An automated pickling apparatus and method of pickling

Abstract

The application discloses an automatic pickling device and a pickling method, which comprises a plurality of pickling pools, a filtering pool, a mixing pool, a circulating system and a control system, each of the pickling pools and the mixing pool is provided with a heating sheet and a salinity sensor, a temperature sensor and the like. The filtering pool performs two-stage filtering on the pickling liquid. The mixing pool is used for adjusting the components and temperature of the pickling liquid. The control system comprises heating, calculation, liquid supplementing and circulating modules. The circulating system automatically executes the recycling, filtering, adjusting and heating processes of the pickling liquid, and performs liquid supplementing and condition control on each pickling pool. The device realizes the recycling of the pickling liquid, can effectively control the pickling conditions, ensures the consistent product quality, saves the production cost, improves the production efficiency and reduces the waste liquid discharge. The pickling method of the application realizes automatic pickling through the device.

Description

Technical Field

[0001] This invention relates to the field of food processing technology, specifically to an automated pickling equipment and pickling method. Background Technology

[0002] Traditional food pickling processes, especially in large-scale production, generally have several problems. For example, in terms of the use of pickling liquid, traditional methods often involve single-use or simple filtration followed by reuse. This not only wastes water resources and pickling raw materials (such as salt and spices), significantly increasing production costs, but also makes it easy for microorganisms to grow and flavor substances to deteriorate after repeated use of insufficiently treated pickling liquid, making it difficult to guarantee the quality and safety of the final product.

[0003] Furthermore, in traditional pickling processes, the composition (such as salt concentration and acidity) and state (such as temperature) of the pickling solution often rely on manual experience for adjustment and control, lacking real-time and precise monitoring and adjustment methods. This makes pickling conditions susceptible to environmental factors and human error, resulting in significant differences in flavor, texture, and maturity between different batches or even different pickling units within the same batch, making it difficult to guarantee the uniformity and stability of product quality. At the same time, the extensive manual intervention also leads to problems such as high labor intensity and low production efficiency.

[0004] Traditional pickling equipment often falls short in terms of comprehensiveness and systematic approach. It lags behind in areas such as the recycling of pickling solutions, online purification, and intelligent analysis and precise adjustment of components. Existing filtration systems may have simple structures, offering limited effectiveness in removing complex suspended impurities, grease, and some pigments from the pickling solution after use, thus restricting its efficient reuse. Summary of the Invention

[0005] In order to overcome the technical defects of existing technologies, such as the inability to recycle pickling liquid and insufficient level of intelligent control, this invention provides an automated pickling device and pickling method.

[0006] To solve the above problems, the present invention is implemented according to the following technical solution:

[0007] The automated pickling equipment and pickling method of the present invention include:

[0008] Several pickling tanks, each of which is equipped with a feed inlet, a liquid replenishment inlet, an outlet, and a top gas exhaust window, and the inner wall of the tank is fitted with an electric heating element, a salinity sensor, a temperature sensor, and a liquid level sensor;

[0009] The filter tank has a first-stage filtration unit and a second-stage filtration unit arranged from top to bottom inside. The filter tank is provided with a first pipeline, which is connected to the outlet for introducing the pickling liquid into the filter tank.

[0010] The mixing tank is equipped with a stirring device, and electric heating elements, a salinity sensor, and a temperature sensor are embedded in the side walls. A second pipeline is provided at the bottom, which is connected to the liquid replenishment inlet of the pickling tank. A third pipeline and a water replenishment pipe connected to an external water supply system are provided at the top. One end of the third pipeline is connected to the outlet of the filter tank, and the other end is connected to the top of the mixing tank. The feeding device can add preset pickling materials to the mixing tank to adjust the composition of the pickling liquid.

[0011] A circulation system, comprising solenoid valves and water pumps installed on a first pipeline, a second pipeline, and a third pipeline, for controlling the flow direction of the pickling liquid;

[0012] The control system includes a heating module, a calculation module, a replenishment module, and a circulation module. The heating module is connected to electric heating elements in the pickling tank and the mixing tank to control the temperature of the pickling liquid. The calculation module connects to and processes feedback data from various sensors in the pickling tank and the mixing tank, performs analysis and calculation, and adjusts the composition and state of the pickling liquid based on the analysis results. The replenishment module controls the circulation system to replenish the adjusted pickling liquid from the mixing tank to the target pickling tank based on the state information fed back by the calculation module. The circulation module controls the start, stop, and opening / closing of the water pump and solenoid valve in the circulation system to realize the process of pickling liquid recovery, filtration, adjustment, heating, and replenishment.

[0013] In a first aspect of the present invention, the filter tank is provided with an automatic backwashing device, the automatic backwashing device including an ultrasonic cleaner backwashing pipe and a spray head disposed on the backwashing pipe; the first stage filtration unit is a stainless steel filter screen layer, and the second stage filtration unit is a polytetrafluoroethylene adsorption layer.

[0014] In a first aspect of the present invention, the control system triggers backwashing in the following manner:

[0015] The control system is connected to pressure sensors installed before and after the first-stage filtration unit and an ultrasonic cleaner located at the bottom of the second-stage filtration unit.

[0016] When the pressure difference across the first-stage filtration unit exceeds a preset threshold, the control system controls the backwashing pipe to open for flushing.

[0017] When the cumulative processing capacity of the second-stage filtration unit reaches the preset value, the ultrasonic cleaner is activated.

[0018] In a first aspect, the control system further includes a user interface for displaying the real-time operating status of the equipment, various collected parameters, setting pickling process parameters and alarm information, and for implementing control through the user interface.

[0019] In a first aspect of the present invention, the control system has a thermal balance mode. When the temperature sensor readings of two adjacent pickling tanks are detected to differ by more than a preset value, the control system automatically adjusts the power of the electric heating element in the corresponding pickling tank.

[0020] In a first aspect of the present invention, the circulation system further includes a flow meter and a conductivity sensor, the flow meter being installed on the second pipeline and the conductivity sensor being located at the replenishment inlet.

