Thaflavin preparation system based on continuous fermentation structure

Abstract

The invention relates to the technical field of fermentation, and discloses a theaflavin preparation system based on a continuous fermentation structure, the theaflavin preparation system comprises fermentation equipment, the fermentation equipment comprises a fermentation early-stage tank, a fermentation middle-stage tank and a fermentation later-stage tank, the interior of the fermentation early-stage tank is a fermentation early-stage suitable environment, the interior of the fermentation middle-stage tank is a fermentation middle-stage suitable environment, and the interior of the fermentation later-stage tank is a fermentation later-stage suitable environment; the interior of the fermentation later-stage tank is a suitable environment for the fermentation later stage, mixed liquid in different fermentation stages is conveyed through the connecting piece, and the stirring pieces are located in the fermentation early-stage tank, the fermentation middle-stage tank and the fermentation later-stage tank and rotate at different speeds. Fermentation equipment is divided into a fermentation early-stage tank, a fermentation middle-stage tank and a fermentation later-stage tank, and the fermentation process is divided into three stages which are carried out in different equipment, so that the problem of production interruption caused by shutdown cleaning in the traditional single-tank fermentation of different batches of mixed liquid is effectively avoided, continuous fermentation is realized, and the production efficiency is improved. The production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the field of fermentation technology, and in particular to a theaflavin preparation system based on a continuous fermentation structure. Background Art

[0002] The enzymatic oxidation of theaflavins is a key process for producing theaflavins. The process begins with the selection of fresh tea leaves, which are homogenized to disrupt the cells and release tea polyphenols and other substrates. This is followed by liquid fermentation. During this process, polyphenol oxidase (PPO) is generated by the tea leaves themselves, or by the introduction of exogenous enzymes rich in PPO, such as from apples and vegetables. Under a controlled temperature of 28-30°C and a pH of 4.6-4.8, the enzyme catalyzes the oxidative polymerization of catechins and other components of the tea polyphenols, gradually producing theaflavins.

[0003] The existing theaflavins fermentation process uses a single reactor, which needs to be thoroughly cleaned after each batch of fermentation. Since tea polyphenols, proteins, polysaccharides and other substances in the fermented slurry in the reactor will stubbornly adhere to the inner wall of the equipment, the stirring paddles, the pipes and other parts, thorough cleaning is difficult and requires a lot of time for downtime and cleaning. This not only leads to discontinuous production process, long intervals between batches, low equipment utilization, and increased production costs, but also disrupts the steady state of the fermentation environment with each shutdown and restart, requiring the early stage of fermentation to go through the induction period again to activate enzyme activity and establish suitable temperature, humidity, pH and other conditions. This makes it difficult to maintain stability at each stage of the fermentation process, which is not conducive to the stable and efficient production of theaflavins, affecting the consistency of product quality and the increase in output. Summary of the Invention

[0004] Technical problems solved

[0005] In view of the above-mentioned shortcomings of the prior art, the present invention provides a theaflavin preparation system based on a continuous fermentation structure, which can effectively solve the problem of discontinuous single-tank production process in the prior art.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0007] The present invention provides a theaflavins preparation system based on a continuous fermentation structure, comprising:

[0008] Fermentation equipment, comprising an early fermentation tank, a mid-fermentation tank, and a late fermentation tank arranged in series, wherein the interior of the early fermentation tank is a suitable environment for the early fermentation stage, the interior of the mid-fermentation tank is a suitable environment for the mid-fermentation stage, and the interior of the late fermentation tank is a suitable environment for the late fermentation stage, effectively avoiding the production interruption problem caused by the need to stop and clean between different batches of mixed liquid fermentation in a traditional single tank, and achieving continuous fermentation;

[0009] Connectors, wherein the early fermentation tank, the mid-fermentation tank, and the late fermentation tank are connected to each other by adjacent connectors, and the mixed liquids at different fermentation stages are transmitted through the connectors;

[0010] A stirring member, the stirring member is located inside the early fermentation tank, the middle fermentation tank, and the late fermentation tank, and rotates at different speeds;

[0011] Feeding ports, the feeding ports being located at the top of the early fermentation tank, the mid-fermentation tank and the late fermentation tank;

[0012] Cleaning parts, the cleaning parts are located at the top of the early fermentation tank, the middle fermentation tank and the late fermentation tank, and the cleaning parts are located at a lower position relative to the feed opening;

[0013] Wherein, the connecting piece includes a movable ring for stirring the mixed liquid during the transmission process.

