is 1L of clean water: 20ml of disinfectant. It is circulated and rinsed for 30 minutes, and then rinsed with sterile water until there is no residue. After cleaning, it is sealed and reserved to prevent secondary contamination.

[0036] (9) Aging and storage: After sterilization, the liquor is transferred to an aging tank and stored in a constant-temperature wine cellar at 17°C. It is left to stand in the dark for 5 months, during which the alcohol content, total acid, and changes in flavor substances are regularly detected.

[0037] (10) Blending and formulation: According to the actual needs of finished product production, raw liquors with different precisions are used for blending. After blending, the alcohol content is 16.8% vol, the total sugar is 8.7g / L, and the pH is 4.35.

[0038] (11) Filtration: The blended liquor is filtered through a pre-filter and a micron filter in sequence to remove fine particles and colloids, avoid the growth of microorganisms, and ensure that the liquor is clear and transparent.

[0039] (12) Wine sterilization: Secondary sterilization of the liquor is carried out before filling for each production batch. The sterilization time is 20 minutes and the temperature is 120°C.

[0040] (13) Cleaning and disinfection of containers: Each empty filling bottle is rinsed and sterilized with sterile water, then automatically dried and transferred to the filling workshop through a conveyor belt.

[0041] (14) Filling and sealing: A fully automatic filling machine is used for quantitative filling to ensure the sealing performance.

[0042] (15) Finished product warehousing: After the finished products are labeled and packed in boxes, they should be stored in a warehouse at room temperature of 25°C, which is cool, dry and well-ventilated. They shall not be stacked outdoors, exposed to sunlight, rain or near heat sources, and shall not be stored in the same warehouse with toxic, harmful, corrosive, volatile or odorous substances. There should be a 100mm spacer material at the bottom of the packing box in contact with the ground.

[0043] Second Embodiment

[0044] (1) Raw material inspection: Select high-quality raw material rice that meets the standards. Do not use mildewed, deteriorated, or raw material rice containing or contaminated with toxic and harmful substances. During inspection, visual inspection, odor detection and laboratory sampling inspection are carried out to ensure compliance with food safety standards. Unqualified raw materials are immediately returned, and batch information of each raw material is recorded for traceability.

[0045] (2) Soaking rice: The glutinous rice is soaked in water, and the water level should completely cover the rice layer. The soaking water is changed regularly to prevent rancidity. After soaking, drain until there is no dripping water and the surface is slightly sticky, providing a uniform moisture basis for subsequent steaming of rice.

[0046] (3) Steaming rice: Use a steam jacketed pan for steaming. The steaming temperature is 100°C and the duration is 40 minutes. After steaming, the rice grains should be fully cooked, loose and non-sticky.

[0047] (4) Transferring to the vat: After the steamed rice is cooled, it is put into the fermentation vat at a ratio of glutinous rice 80, water 120, and koji 0.3. After transferring, gently press and level it, cover the vat mouth with a sterile gauze to maintain a micro-aerobic environment to activate the initial reproduction of yeast.

[0048] (5) Saccharification and fermentation: Ferment at a low temperature of 20°C for 28 days throughout the process to inhibit the growth of miscellaneous bacteria.

[0049] (6) Pressing and separation: The fermented mash is pressed by a filter press to separate the liquor from the distillers grains. After the liquor is collected, it is left to stand for 24 hours, and the bottom sediment is removed by siphoning to ensure that the raw liquor is clear and free of suspended matter.

[0050] (7) Wine frying: The raw liquor is treated by an ultra-high temperature instantaneous sterilizer to inactivate the residual yeast and miscellaneous bacteria. After sterilization, the liquor is quickly cooled to below 25°C to avoid flavor loss due to high-temperature oxidation. Volatile odors are removed synchronously during the wine frying process, and the stability of the liquor body is significantly improved.

[0051] (8) Cleaning and sterilizing of wine tanks: Before and after each batch of production, use a mixture of clean water and Ande disinfectant to clean and sterilize containers such as wine tanks in the fermentation area. The mixing ratio of clean water and Ande disinfectant is 1L of clean water: 20ml of disinfectant. Circulate and rinse for 30 minutes, then rinse with sterile water until there is no residue. After cleaning, close and reserve to prevent secondary contamination.

[0052] (9) Aging and storage: After sterilization, the liquor is transferred to an aging tank and stored in a constant-temperature wine cellar at 17°C. It is left to stand in the dark for 5 months, during which the alcohol content, total acid, and flavor substance changes are regularly detected.

[0053] (10) Blending and adjustment: According to the actual production needs of the finished product, base wines with different precisions are used for blending. After blending, the alcohol content is 8.5% vol, the total sugar is 5.2 g / L, and the pH is 3.8.