[0021] In a first aspect of the present invention, the calculation module of the control system constructs a time-temperature integral function model based on the Arrhenius equation, which is used to calculate the pickling endpoint of the food in each pickling tank in real time. When a preset maturity threshold is reached, the control system automatically terminates the heating and stirring of the corresponding pickling tank. The Arrhenius equation is:

[0022]

[0023] Where k is the reaction rate constant in units of concentration, T is the temperature, and E is the reaction rate constant. a The activation energy in the pickling reaction, where R is the molar gas constant.

[0024] In a first aspect of the present invention, the control system based on a computing module has the following functions, which include:

[0025] S100: Real-time data on replenishment flow rate, real-time conductivity and salinity of pickling liquid are acquired through a flow meter, a conductivity sensor and a salinity sensor installed in the pickling tank.

[0026] S200: Verify the acquired salinity data and real-time conductivity data to determine the current concentration of the pickling solution;

[0027] S300: Based on the preset target conductivity and the current concentration of the pickling liquid, the PID control algorithm is used to calculate the speed adjustment of the water pump in the circulation system and the opening adjustment of the relevant solenoid valves.

[0028] S400: Output the adjustment amount to control the water pump and solenoid valve, thereby maintaining the conductivity of the pickling liquid in the pickling tank within the target conductivity range.

[0029] In a first aspect of the present invention, the calculation module performs the following operations based on the pickling maturity prediction model constructed according to the Arrhenius equation to adjust the target conductivity setpoint of the PID control algorithm:

[0030] i. Calculate the current pickling stage or cumulative equivalent pickling maturity of the pickling tank based on the pickling maturity prediction model;

[0031] ii. Based on the pickling stage or intensity, select or calculate the target conductivity setpoint for the current PID control loop from a preset multi-stage salt concentration or conductivity target database.

[0032] In a second aspect, the present invention provides an automated pickling method, performed using an automated pickling device.

[0033] Based on the control system, the method includes the following steps:

[0034] S1: The control system sets the target pickling temperature and target salt concentration for different pickling tanks. The target pickling temperature can be selected from a preset range group including 36.4-37.4℃, 22.5-37.5℃, and 15.5-16.5℃. After the food to be pickled is put into the pickling tank, the initial pickling solution is injected.

[0035] S2: The filtered pickling liquid is transported to the mixing tank through the third pipeline. In the mixing tank, its salt concentration and composition are automatically adjusted according to sensor data, and heated to the preset replenishment temperature.

[0036] S3: During the pickling process, for each pickling tank, the following actions are automatically performed: the set pickling temperature is maintained by its electric heating element; when the liquid level sensor detects a drop in liquid level or salinity, liquid replenishment is initiated, and the heated pickling liquid from the mixing tank in step S2 is automatically replenished through the second pipeline to restore it to the target state; and the pickling maturity is calculated in real time according to the pickling maturity prediction model constructed by the calculation module.

[0037] S4: When any of the pickling tanks reaches the preset pickling time, or when the pickling maturity calculated according to step S3 reaches the preset threshold, the heating of the pickling tank is automatically stopped. When stirring or replenishing liquid, stirring or replenishing liquid is stopped at the same time, and a pickling completion signal is issued.

[0038] S5: After pickling is completed, the pickling liquid used in the pickling tank is automatically transported to the filtration tank through the first pipeline for filtration treatment;

[0039] S6: The filtered marinade is transported to the mixing tank through the third pipeline for the next marinade preparation.

[0040] The automated pickling equipment and pickling method described in this invention have the following advantages compared to existing technologies:

[0041] By implementing a two-stage filtration system in the filtration tank to treat the used pickling liquid, and then automatically adjusting and reheating the filtered liquid in the mixing tank, the equipment achieves the recycling of the pickling liquid. This significantly reduces the amount of new pickling liquid needed, effectively saving water, salt, spices, and other pickling raw materials, thereby lowering production costs. The equipment is equipped with salinity sensors, temperature sensors, and electric heating elements in both the mixing tank and each pickling tank. The control system automatically adjusts the composition, state, and temperature of the pickling liquid based on real-time monitoring data and controls the pickling conditions in each tank. A replenishment module supplies the adjusted and heated pickling liquid from the mixing tank to the target pickling tank, ensuring the stability of the concentration and temperature of the pickling liquid in each tank, thus guaranteeing the flavor and texture of products from different batches and pickling units. Through the control system and its included heating, calculation, replenishment, and circulation modules, the entire process from pickling liquid recovery to filtration, component adjustment, heating, replenishment, and pickling process monitoring is fully automated. This system reduces human intervention, lowers the risk of product quality fluctuations due to human error, alleviates the labor intensity of workers, and significantly improves overall production efficiency. By recovering and recycling the pickling liquid, the equipment reduces the discharge of waste pickling liquid, easing the pressure on subsequent wastewater treatment. Each pickling tank is equipped with an independent heating device and sensors. The control system can independently set and regulate the process parameters of each pickling tank (such as temperature and salt concentration adjusted by replenishing the liquid), improving its ability to meet different pickling needs. Attached Figure Description

[0042] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, wherein:

[0043] Figure 1 This is an overall schematic diagram of an automated constant temperature pickling device according to the present invention;

[0044] Figure 2 This is a schematic diagram of the pickling tank in an automated constant temperature pickling device of the present invention;

[0045] Figure 3 This is a flowchart of an automated constant temperature pickling device and pickling method according to the present invention;

[0046] The attached diagram includes a coordinate graph showing the relationship between temperature, salt concentration, and time, with the optimal pickling area marked.

[0047] In the diagram: 1-Hard pickling tank, 2-Filtration tank, 3-Mixing tank, 4-Circulation system, 5-Control system; 11-Feed inlet, 12-Liquid replenishment inlet, 13-Discharge outlet, 14-Top gas exhaust window; 21-First-stage filtration unit, 22-Second-stage filtration unit; 31-Stirring device, 33-Water replenishment pipe, 34-Feeding device; 41-First pipeline, 42-Second pipeline, 43-Third pipeline, 44-Solenoid valve, 45-Water pump; 55-User control interface. Detailed Implementation

[0048] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0049] Example 1

[0050] The automated pickling equipment of the present invention includes:

[0051] like Figures 1 to 3 As shown, it includes several pickling tanks 1, filtration tanks 2, mixing tanks 3, circulation system 4, and control system 5.