[0014] Furthermore, the stirring element arranged inside the early fermentation tank consists of a motor, a stirring shaft and a rotary blade group. The motor is located at the top of the early fermentation tank, the output end of the motor is connected to the stirring shaft, and the bottom end of the stirring shaft is provided with a rotary blade group.

[0015] Furthermore, the stirring element arranged inside the mid-fermentation tank is composed of a motor, a stirring shaft, a rotary blade group and a stirring blade 1. The motor is located at the top of the mid-fermentation tank, and the output end of the motor is connected to the stirring shaft for transmission. The upper part of the stirring shaft is provided with a stirring blade 1, and the bottom end of the stirring shaft is provided with a rotary blade group.

[0016] Furthermore, the stirring element arranged inside the late fermentation tank is composed of a motor, a stirring shaft, a rotary blade group and stirring blade 2. The motor is located at the top of the late fermentation tank, and the output end of the motor is transmission-connected to the stirring shaft. The lower part of the stirring shaft is sleeved with a rotary blade group, and the bottom end of the stirring shaft is fixedly connected to stirring blade 2, and stirring blade 2 is located inside the conical cylinder fixedly connected to the bottom end of the late fermentation tank.

[0017] Furthermore, the connecting part also includes a connecting port 1 located at the liquid outlet position of the early fermentation tank and the mid-fermentation tank, the outer wall of the connecting port 1 is rotatably connected to the inner wall of the movable ring, the outer wall of the movable ring is evenly fixed with damping blocks, the top of the damping blocks is in contact with the outer wall of the rotary blade group, the inner wall of the movable ring is fixedly connected to a guide plate with a slope design, the outer wall of the connecting port 1 is fixedly connected to a pipe, the other end of the pipe is fixedly connected to the connecting port 2, and the connecting port 2 is fixedly connected to the liquid inlet position of the mid-fermentation tank and the late fermentation tank.

[0018] Furthermore, the rotary blade group includes a fixed ring fixedly connected to the stirring shaft, the outer wall of the fixed ring is symmetrically fixed with fan blades, the upper surface of the fan blade adopts a symmetrical inclined design, the other end of the fan blade is fixedly connected to a round block, the outer wall of the round block is provided with a clamping block, and the top of the round block is rotatably connected to a rotary vane.

[0019] Furthermore, the cleaning part includes an inner ring fixedly connected to the outer wall of the top end of the stirring shaft, a nozzle group 1 is provided at the bottom end of the inner ring, a fixing frame is fixedly connected to the outer wall of the inner ring, a middle ring and an outer ring are fixed at intervals at the bottom end of the fixing frame, and a nozzle group 2 is provided at the bottom end of the outer ring.

[0020] Furthermore, the outer wall of the cone is provided with a discharge port for fully discharging the liquid.

[0021] Compared with the prior art, the technical solution provided by the present invention has the following beneficial effects:

[0022] The present invention divides the fermentation equipment into three devices: an early fermentation tank, a mid-fermentation tank, and a late fermentation tank. By dividing the fermentation process into three stages and performing them in different devices, the production interruption problem caused by the need to stop and clean different batches of mixed liquid in the traditional single-tank fermentation is effectively avoided, continuous fermentation is achieved, and production efficiency is improved.

[0023] The present invention combines a cleaning piece with a stirring piece of different structure. After the early fermentation tank passes the liquid into the mid-fermentation tank, the residue is suspended by increasing the water spray volume and combining stirring for cleaning, which is convenient for discharge together with the cleaning water, thereby reducing the interference of the residue on subsequent batches of fermentation. When the early tank is cleaned, the valve of the mid-term tank is closed, which can maintain a stable fermentation environment inside it and is not disturbed by the outside world. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. Those skilled in the art can also derive other drawings based on these drawings without inventive effort.

[0025] Figure 1 Schematic diagram of the overall structure of an embodiment of the present invention;

[0026] Figure 2 This is a schematic diagram of the cross-sectional structure of an early fermentation tank according to an embodiment of the present invention;

[0027] Figure 3 This is a schematic diagram of the cross-sectional structure of a mid-fermentation tank according to an embodiment of the present invention;

[0028] Figure 4This is a schematic diagram of the cross-sectional structure of a late fermentation tank according to an embodiment of the present invention;

[0029] Figure 5 This is a schematic diagram of the connection structure of the connector according to an embodiment of the present invention;

[0030] Figure 6 This is a schematic diagram of the connection structure of the rotary blade group according to an embodiment of the present invention;

[0031] Figure 7 Schematic diagram of the cleaning element structure and its splashing area according to an embodiment of the present invention.