[0054] (11) Filtration: The blended liquor is filtered through a pre-filter and a micron filter in sequence to remove fine particles and colloids, prevent the growth of microorganisms, and ensure the liquor is clear and transparent.

[0055] (12) Liquor sterilization: Secondary sterilization of the liquor is carried out before filling for each production batch. The sterilization time is 20 minutes and the temperature is 120°C.

[0056] (13) Container cleaning and disinfection: Each empty filling bottle is rinsed and sterilized with sterile water, then automatically dried and transferred to the filling workshop via a conveyor belt.

[0057] (14) Filling and sealing: A fully automatic filling machine is used for quantitative filling to ensure airtightness.

[0058] (15) Finished product warehousing: After the finished product is labeled and boxed, it should be stored in a warehouse at a cool, dry, and well-ventilated place at a room temperature of 25°C. It shall not be stacked outdoors, exposed to sunlight, rain, or near heat sources, and shall not be stored in the same warehouse with toxic, harmful, corrosive, volatile, or odoriferous substances. The bottom of the packing box in contact with the ground is padded with a 100-mm spacer material.

[0059] Third Embodiment

[0060] (1) Raw material acceptance: High-quality raw material rice that meets the standards is selected. Raw material rice that is moldy, spoiled, contains toxic or harmful substances, or is contaminated by toxic or harmful substances shall not be used. During acceptance, visual inspection, odor detection, and laboratory sampling inspection are carried out to ensure compliance with food safety standards. Unqualified raw materials are immediately returned, and batch information of each raw material is recorded for traceability.

[0061] (2) Soaking rice: Glutinous rice is soaked in water, and the water level should completely cover the rice layer. The soaking water is changed regularly to prevent rancidity. After soaking, it is drained until there is no dripping and the surface is slightly sticky, providing a uniform moisture basis for subsequent rice steaming.

[0062] (3) Rice steaming: A steam jacketed pan is used for steaming. The steaming temperature is 100°C and the duration is 40 minutes. After steaming, the rice grains should be thoroughly cooked, loose, and non-sticky.

[0063] (4) Transfer to the vat: After the steamed rice is cooled, it is put into the fermentation vat at a ratio of 120 parts of glutinous rice, 80 parts of water, and 0.5 part of distiller's yeast. After transfer to the vat, it is gently pressed and leveled, and the vat mouth is covered with a sterile gauze to maintain a micro-oxygen environment to activate the initial reproduction of yeast.

[0064] (5) Saccharification and fermentation: Initial fermentation at 30°C for 3 days, followed by main fermentation at 25°C for 22 days, with a total cycle of 25 days.

[0065] (6) Pressing and separation: The fermented mash is pressed by a filter press to separate the liquor from the distillers grains. After the liquor is collected, it is allowed to stand for 24 hours, and the bottom sediment is removed by siphoning to ensure that the raw liquor is clear and free of suspended matter.

[0066] (7) Wine frying: The raw liquor is treated by an ultra-high temperature instantaneous sterilizer to inactivate residual yeast and miscellaneous bacteria. After sterilization, the liquor is quickly cooled to below 25°C to avoid loss of flavor due to high-temperature oxidation. During the wine frying process, volatile off-flavors are simultaneously removed, and the stability of the wine body is significantly improved.

[0067] (8) Cleaning and sterilization of wine tanks: Before and after each batch of production, the wine tanks and other containers in the fermentation area are cleaned and sterilized using a mixture of clean water and Ander disinfectant. The mixing ratio of clean water to Ander disinfectant is 1L of clean water: 20ml of disinfectant. Circulate and rinse for 30 minutes, then rinse with sterile water until there is no residue. After cleaning, seal and store for use to prevent secondary contamination.

[0068] (9) Aging and storage: The sterilized liquor is transferred to an aging tank and stored in a constant-temperature wine cellar at 17°C. It is left to stand in the dark for 5 months, during which the alcohol content, total acid, and changes in flavor substances are regularly detected.

[0069] (10) Blending and formulation: According to the actual needs of finished product production, raw liquors with different precisions are used for blending. After blending, the alcohol content is 35.0% vol, the total sugar is 18.5 g / L, and the pH is 4.6.

[0070] (11) Filtration: The blended liquor is filtered through a pre-filter and a micron filter in sequence to remove fine particles and colloids, avoid the growth of microorganisms, and ensure that the liquor is clear and transparent.

[0071] (12) Wine sterilization: Secondary sterilization of the liquor is carried out before filling for each production batch. The sterilization time is 20 minutes and the temperature is 120°C.

[0072] (13) Container cleaning and disinfection: Each empty filling bottle is rinsed and sterilized with sterile water, then automatically dried and transferred to the filling workshop via a conveyor belt.

[0073] (14) Filling and capping: A fully automatic filling machine is used for quantitative filling to ensure sealing.