[0052] Several pickling tanks 1 are used to hold the food to be pickled and the pickling liquid. In this embodiment, three or more pickling tanks 1 can be set up to pickle different batches or different types of food. Each pickling tank 1 is equipped with an inlet 11 for filling food, a liquid replenishment inlet 12 for replenishing the pickling liquid, an outlet 13 for discharging used pickling liquid, and a top gas exhaust window 14 for discharging gases generated during the pickling process. In order to precisely control the pickling conditions, the inner wall of each pickling tank 1 is embedded with an electric heating element for heating the pickling liquid, a salinity sensor for real-time monitoring of the salt concentration of the pickling liquid, a temperature sensor for monitoring the temperature, and a liquid level sensor for monitoring the liquid level.

[0053] The filter tank 2 is used to purify the used pickling liquid discharged from the pickling tank 1. In this embodiment, the filter tank 2 has a first-stage filter unit 21 and a second-stage filter unit 22 arranged sequentially from top to bottom. The first-stage filter unit 21 can use a stainless steel filter mesh layer to intercept larger solid impurities in the pickling liquid. The second-stage filter unit 22 can use a polytetrafluoroethylene adsorption layer or other materials with adsorption capacity to further remove fine particles, oils, and some pigments from the pickling liquid. The filter tank 2 is connected to the outlet 13 of each pickling tank 1 through a first pipe 41, and the used pickling liquid is introduced into the inlet of the filter tank 2 through the first pipe 41. The filter tank 2 also has an outlet for the filtered pickling liquid.

[0054] In this embodiment, polytetrafluoroethylene has the following advantages:

[0055] Pickling solutions typically contain high concentrations of salt (sodium chloride) and may also contain acidic or alkaline substances as well as various flavoring ingredients, all of which can corrode ordinary materials.

[0056] Polytetrafluoroethylene (PTFE) is resistant to almost all chemicals. This means that even when in prolonged contact with complex pickling solutions, PTFE components (such as filter membranes, adsorption layers, pipe linings, and seals) will not be corroded or damaged, and no harmful substances will leach into the pickling solution, thus ensuring the purity of the pickling solution and food safety.

[0057] At the same time, this corrosion resistance also greatly extends the service life of related components, reducing the frequency and cost of equipment maintenance.

[0058] During the use of pickling liquid, especially when it is recycled, some solid particles, oils, or denatured proteins may precipitate out.

[0059] The surface of polytetrafluoroethylene (PTFE) has an extremely low coefficient of friction and excellent non-stick properties, making it difficult for these exudates to adhere to the PTFE material surface.

[0060] For filtration devices, this means that the filter screen or membrane is less likely to get clogged, can maintain effective filtration for a longer period of time, and reduces the frequency and difficulty of backwashing.

[0061] For other parts that come into contact with the brine, such as the inner walls of pipes or the lining of the tank (if used), the non-stick properties make cleaning easier, reduce the formation of dirt residue, and help maintain the hygiene of the equipment.

[0062] Polytetrafluoroethylene (PTFE) exhibits excellent resistance to high and low temperatures (typically usable for extended periods from -180°C to +260°C). It will not deform, degrade, or release harmful substances due to temperature changes. PTFE is non-toxic and meets the requirements for food-grade materials. In pickling equipment, any material in direct contact with food or pickling liquid must ensure food safety. Using PTFE as a filter material or contact surface material ensures that pickled foods will not be contaminated due to inherent material properties.

[0063] The mixing tank 3 is the core unit for adjusting and reprocessing the pickling solution. The mixing tank 3 is equipped with a stirring device 31, optionally an electric stirring paddle, to ensure that the added materials are thoroughly and evenly mixed with the pickling solution. The mixing tank 3 also has a feeding device 34, which automatically adds preset pickling materials or concentrated solutions to the mixing tank to adjust the composition of the pickling solution. For example, the automatic feeding device 34 may optionally include a connection to an external solid pickling material storage hopper, and its specific actions are executed by commands from the subsequent control system 5. The side walls of the mixing tank 3 are also embedded with electric heating elements, salinity sensors, and temperature sensors to monitor the initial state of the pickling solution entering the mixing tank and to heat and adjust its composition. The bottom of the mixing tank 3 has a second pipe 42, which connects to the replenishment inlet 12 of each pickling tank 1, for replenishing the pickling solution that has been adjusted and heated to the required standard into the pickling tank 1. The top of the mixing tank 3 is connected to the filtered pickling solution outlet of the filtration tank 2 via a third pipe 43, for receiving the filtered pickling solution. Meanwhile, the top of the mixing tank 3 is also equipped with a water supply pipe 33 connected to an external water supply system, which is used to add clean water under the instruction of the control system 5 to adjust the salt concentration of the pickling solution.

[0064] The circulation system 4 comprises a first pipeline 41, a second pipeline 42, a third pipeline 43, several solenoid valves 44 installed on these pipelines, and at least one water pump 45. The water pump 45 provides power for the transport of the pickling liquid, while the solenoid valves 44 precisely control the opening and closing of each pipeline according to the instructions of the control system 5, thereby achieving directional flow and circulation of the pickling liquid between the various tanks. For example, by controlling the relevant valves and water pumps, waste liquid in pickling tank 1 can be pumped to filtration tank 2; liquid treated in filtration tank 2 can be pumped to mixing tank 3; and qualified pickling liquid adjusted and heated in mixing tank 3 can be pumped to the designated pickling tank 1 for replenishment.