[0032] The numbers in the figure represent: 1. Fermentation equipment; 11. Early fermentation tank; 12. Mid-fermentation tank; 13. Late fermentation tank; 131. Cone; 2. Connector; 21. Pipeline; 22. Connector 1; 24. Connector 2; 25. Movable ring; 26. Damping block; 27. Guide plate; 3. Discharge port; 5. Stirring element; 51. Motor; 52. Stirring shaft; 53. Rotary blade group; 531. Fixed ring; 532. Fan blade; 533. Round block; 535. Block; 536. Rotary vane; 55. Stirring blade 1; 56. Stirring blade 2; 6. Discharge port; 7. Cleaning element; 71. Inner ring; 72. Nozzle group 1; 73. Fixed frame; 75. Middle ring; 76. Nozzle group 2; 77. Outer ring. DETAILED DESCRIPTION

[0033] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0034] The present invention will be further described below with reference to the embodiments.

[0035] Example:

[0036] See also Figure 1-Figure 7The present invention provides a technical solution for a theaflavin preparation system based on a continuous fermentation structure: it includes a fermentation device 1, which includes an early fermentation tank 11, a mid-fermentation tank 12 and a late fermentation tank 13 arranged in series, the interior of the early fermentation tank 11 is a suitable environment for the early fermentation stage, the interior of the mid-fermentation tank 12 is a suitable environment for the mid-fermentation stage, and the interior of the late fermentation tank 13 is a suitable environment for the late fermentation stage, avoiding the production interruption problem caused by cleaning between batches of traditional single-tank fermentation and realizing continuous fermentation, a stirring member 5, the stirring member 5 is located inside the early fermentation tank 11, the mid-fermentation tank 12 and the late fermentation tank 13, and rotates at different speeds; a discharge port 6, the discharge port 6 is located at the top of the early fermentation tank 11, the mid-fermentation tank 12 and the late fermentation tank 13; a cleaning member 7, the cleaning member 7 is located at the top of the early fermentation tank 11, the mid-fermentation tank 12 and the late fermentation tank 13, and the cleaning member 7 is located at a lower position relative to the discharge port 6.

[0037] refer to Figure 1 and Figure 2 The stirring member 5 arranged inside the early fermentation tank 11 is composed of a motor 51, a stirring shaft 52 and a rotary blade group 53. The motor 51 is located at the top of the early fermentation tank 11, and the output end of the motor 51 is transmission-connected to the stirring shaft 52. The bottom end of the stirring shaft 52 is sleeved with a rotary blade group 53. The stirring speed in the early fermentation stage is relatively slow. At this stage, the microorganisms are in the adaptation period and the early logarithmic growth period, and a relatively stable environment is required for cell activation and initial proliferation. The slower stirring speed can avoid mechanical damage to the microbial cells, which is conducive to their better adaptation to the new environment. At the same time, it can also reduce problems such as excessive changes in dissolved oxygen caused by excessive stirring, and prevent adverse effects on microbial growth. Its advantage is that it can create a mild and stable initial growth environment for microorganisms, help microorganisms to smoothly start the growth and metabolism process, improve the synchronization of microbial growth, and enable the bacterial community to enter the logarithmic growth period more neatly, laying a good foundation for the smooth progress of the subsequent fermentation process and the efficient synthesis of products. It can also save energy consumption to a certain extent and reduce fermentation costs.