[0074] (15) Finished product warehousing: After the finished product is labeled and boxed, it should be stored in a warehouse that is cool, dry, well-ventilated, and at a room temperature of 25°C. It shall not be stacked outdoors, exposed to sunlight, rain, or near heat sources, and shall not be stored in the same warehouse with toxic, harmful, corrosive, volatile, or odorous substances. The bottom of the packing box in contact with the ground is padded with 100 mm of spacer material.

[0075] The above are only the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. A brewing process for sake, characterized in that, The brewing process includes: (1) Raw material acceptance: Select high-quality raw material rice that meets the standards. Do not use raw material rice that is moldy, deteriorated, contains toxic or harmful substances, or is contaminated by toxic or harmful substances. During acceptance, visually inspect, conduct odor detection, and conduct laboratory spot checks to ensure compliance with food safety standards. Immediately return unqualified raw materials. Record batch information for each raw material for traceability. (2) Soaking rice: Place glutinous rice in water for soaking. The water level should completely cover the rice layer. Regularly change the soaking water to prevent rancidity. After soaking, drain until there is no dripping, and the surface is slightly sticky to provide a uniform moisture basis for subsequent steaming of rice. (3) Steaming rice: Use a steam jacketed pan for steaming. After steaming, the rice grains should be thoroughly cooked, loose and not sticky. (4) Transferring to the vat: After the steamed rice is cooled, put the rice, water, and koji into the fermentation vat at a ratio of 100:100:0.

4. After transferring to the vat, gently press and level it. Cover the vat mouth with a sterile gauze to maintain a micro-oxygen environment to activate the initial reproduction of yeast. (5) Saccharification and fermentation: The fermentation time is 15 - 28 days, and the fermentation is carried out at a normal temperature below 28°C. (6) Pressing and separation: Press the fermented mash through a filter press to separate the liquor from the distillers grains. After collecting the liquor, let it stand for 24 hours, and use the siphon method to remove the bottom sediment to ensure that the raw liquor is clear and free of suspended matter. (7) Wine frying: Treat the raw liquor with an ultra-high temperature instantaneous sterilizer to inactivate the residual yeast and miscellaneous bacteria. After sterilization, quickly cool the liquor to below 25°C to avoid flavor loss due to high-temperature oxidation. Synchronously remove volatile odors during the wine frying process, and significantly improve the stability of the liquor body. (8) Cleaning and sterilizing the wine tank: Before and after each batch of production, use clean water to mix with Ande disinfectant to clean and sterilize containers such as wine tanks in the fermentation area. Circulate and rinse for 30 minutes, then rinse with sterile water until there is no residue. After cleaning, seal and reserve for use to prevent secondary contamination. (9) Aging and storage: Transfer the sterilized liquor to an aging tank and store it in a constant temperature wine cellar at 15 - 20°C. Let it stand in the dark for 3 - 6 months. During this period, regularly detect the changes in alcohol content, total acid, and flavor substances. (10) Blending and formulation: According to the actual needs of finished product production, blend raw liquors with different precisions, and control the alcohol content within the range of ≤20°C and ≥8°C. (11) Filtration: The blended liquor is filtered through a pre-filter and a micron filter in sequence to remove fine particles and colloids, avoid the growth of microorganisms, and ensure that the liquor is clear and transparent. (12) Wine sterilization: Conduct secondary sterilization of the liquor before filling for each production batch. The sterilization time is 20 minutes, and the temperature is 115°C - 125°C. (13) Cleaning and disinfecting containers: Rinse and sterilize each empty filling bottle with sterile water, then automatically dry it and transfer the empty bottles to the filling workshop through a conveyor belt. (14) Filling and sealing: Use a fully automatic filling machine for quantitative filling to ensure tightness. (15) Finished product warehousing: After labeling, the finished products are packed in boxes. They should be stored in a warehouse that is cool, dry, well-ventilated, and at a room temperature of 5°C - 35°C. Do not stack them outdoors, expose them to sunlight, rain, or place them near heat sources. Do not store them in the same warehouse with toxic, harmful, corrosive, volatile, or odorous items. Place a 100-mm spacer material at the bottom of the packing box in contact with the ground.

2. The brewing process of sake according to claim 1, characterized in that, The steaming temperature in step (3) is 100 - 105°C, and the duration is 40 - 50 minutes.

3. The brewing process of sake according to claim 1, characterized in that, In step (5), the saccharifying enzyme activity is promoted at 28°C for the first 7 days before saccharification and fermentation, and then the temperature is lowered to 20°C in the next 18 days to inhibit miscellaneous bacteria and slowly produce wine. Stir 1-2 times a day to ensure uniform distribution of oxygen.

4. The brewing process of sake according to claim 1, characterized in that, In step (8), the mixing ratio of clean water and Ande disinfectant is 1L of clean water: 20ml of disinfectant.

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