[0065] The control system 5 is the central hub of the entire automated pickling equipment. In this embodiment, the control system 5 is a programmable logic controller (PLC) based cabinet. The control system 5 includes a preset heating module, a calculation module, a liquid replenishment module, and a circulation module. The heating module is electrically connected to the heating elements in all the pickling tanks 1 and the mixing tank 3. Based on feedback data from temperature sensors and preset process parameters, it controls the heating power of each heating element to maintain the pickling liquid at the target temperature. The calculation module connects to and processes feedback data from salinity sensors, temperature sensors, level sensors in each of the pickling tanks 1 and the mixing tank 3, as well as other sensors (such as flow meters and conductivity sensors) configured in the circulation system 4. This module performs real-time analysis and calculation on this data to determine whether the current salt concentration of the pickling liquid meets the standard, whether water or concentrated pickling material needs to be added, calculates the liquid replenishment volume, predicts the pickling endpoint, and generates corresponding control commands based on the analysis and calculation results. The replenishment module, based on status information (such as low salt concentration or insufficient liquid level in a certain pickling tank) and instructions from the calculation module, controls the circulation system 4 to replenish the adjusted and heated pickling liquid from the mixing tank 3 to the target pickling tank 1. The circulation module is specifically responsible for controlling the start / stop and opening / closing states of the water pump 45 and various solenoid valves 44 in the circulation system 4 to execute various processes of the control system instructions, such as the recovery and filtration of the pickling liquid, the transportation from the filtration tank to the mixing tank, the adjustment and heating in the mixing tank (through instructions to the heating module and possible water / material replenishment actions), and the automated operation of the complete process of replenishing liquid from the mixing tank to the pickling tank.

[0066] In this embodiment, since this automated pickling equipment is mainly used for pickling salted duck eggs, the pickling solution used is mainly composed of water and edible salt. Its state is as follows:

[0067] According to the requirements of the pickling process, a brine solution with a specific target salt concentration is prepared. During the pickling process, the salt concentration is monitored in real time by the control system 5 through a salinity sensor, and can be adjusted by the mixing tank 3 and the replenishment module (such as by adding clean water through the water replenishment pipe 33 to dilute or by adding concentrated brine / solid salt through the feeding device 34 to increase the concentration).

[0068] The temperature of the pickling solution is monitored by a temperature sensor in the control system 5 and precisely controlled by electric heating elements in the pickling tank 1 and the mixing tank 3 to maintain the target temperature set for this process. Heating is required at certain stages to accelerate pickling or to maintain a lower temperature at other stages.

[0069] Used pickling liquid can be pumped to filter tank 2 through circulation system 4 for filtration and purification to remove impurities. Then it enters mixing tank 3 for component adjustment and reheating before being replenished to pickling tank 1 for reuse, thereby maintaining the cleanliness of the pickling liquid and the stability of its effective components.

[0070] The working process of the automated pickling equipment of this invention is as follows: First, the food to be pickled is placed into the pickling tank 1 through the inlet 11, and the initial pickling liquid is injected. During the pickling process, the control system 5 monitors the temperature, salt concentration, and liquid level in each pickling tank 1 in real time. When the pickling cycle ends or the pickling liquid needs to be treated, the control system 5 pumps the used pickling liquid from the pickling tank 1 to the filter tank 2 for two-stage filtration through the first pipeline 41 via the circulation module and circulation system 4. The filtered pickling liquid enters the mixing tank 3 through the third pipeline 43. In the mixing tank 3, the calculation module of the control system 5 determines whether the concentration and temperature need to be adjusted based on the data from the salinity sensor and temperature sensor, and controls the water replenishment pipe 33 to replenish water and replenish through the feeding device. At the same time, the heating module controls the electric heating element of the mixing tank 3 to heat the pickling liquid to the preset replenishment temperature. When a pickling tank 1 needs replenishment (e.g., due to a decrease in salt concentration or a drop in liquid level), the replenishment module instructs the circulation module to replenish the pickling liquid that has been adjusted and heated to the required standard in the mixing tank 3 to the pickling tank 1 through the second pipeline 42. The entire process is automatically completed by the control system 5 without manual intervention.

[0071] To ensure that the filter tank 2 can effectively purify the recovered pickling liquid in a long-term and stable manner, and to reduce the frequency of manual maintenance, in a first aspect of the present invention, the filter tank 2 is equipped with an automatic backwashing device. This automatic backwashing device includes an ultrasonic cleaner for cleaning the second-stage filter unit 22, a backwashing pipe for rinsing the first-stage filter unit 21, and multiple spray heads disposed at the end of or along the backwashing pipe. The backwashing pipe is connected to an external clean water source via a solenoid valve.

[0072] In this embodiment, the first-stage filtration unit 21 inside the filtration tank 2 is specifically a stainless steel filter mesh layer with a pore size of 2mm, which is sufficient to effectively intercept larger solid impurities in the used pickling liquid, such as food residue and some sediment. This stainless steel filter mesh layer has good mechanical strength and corrosion resistance, making it suitable for preliminary filtration.

[0073] The second-stage filtration unit 22 is located below the first-stage filtration unit 21 (i.e., the marinating liquid flows through the first stage of filtration and then through the second stage), specifically a polytetrafluoroethylene (PTFE) adsorption layer. It can further filter finer suspended particles and adsorb oils, some large organic molecules, and pigments in the marinating liquid, thereby achieving deep purification of the marinating liquid.

[0074] The control system 5 works closely with the automatic backwashing device to achieve intelligent cleaning and maintenance. Specifically, the control system 5 is connected to pressure sensors installed at the inlet and outlet ends (or in the pipelines before and after them) of the first-stage filtration unit 21. The control system 5 monitors the pressure difference between these two pressure sensors in real time. When the pressure difference exceeds a preset threshold (e.g., 10 kPa, indicating that the filter screen is clogged to a certain extent), the control system 5 automatically executes the backwashing procedure for the first-stage filtration unit: the backwashing time and frequency can be set by the user on the human-machine interface of the control system 5.