[0038] refer to Figure 1 and Figure 3The stirring member 5 arranged inside the mid-fermentation tank 12 is composed of a motor 51, a stirring shaft 52, a rotary blade group 53 and a stirring blade 55. The motor 51 is located at the top of the mid-fermentation tank 12, and the output end of the motor 51 is connected to the stirring shaft 52 in a transmission manner. The upper part of the stirring shaft 52 is provided with a stirring blade 55, and the lower end of the stirring shaft 52 is provided with a rotary blade group 53. Due to the internal environment requirements of the mid-fermentation tank 12, the stirring speed in the mid-fermentation is increased. This is mainly because as the microorganisms multiply in large numbers, the demand for oxygen and nutrients increases significantly. Accelerating stirring can promote oxygen transfer and uniform distribution of nutrients. At the same time, the heat generated by microbial metabolism increases. Increasing the stirring speed is conducive to heat dissipation and ensuring uniform temperature. In addition, it can improve the metabolic environment of microorganisms and affect the morphology of microorganisms to promote their growth. The benefits include providing more suitable growth conditions for microorganisms, enhancing mass transfer effects, accelerating heat dissipation to ensure temperature stability, reducing the accumulation of metabolic products to avoid product inhibition, promoting product synthesis and ensuring uniform distribution of products, thereby improving the quality and yield of products, and ultimately improving the overall efficiency and benefits of the fermentation process.

[0039] refer to Figure 1 and Figure 4 The stirring member 5 arranged inside the late fermentation tank 13 is composed of a motor 51, a stirring shaft 52, a rotary blade group 53 and a stirring blade 2 56. The motor 51 is located at the top of the late fermentation tank 13. The output end of the motor 51 is connected to the stirring shaft 52 in a transmission manner. The rotary blade group 53 is sleeved on the lower part of the stirring shaft 52. The stirring blade 2 56 is fixedly connected to the bottom end of the stirring shaft 52 to uniformly collect and process the residue after cleaning to avoid residue and achieve comprehensive cleaning.

[0040] In existing production, after the previous batch of fermentation is completed, fermentation liquid, microorganisms and other substances may remain on the inner wall of the fermentation equipment 1, the pipeline 21 and other parts. If they are not cleaned, the miscellaneous bacteria in these residual substances may multiply in large numbers during the new batch of fermentation, compete with the target microorganisms or enzymes for nutrients, affect the fermentation process of theaflavins, and lead to reduced fermentation efficiency and product quality, and may even produce odors, harmful substances, etc. Therefore, after the liquid fermentation of a batch of homogenized fresh tea leaves is completed, it is usually necessary to clean the fermentation equipment 1 before the next batch of homogenized fresh tea leaves are put into use. Therefore, the fermentation process is intermittent rather than continuous. In view of this, the present invention divides the fermentation equipment 1 into three devices: the early fermentation tank 11, the mid-fermentation tank 12 and the late fermentation tank 13. By dividing the fermentation process into three stages and carrying out them in different equipment, the production interruption problem caused by the need to stop and clean the traditional single-tank fermentation of different batches of mixed liquids is effectively avoided, continuous fermentation is achieved, and production efficiency is improved.

[0041] The internal environment of the fermentation early stage tank 11 is as follows:

[0042] Oxygen: Sterile air is introduced into the fermentation system through a microporous aeration device installed on the side of the early fermentation tank 11 at a relatively low ventilation rate, such as 0.1-0.2 vvm, which is the volume of air introduced per unit volume of fermentation liquid per minute. At the same time, low-speed stirring, such as 50-100 r / min, is used to evenly distribute the oxygen and activate related enzymes such as polyphenol oxidase.

[0043] Temperature: A jacketed or coiled temperature control system is used to connect the pre-fermentation tank 11 to a constant temperature water bath or oil bath. The temperature in the reactor is accurately controlled between 20°C and 25°C through circulating heating or cooling media such as hot water, cold water or thermal oil, and the temperature fluctuation is controlled within ±1°C.

[0044] Humidity: A humidity sensor is installed in the fermentation tank 11 to monitor the humidity in real time. When the humidity is lower than 80%, the humidity is adjusted by spraying an appropriate amount of sterile water into the reactor to maintain it within the range of 80%-90%.

[0045] pH value: Use a pH electrode to monitor the pH value of the fermentation broth in real time. When the pH value deviates from the range of 5-6, automatically add dilute acid such as citric acid or dilute alkali such as sodium hydroxide solution for adjustment. During the adjustment process, add slowly and stir continuously to prevent the local pH value from changing too much.

[0046] The internal environment of the fermentation mid-term tank 12 is as follows:

[0047] Oxygen: Increase the aeration volume of the aerator to 0.3-0.5 vvm and the stirring speed to 100-150 r / min to enhance gas-liquid mass transfer and ensure adequate oxygen supply. Alternatively, pure oxygen or oxygen-enriched air can be used instead of sterile air to further increase the oxygen concentration, but care must be taken to control the dissolved oxygen level to avoid excessive oxidation.

[0048] Temperature: The temperature is raised to 25-30°C through the temperature control system with an accuracy of ±0.5°C. According to the temperature change trend during the fermentation process, the automatic heating or cooling program can be set to ensure that the temperature is stable within the appropriate range.

[0049] Humidity: Continuously monitor humidity and maintain it at around 90%. When humidity drops, add sterile water promptly. An automatic spray system can be used to automatically adjust the amount of water sprayed based on feedback from the humidity sensor.

[0050] pH value: Pay close attention to changes in pH. Acidic substances may be produced during the fermentation process, causing the pH to drop. When the pH drops below 4.5, add a dilute alkaline solution to adjust it to maintain a pH between 4.5 and 5.5. Also, regularly sample and analyze the fermentation broth to understand the causes and trends of pH changes.

[0051] The internal environment of the late fermentation tank 13 is as follows;

[0052] Oxygen: Reduce the ventilation volume to 0.5-0.1vvm and the stirring speed to 30-50r / min to reduce the ingress of oxygen and inhibit further oxidation of theaflavins. Alternatively, a certain amount of inert gas such as nitrogen can be introduced into the reactor to replace some of the air and create a relatively low-oxygen environment.

[0053] Temperature: Use a temperature control system to lower the temperature to 20-25°C, with temperature fluctuations controlled within ±1°C. A staged cooling method can be used to gradually lower the temperature so that the fermentation system smoothly transitions to the stable phase.

[0054] Humidity: Adjust the humidity to around 85% by controlling the evaporation and replenishment of water. Increase ventilation appropriately to promote water loss, and add a small amount of sterile water as appropriate based on humidity monitoring results.

[0055] pH value: Maintain a pH value of around 5 through regular monitoring and fine-tuning. When the pH value fluctuates, promptly add dilute acid or alkaline solution to adjust it to ensure the presence of theaflavins in a stable acid-base environment.

[0056] First, the fresh tea leaves are homogenized and then enter the early fermentation tank 11 to begin fermentation. The stirring element 5 is started to ensure that the debris is suspended. Then the liquid in the early fermentation tank 11 is transferred to the mid-fermentation tank 12 within the specified time or conditions. After the transfer is completed, the early fermentation tank 11 starts to be cleaned, the stirring element 5 continues to operate, the cleaning element 7 sprays clean water, and the residue is discharged; then the liquid in the mid-fermentation tank 12 is transferred to the late fermentation tank 13 within the specified time or conditions. After the transfer is completed, the late fermentation tank 13 starts to be cleaned, the stirring element 5 continues to operate, the cleaning element 7 sprays clean water, and the residue is discharged; finally, the liquid in the late fermentation tank 13 is completely discharged after the fermentation is completed, and the debris is removed through an external filtering device. After it is completely discharged, the late fermentation tank 13 starts to clean and prepares to receive the next batch of liquid.

[0057] refer to Figure 2 、 Figure 5 and Figure 6The connecting member 2 also includes a connecting port 12 located at the liquid outlet position of the fermentation mid-term tank 12, the outer wall of the connecting port 12 is rotatably connected to the inner wall of the movable ring 25, the outer wall of the movable ring 25 is evenly fixed with damping blocks 26, the top of the damping block 26 contacts the outer wall of the rotary blade group 53, the inner wall of the movable ring 25 is fixedly connected with a guide plate 27 with an inclined surface design, the outer wall of the connecting port 12 is fixedly connected to the pipe 21, the other end of the pipe 21 is fixedly connected to the connecting port 24, the connecting port 24 is fixedly connected to the liquid inlet position of the fermentation mid-term tank 12, the rotary blade group 53 includes a fixed ring 531 fixedly connected to the stirring shaft 52, the outer wall of the fixed ring 531 is symmetrically fixed with fan blades 532, the upper surface of the fan blades 532 adopts a symmetrical inclined design, the other end of the fan blade 532 is fixedly connected to a round block 533, the outer wall of the round block 533 is provided with a block 535 connected to the top of the movable ring 25 for damping, and the top of the round block 533 is rotatably connected to a rotary vane 536;

[0058] refer to Figure 3 、 Figure 5 and Figure 6 The connecting member 2 also includes a connecting port 1 22 located at the liquid outlet position of the mid-fermentation tank 12. The outer wall of the connecting port 1 22 is rotatably connected to the inner wall of the movable ring 25. Damping blocks 26 are evenly fixed on the outer wall of the movable ring 25. The top of the damping block 26 contacts the block 535 provided on the outer wall of the rotary blade group 53. The inner wall of the movable ring 25 is fixedly connected to a guide plate 27 with an inclined surface design. The outer wall of the connecting port 1 22 is fixedly connected to the pipe 21. The other end of the pipe 21 is fixedly connected to the connecting port 24. The connecting port 24 is fixedly connected to the liquid inlet position of the late-fermentation tank 13.