[0075] For the cleaning of the second-stage filtration unit 22, when the cumulative amount of pickling liquid processed by the second-stage filtration unit reaches a preset value (e.g., 50 m³, estimated by the flow accumulation or timer inside the control system 5), and it is determined that its adsorption / filtration efficiency has decreased, the control system 5 activates the ultrasonic cleaner. The ultrasonic cleaner generates high-frequency oscillations, creating a cavitation effect in the pickling liquid or special cleaning solution, and non-contactly peels off the contaminants adsorbed on the surface and internal micropores of the polytetrafluoroethylene adsorption layer, completing the cleaning and regeneration. The time and cycle of ultrasonic cleaning can also be preset. Simultaneously or after ultrasonic cleaning, a suitable amount of fluid (such as clean water or pickling liquid filtered through the first stage) can be used for rinsing to remove the detached contaminants.

[0076] Example 2

[0077] As another aspect of the invention, the control system 5 is equipped with a user interface 55. This user interface 55 is designed to provide operators with a comprehensive and intuitive way to interact with the automated marinating equipment.

[0078] The user interface 55 can display the real-time operating status of the entire equipment, including the current working status of each pickling tank 1, filtration tank 2, mixing tank 3, and circulation system 4. Key parameters of all connected sensors, such as the temperature and salinity sensors in each pickling tank 1 and mixing tank 3, the measured temperature and salinity data, and the readings of the liquid level sensors, are clearly displayed.

[0079] The user interface allows operators to set and adjust various pickling process parameters.

[0080] In the event of any equipment malfunction or parameter deviation from the set value, the user interface 55 will display alarm information, usually accompanied by an audible prompt, and provide diagnostic information to assist in troubleshooting.

[0081] In another aspect of the invention, the control system 5 includes a thermal balance mode to ensure temperature uniformity among the different curing tanks 1, or to effectively manage energy distribution when multiple curing tanks 1 are operating simultaneously. The computing module of the control system 5 continuously monitors temperature readings from temperature sensors in each curing tank 1.

[0082] As another specific feature of the invention, specifically, a flow meter is installed on a second pipeline 42 (which, according to the determined equipment structure, connects the outlet of the mixing tank 3 to the replenishment inlet 12 of the pickling tank 1). A conductivity sensor is installed at or near the replenishment inlet 12 of each pickling tank 1 on the pipeline.

[0083] The flow meter provides real-time flow rate data of the adjusted and heated brine supplied from mixing tank 3 to brine tank 1.

[0084] The online conductivity sensor measures the conductivity of the pickling liquid immediately as it is about to enter the pickling tank 1. This allows the control system 5 to confirm whether the liquid supplied from the mixing tank 3 has reached the target conductivity before entering the pickling tank 1 (and thus infer the salt concentration).

[0085] In a first aspect, the calculation module of the control system constructs a time-temperature integral function model based on the Arrhenius equation to calculate the pickling endpoint of the food in each pickling tank in real time. When a preset maturity threshold is reached, the control system automatically terminates the heating and stirring of the corresponding pickling tank. The Arrhenius equation is:

[0086]

[0087] In this model, k is defined as the reaction rate constant of the key quality indicator during the pickling process; T is the absolute temperature of the pickling liquid, which is monitored in real time by a temperature sensor installed in the pickling tank 1 and fed back to the calculation module; Ea is the activation energy of the key quality change reaction; and R is the molar gas constant.

[0088] Throughout the pickling process, the calculation module acquires the real-time temperature T of the pickling liquid from a temperature sensor at preset time intervals (e.g., every minute). For each time interval, the calculation module uses the aforementioned Arrhenius equation (or its integral form, and possibly further combined with factors such as the effect of salt concentration on the rate) to calculate the increment of pickling maturity generated within that time interval at that temperature T. Subsequently, the calculation module adds this increment to the existing maturity value of the pickling tank, thereby tracking and updating the current pickling maturity of the food in real time.

[0089] In a first aspect of the invention, the calculation module performs the following operations based on the pickling maturity prediction model constructed according to the Arrhenius equation: to adjust the target conductivity setpoint of the PID control algorithm:

[0090] i. Calculate the current pickling stage or pickling maturity of the pickling tank based on the pickling maturity prediction model;

[0091] ii. Based on this pickling stage, select or calculate the target conductivity setpoint for the current PID control loop from a preset multi-stage salt concentration or conductivity target database.

[0092] To further enhance the control of the pickling process, the control system 5 of this invention, through its calculation module, utilizes the aforementioned pickling maturity prediction model based on the Arrhenius equation to dynamically adjust the target conductivity (indirectly reflecting salt concentration) setpoint of the PID control algorithm for the pickling liquid in the pickling tank 1. Its specific execution operation is as follows:

[0093] i. Calculate the current pickling stage based on the pickling maturity prediction model: Throughout the pickling process, the calculation module uses the Arrhenius model to continuously calculate the specific pickling stage or the achieved pickling maturity of the food based on the real-time monitored temperature and pickling time in pickling tank 1. This stage information can be quantified; for example, the total target maturity can be divided into several intervals, such as early, middle, and late stages, or the pickling maturity percentage can be used directly.

[0094] ii. Selecting or calculating the PID target conductivity setpoint based on the pickling stage: The internal database or process parameter settings of control system 5 pre-store a multi-stage salt concentration or conductivity target database. This database associates different pickling stages (or cumulative equivalent pickling maturity ranges) with the ideal target conductivity value (or salt concentration target value) of the pickling solution for that stage. For example, a certain pickling process may require:

[0095] Early pickling stage (0%–30% maturity): Target conductivity set at a relatively high S0. h This facilitates rapid penetration.

[0096] Mid-pickled stage (31%–70% maturity): Target conductivity set at medium S m To maintain stable penetration and flavor formation.

[0097] Late pickling stage (71%–100% maturity): Target conductivity set at a relatively low S0. l This is to avoid the product being too salty and to make minor flavor adjustments.

[0098] The calculation module automatically queries and selects the corresponding target conductivity setting value from the target database for the current pickling stage or pickling maturity obtained in real time based on step (i).