[0059] refer to Figure 4 、 Figure 5 and Figure 6 The stirring blade 2 56 is located inside the cone 131 fixedly connected to the bottom end of the fermentation late tank 13. The outer wall of the cone 131 is provided with a discharge port 3 for fully discharging the liquid. The residue stirred and mixed by the stirring blade 2 56 can be completely discharged from the cone 131 under the driving force of the rotation force of the stirring blade 2 56 and gravity.

[0060] The motor 51 drives the stirring shaft 52 to rotate, and the stirring shaft 52 drives the fixed ring 531 of the rotary blade group 53 to rotate synchronously, and the fixed ring 531 drives the fan blades 532 to rotate. When the fixed ring 531 rotates, the liquid inside the tank body is stirred. At the same time, the symmetrically inclined slope design can prevent residue from staying on its surface. The rotation of the fan blades 532 drives the round block 533 to rotate. The outer wall of the round block 533 is arc-shaped and does not fit the inner wall of the tank body. Its rotation path will not be disturbed by the tank body. When the round block 533 rotates, it drives the block 535 to rotate. When the block 535 rotates to the area of the movable ring 25 of the connecting piece 2, the block 535 contacts the protruding damping block 26, and the block 53 5 applies a force to the damping block 26, which drives the movable ring 25 to rotate on the outer wall of the connecting port 22. The rotation of the movable ring 25 simultaneously drives the guide plate 27 to rotate. The rotation of the guide plate 27 causes the mixture to generate local eddy currents and turbulence, thereby increasing the material exchange between different parts of the slurry, strengthening the mixing effect, and enabling the fermentation substrate, microorganisms, and various additives to be more fully contacted and mixed. The flow effect generated by the guide plate 27 keeps the solid particles in a suspended state at all times, increases the sedimentation resistance of the particles, reduces the possibility of sedimentation, ensures the uniform transmission of the mixed slurry in the connecting piece 2, and avoids problems such as blockage of the connecting piece 2 and uneven fermentation due to sedimentation.

[0061] refer to Figure 5 The connecting member 2 also includes a connecting port 1 22 located at the liquid outlet position of the early fermentation tank 11 and the mid-fermentation tank 12. The outer wall of the connecting port 1 22 is rotatably connected to the inner wall of the movable ring 25. The outer wall of the movable ring 25 is evenly fixed with damping blocks 26. The top of the damping block 26 contacts the outer wall of the rotary blade group 53. The inner wall of the movable ring 25 is fixedly connected to a guide plate 27 with an inclined surface design. The outer wall of the connecting port 1 22 is fixedly connected to the pipe 21. The other end of the pipe 21 is fixedly connected to the connecting port 24. The connecting port 24 is fixedly connected to the liquid inlet position of the mid-fermentation tank 12 and the late fermentation tank 13.

[0062] The inner wall diameter of the connection port 22 is designed with a tapered design, so that the cross-sectional area gradually decreases while the pressure increases to a certain extent, thereby increasing the flow rate of the mixed liquid, which is conducive to the rapid discharge of the mixed liquid. The higher flow rate and pressure can form a stronger discharge force at the connection port 22, effectively preventing the mixed liquid from flowing back, ensuring that the material flows in the specified direction, and avoiding the discharged mixed liquid from returning to the device, affecting the production process and product quality; the increase in flow rate increases the amount of mixed liquid discharged per unit time, which can speed up the entire discharging process and improve production efficiency. Especially for large-scale production, it can effectively shorten the discharging time and save time for the next batch of production; the tapered design makes the mixed liquid more concentrated when it flows out, forming a more stable liquid flow, and also facilitates accurate measurement and subsequent processing of the discharged material.