[0099] In another aspect of the invention, the control system 5 achieves precise closed-loop control of the conductivity (indirectly reflecting salt concentration) of the pickling liquid in the pickling tank 1 through its calculation module. This function ensures that the pickling liquid remains within the target concentration range, and its specific execution steps are as follows:

[0100] S100: The multi-source data real-time acquisition control system 5 continuously monitors the flow meter installed on the second pipeline 42 of the circulation system 4 to obtain the instantaneous flow rate of the liquid replenished to the pickling tank 1; at the same time, it monitors the online conductivity sensor installed at the liquid replenishment inlet 12 of the pickling tank 1 (or its nearby pipeline) to obtain the real-time conductivity data of the liquid entering the pickling tank 1; and reads the salinity data of the salinity sensor inside the target pickling tank 1 in real time.

[0101] S200: The sensor data redundancy verification and effective concentration determination calculation module compares and verifies the salinity data obtained from the salinity sensor and the real-time conductivity data obtained from the online conductivity sensor to determine the effective concentration value of the pickling solution currently used for control.

[0102] S300: The calculation module for the control adjustment amount calculates the amount of adjustment required for the speed of the water pump 45 in the circulation system 4 and the opening adjustment required for the relevant solenoid valve 44 on the second pipeline 42, based on the deviation between the preset target conductivity (which may be optimized based on the relationship data between egg yolk oil core ratio and salinity in Table 1 to achieve the best product quality) and the current effective concentration of the marinating liquid (converted conductivity value) determined in step S200, using a PID control algorithm.

[0103] S400: The adjustment command output and closed-loop control calculation module outputs the calculated speed adjustment and opening adjustment amounts. These modules then control the water pump 45 to adjust its speed and the solenoid valve 44 to adjust its opening, thereby precisely controlling the flow rate and speed of the pickling liquid replenished, adjusted, and heated from the mixing tank 3 to the target pickling tank 1. Ultimately, the overall conductivity of the pickling liquid in the pickling tank 1 is dynamically maintained within the preset target conductivity range. As shown in Table 1, the equipment verification data shows that this system can achieve excellent control stability (e.g., fluctuation value less than ±5% over 24 hours) when the target conductivity range is set.

[0104] In another aspect of the invention, the control system 5 includes a thermal balance mode to ensure temperature uniformity among the different pickling tanks 1. The calculation module of the control system 5 continuously monitors temperature readings from temperature sensors in each pickling tank 1.

[0105] If the control system 5 detects that the temperature difference between any two adjacent pickling tanks 1 exceeds a preset threshold, it automatically activates the heat balance mode. Once activated, the control system 5, through its heating module, automatically adjusts the power supplied to the electric heating elements in the corresponding pickling tank 1 to minimize the temperature difference and ensure a more consistent pickling environment for all operating pickling tanks. According to the equipment verification data in Table 1, this heat balance mode can effectively control the temperature difference between tanks within the set accuracy.

[0106] Comparative verification of the effects of the device of the present invention (which can be presented as a separate paragraph following the embodiments):

[0107] To further verify the superior performance of the automated pickling equipment of this invention, a comparative experiment was conducted with traditional pickling methods. Relevant comparative data are shown in Table 1 below. Taking salted duck eggs as an example, using the equipment of this invention, under controlled temperature and salt concentration conditions, the yolk oil yield and pickling efficiency were significantly improved, and the pickling cycle was greatly shortened. Simultaneously, the uniformity of salt penetration in the product was also significantly improved, which helps to enhance the taste and quality consistency of the final product.

[0108] Table 1: Parameters and Validation Data of Automated Marinating Equipment

[0109] Data derived from Arrhenius The influence coefficient of temperature fluctuation on pickling speed For every 1°C increase in temperature, the pickling time is shortened by 5%. quality 1. Relationship between egg yolk oil core ratio and salinity At a salinity of 10%, the oil core rate was 60%; at 12%, it was 85%; and at 14%, it was 90%, showing a positive correlation before leveling off. 2. Relationship between core defect incidence and temperature Temperature <30℃, core hardening rate <1%; Temperature 30-35℃, core hardening rate 1%~3%; Temperature >38℃, core hardening rate >5%. Equipment verification 1. Temperature difference control accuracy between pools in thermal balance mode Within ±0.5℃ 2. Conductivity control stability (target range 13.5-14.5 mS / cm) Continuous 24-hour fluctuation <±2% Comparative experimental data 1. Egg yolk oil core ratio and marinating time (for this equipment) After being marinated at a constant temperature of 36℃ for 12 days, the egg yolks yielded an oil content of 92%. 2. Egg yolk oil content and marinating time (traditional method) It takes 25 days at 25℃ to achieve a 92% oil extraction rate. 3. Salt penetration uniformity index (compared to traditional methods using this equipment) Traditional methods achieve a success rate of approximately 70%, while this equipment increases it to approximately 90%.

[0110] Specific implementation steps of the automated pickling method:

[0111] A second aspect of the present invention provides an automated pickling method, which utilizes the automated pickling equipment of any of the preceding claims and is automatically executed by its control system 5. The pickling cycle may include the following steps:

[0112] S1: Initialization and Feeding The operator first sets the target pickling temperature for each of the several pickling tanks 1 to be used through the user interface 55 of the control system 5. These target pickling temperatures can be selected from multiple preset temperature range groups. For rapid pickling processes, the first temperature range of 36.4℃ to 37.4℃ is selected; for medium-temperature stable flavor formation, the second temperature range of 22.5℃ to 0.5℃ is selected; or for low-temperature long-term pickling, the third temperature range of 15.5℃ to 16.5℃ is selected.

[0113] Set the initial target salt concentration or conductivity value for each pickling tank. After setting the parameters, put the food to be pickled into the corresponding target pickling tank through the food inlet 11 of each pickling tank 1. Then, the control system 5 controls the circulation system 4 to inject the initial pickling solution, which has been prepared and heated in the mixing tank 3, into the pickling tank 1 with the added food through the second pipeline 42 until the liquid level sensor detects that the preset liquid level has been reached.

[0114] S2: Recovery and Preliminary Treatment of Used Pickling Solution After a pickling cycle is completed (or during the pickling process, based on preset data, such as reaching a certain number of cycles or contaminant indicators), the control system 5 initiates the pickling solution recovery program. The circulation module controls the corresponding solenoid valve 44 and water pump 45 to pump the used pickling solution from the target pickling tank 1 to the filter tank 2 through its outlet 13 and the first pipeline 41. In the filter tank 2, the pickling solution flows sequentially through the first-stage filter unit 21 and the second-stage filter unit 22 to remove solid impurities, suspended solids, some oils, and pigments.

[0115] S3: Adjustment and Heating Regeneration of the Filtered Marinade The marinade treated in the filtration tank 2 is transported to the mixing tank 3 through the third pipeline 43. At this time, the calculation module analyzes the composition of the currently recovered marinade based on the readings of the salinity and temperature sensors in the mixing tank 3. Based on the difference between the analysis results and the preset standard formula or target parameters of the marinade, the calculation module generates adjustment instructions. According to these instructions, the replenishment module controls the water replenishment pipe 33 connected to the external water supply system to replenish an appropriate amount of clean water to the mixing tank 3 to reduce the salt concentration, or instructs the automatic replenishment device 34 to add concentrated brine, new marinating seasonings, etc., to increase the salt concentration or adjust the flavor.

[0116] The heating module controls the electric heating element in the mixing tank 3 to start, heating the adjusted marinating liquid to the preset replenishment temperature (this temperature is the same as or slightly higher than the target marinating temperature to compensate for heat loss during transportation). The stirring device 31 in the mixing tank 3 works continuously during this process to ensure that the materials are mixed evenly and that the temperature and concentration distribution are consistent.

[0117] S4: Independent and precise control and dynamic liquid replenishment of the pickling tanks. During the pickling process in each pickling tank 1, the control system 5 independently and continuously performs the following control operations:

[0118] The heating module controls the electric heating element in the pickling tank, and based on the feedback from the temperature sensor, the temperature of the pickling liquid is precisely maintained at the target temperature set for the tank in step S1.

[0119] If a stirring device is installed, its operation will be controlled according to a preset program or conditions.

[0120] The replenishment module is activated when the level sensor detects a drop in liquid level (e.g., due to evaporation or food absorption), or when the salinity sensor (or conductivity sensor) detects a deviation of the salt concentration from the target setpoint for the current stage (which may vary based on the aforementioned Arrhenius model-based adjustments). The control circulation system 4, via the second pipeline 42, draws the regenerated pickling liquid, adjusted and heated to the appropriate level in step S3, from the mixing tank 3 and replenishes it to the corresponding pickling tank 1 until the liquid level and salt concentration return to the target range. This replenishment process uses a PID control algorithm to control the flow rate and replenishment volume.

[0121] Gases generated during the pickling process are discharged naturally or under control through the top gas exhaust window 14.

[0122] S5: Pickling Maturity Monitoring and Intelligent Termination. Throughout the pickling process, the calculation module collects real-time data such as temperature from each pickling tank 1 and continuously calculates the pickling maturity of the food in each tank based on the pickling maturity prediction model using the Arrhenius equation. Simultaneously, the control system records the pickling time.

[0123] S6: Completion of Pickling and Subsequent Processing When the pickling time of any pickling tank 1 reaches a preset value, or more preferably, when the calculated pickling maturity reaches a preset maturity threshold, the control system 5 determines that the pickling in that tank is complete. The system will automatically stop heating, stirring, and replenishing the liquid in the pickling tank 1, and will issue a signal indicating completion of pickling through the user interface 55, prompting the operator to proceed with subsequent processes such as unloading and inspection. After pickling is completed, the used pickling liquid in that tank can enter the recycling process according to step S2 to prepare regenerated pickling liquid for the next or other pickling tasks.

[0124] This invention uses different temperature ranges to marinate egg products, which has the following advantages:

[0125] 1. Temperature range of the first pickling tank (36.4℃~37.4℃):

[0126] A temperature close to the incubation environment can accelerate the penetration and reaction of egg whites with the components in the marinating solution, shortening the marinating time.

[0127] For types of pickled eggs that require good sandy texture and oil release within this temperature range, the pickling time needs to be controlled between 10 and 15 days.

[0128] Suitable for rapid production needs, improving production efficiency.

[0129] Within this temperature range, the salt penetrates evenly, preventing the egg yolk from solidifying prematurely and improving the quality of the finished product.

[0130] 2. Temperature range of the second pickling tank (22.5℃~5℃):

[0131] The temperature is moderate, which is suitable for the stable formation of flavor compounds during the pickling process.

[0132] At this temperature, the rate of salt penetration and the rate of chemical reactions inside the egg can be balanced, resulting in a more delicate texture for the pickled eggs.

[0133] This effectively avoids protein denaturation caused by high temperatures, maintaining the integrity and texture of the pickled eggs.

[0134] During the pickling process within this temperature range, a type of pickled egg with good sandy texture and oiliness can be pickled, with a pickling time of 20 to 30 days.

[0135] 3. Temperature range of the third pickling tank (15.5℃~16.5℃):

[0136] Lower temperatures can slow down the pickling process, making it suitable for high-end pickled egg products with richer flavors and firmer textures.

[0137] Within this temperature range, the growth of unwanted bacteria is inhibited, ensuring the safety and hygiene of the pickling process.

[0138] It helps to store pickled eggs for a long time without affecting their flavor and quality.

[0139] During the pickling process, the salt concentration should be controlled between 15% and 20%. If the concentration is too low, the sandy texture and oiliness will not be obvious, while if the concentration is too high, the egg yolk will harden and affect the sandy texture.

[0140] In this invention, the salted eggs can achieve an ideal sandy texture and good oil quality by controlling the pickling process with automated equipment and by using different pickling temperatures and times in the equipment, thereby improving the flavor and taste of the product.

[0141] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. An automated pickling device, characterized in that, include: Several pickling tanks, each of which is equipped with a feed inlet, a liquid replenishment inlet, an outlet, and a top gas exhaust window, and the inner wall of the tank is fitted with an electric heating element, a salinity sensor, a temperature sensor, and a liquid level sensor; The filter tank has a first-stage filtration unit and a second-stage filtration unit arranged from top to bottom inside. The filter tank is provided with a first pipeline, which is connected to the outlet for introducing the pickling liquid into the filter tank. The mixing tank is equipped with a stirring device and a feeding device. The side walls are fitted with electric heating elements, a salinity sensor, and a temperature sensor. The bottom is equipped with a second pipeline that is connected to the liquid replenishment inlet of the pickling tank. The top is equipped with a third pipeline and a water replenishment pipe connected to an external water supply system. One end of the third pipeline is connected to the outlet of the filter tank, and the other end is connected to the top of the mixing tank. The feeding device can add preset pickling materials to the mixing tank to adjust the composition of the pickling liquid. A circulation system, comprising solenoid valves and water pumps installed on a first pipeline, a second pipeline, and a third pipeline, for controlling the flow direction of the pickling liquid; The control system includes a heating module, a calculation module, a replenishment module, and a circulation module. The heating module is connected to electric heating elements in the pickling tank and the mixing tank to control the temperature of the pickling liquid. The calculation module is connected to and processes feedback data from various sensors in the pickling tank and the mixing tank, performs analysis and calculation, and adjusts the composition and state of the pickling liquid based on the analysis results. The replenishment module controls the circulation system to replenish the adjusted pickling liquid from the mixing tank to the target pickling tank based on the state information fed back by the calculation module. The circulation module controls the start, stop, and opening / closing of the water pump and solenoid valve in the circulation system to realize the process of pickling liquid recovery, filtration, adjustment, heating, and replenishment. The calculation module of the control system constructs a time-temperature integral function model based on the Arrhenius equation to calculate the pickling endpoint of the food in each pickling tank in real time. When a preset maturity threshold is reached, the control system automatically terminates the heating and stirring of the corresponding pickling tank. The Arrhenius equation is: Where k is the reaction rate constant in units of concentration, T is the temperature, and E is the reaction rate constant. a The activation energy in the pickling reaction, where R is the molar gas constant; The control system, based on the computing module, has the following functions: The flow rate, real-time conductivity and salinity data of the pickling liquid are obtained in real time through a flow meter, a conductivity sensor and a salinity sensor installed in the pickling tank. The acquired salinity data and real-time conductivity data are verified to determine the current concentration of the pickling solution; Based on the preset target conductivity and the current concentration of the pickling liquid, the PID control algorithm is used to calculate the speed adjustment of the water pump in the circulation system and the opening adjustment of the relevant solenoid valves. The adjustment amount is output to control the water pump and solenoid valve, thereby maintaining the conductivity of the pickling liquid in the pickling tank within the target conductivity range.

2. The automated pickling equipment according to claim 1, characterized in that, The filter tank is equipped with an automatic backwashing device, which includes an ultrasonic cleaner backwashing pipe and a spray head installed on the backwashing pipe; the first-stage filtration unit is a stainless steel filter screen layer, and the second-stage filtration unit is a polytetrafluoroethylene adsorption layer.

3. The automated pickling equipment according to claim 2, characterized in that, The control system triggers backwashing in the following manner: The control system is connected to pressure sensors installed before and after the first-stage filtration unit and an ultrasonic cleaner located at the bottom of the second-stage filtration unit. When the pressure difference across the first-stage filtration unit exceeds a preset threshold, the control system controls the backwashing pipe to open for flushing. When the cumulative processing capacity of the second-stage filtration unit reaches the preset value, the ultrasonic cleaner is activated.

4. The automated pickling equipment according to claim 1, characterized in that, The control system also includes a user interface, which is used to display the real-time operating status of the equipment, various collected parameters, set pickling process parameters and alarm information, and to achieve control through the user interface.

5. The automated pickling equipment according to claim 1, characterized in that, The control system has a thermal balance mode. When the temperature sensor readings of two adjacent pickling tanks are detected to differ by more than a preset value, the control system automatically adjusts the power of the electric heating element in the corresponding pickling tank.

6. The automated pickling equipment according to claim 1, characterized in that, The circulation system also includes a flow meter and a conductivity sensor. The flow meter is installed on the second pipeline, and the conductivity sensor is located at the replenishment inlet.

7. The automated pickling equipment according to claim 1, characterized in that, The calculation module performs the following operations based on the pickling maturity prediction model constructed according to the Arrhenius equation: to adjust the target conductivity setpoint of the PID control algorithm: i. Calculate the current pickling stage or pickling maturity of the pickling tank based on the pickling maturity prediction model; ii. Based on the pickling stage or pickling maturity, select or calculate the target conductivity setpoint for the current PID control loop from the preset multi-stage salt concentration or conductivity target database.

8. An automated pickling method, implemented based on an automated pickling device according to any one of claims 1-7, characterized in that, Based on the control system, the method includes the following steps: S1: The control system sets the target pickling temperature and target salt concentration for different pickling tanks. The target pickling temperature can be selected from a preset range group including 36.4-37.4℃, 22.5-37.5℃, and 15.5-16.5℃. After the food to be pickled is put into the pickling tank, the initial pickling solution is injected. S2: The filtered pickling liquid is transported to the mixing tank through the third pipeline. In the mixing tank, its salt concentration and composition are automatically adjusted according to sensor data, and heated to the preset replenishment temperature. S3: During the pickling process, for each pickling tank, the following actions are automatically performed: the set pickling temperature is maintained by its electric heating element; when the liquid level sensor detects a drop in liquid level or salinity, liquid replenishment is initiated, and the heated pickling liquid from the mixing tank in step S2 is automatically replenished through the second pipeline to restore it to the target state; and the pickling maturity is calculated in real time according to the pickling maturity prediction model constructed by the calculation module. S4: When any of the pickling tanks reaches the preset pickling time, or when the pickling maturity calculated according to step S3 reaches the preset threshold, the heating of the pickling tank is automatically stopped. When stirring or replenishing liquid, stirring or replenishing liquid is stopped at the same time, and a pickling completion signal is issued. S5: After pickling is completed, the pickling liquid used in the pickling tank is automatically transported to the filtration tank through the first pipeline for filtration treatment; S6: The filtered marinade is transported to the mixing tank through the third pipeline for the next marinade preparation.

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