[0063] In contrast to the connection port 1 22, the connection port 2 24 adopts a gradually expanding inner wall diameter design, so that the cross-sectional area gradually increases, and the flow rate of the mixed liquid will gradually decrease, so that the mixed liquid can enter the device more smoothly. The reduced flow rate and smooth change in pressure can make the mixed liquid slowly and evenly enter the device, reducing the impact on the internal structure of the device such as the stirring shaft 52, the tank wall, etc., reducing the risk of equipment wear and damage, and extending the service life of the equipment; the gradually expanding inner wall diameter design enables the mixed liquid to form a relatively gentle flow state when entering the device, which is conducive to more uniform mixing with the existing mixed liquid or other substances in the device, avoiding local excessive concentration or uneven mixing due to excessive feed speed, and providing more favorable conditions for subsequent reactions or treatments; the reduced flow rate makes it easier for operators to accurately control the feed flow rate through control elements such as valves, and can accurately adjust the feed amount according to production needs to ensure the stability of the production process and the consistency of product quality.

[0064] refer to Figure 2 、 Figure 3 、 Figure 4 and Figure 7 The cleaning member 7 includes an inner ring 71 fixedly connected to the outer wall of the top end of the stirring shaft 52, a nozzle group 1 72 is provided at the bottom end of the inner ring 71, a fixing frame 73 is fixedly connected to the outer wall of the inner ring 71, a middle ring 75 and an outer ring 77 are fixed at the bottom end of the fixing frame 73, and a nozzle group 2 76 is provided at the bottom end of the outer ring 77;

[0065] During the fermentation tank cleaning process, in order to achieve comprehensive and efficient cleaning of the agitator shaft 52, the interior of the tank body, and the inner wall, a cleaning device with a unique layout is installed above. It includes three types of nozzles with different directions: an inward-tilted nozzle, a downward-facing vertical nozzle, and an outward-tilted nozzle. The size, flow rate, and other key parameters of each nozzle are gradually increased.

[0066] The outer ring 77, the middle ring 75, and the inner ring 71 are at three different specific angles. The nozzle group 1 72 in the inner ring 71 is tilted inward, toward the direction of the stirring shaft 52. Its installation angle is determined by the diameter, position, and internal structure of the stirring shaft 52, ensuring that the sprayed cleaning liquid can accurately cover the surface of the stirring shaft 52, especially the connection between the stirring shaft 52 and the rotary blade group 53, the key transmission parts of the stirring shaft 52, and other places where residual materials are easily retained. The cleaning liquid sprayed by the nozzle group 1 72 covers the stirring shaft 52 in a fan-shaped or cone-shaped manner. With the impact force and infiltration effect of the cleaning liquid, it can effectively remove materials, microbial plaques, and various types of dirt produced by fermentation attached to the surface of the stirring shaft 52. For complex areas such as the connection between the stirring shaft 52 and the rotary blade group 53, the multi-angle water flow can penetrate into the gaps and completely remove stubborn residues, ensuring that the stirring shaft 52 is restored to a clean state and preventing material residues from affecting the next batch of fermentation.

[0067] The middle ring 75 is installed vertically downward and is located at the center of the cleaning member 7. Its function is to directly flush the bottom of the tank body and the internal space near the bottom. The strong impact of the water flow can effectively remove the material residues deposited at the bottom. The vertical water flow of the middle ring 75 directly impacts the bottom of the tank body, which can quickly break up and wash away the deposited material residues. At the same time, the convection and turbulence formed by the water flow in the tank body drive the cleaning liquid to circulate in the tank, and comprehensively clean the supporting structure, sensors and other components in the tank, so that the entire internal space of the tank body is effectively cleaned, reducing the interference of residual materials on the new batch of fermentation.

[0068] The mounting bracket 73 at the outer ring 77 is arranged at an outward angle, adjusted according to the tank diameter and height. It is used to focus on cleaning the inner wall of the tank, starting from the top and rinsing the inner wall from top to bottom, ensuring that there are no blind spots. The high-flow cleaning liquid sprayed by nozzle group 2 76 spirals downward along the inner wall of the tank, providing a comprehensive and detailed flushing of the inner wall. This removes sticky materials and biofilm adhering to the tank wall, ensuring a smooth and clean tank wall and preventing material accumulation on the tank wall that affects heat and mass transfer efficiency and the stability of the fermentation process.

[0069] Different areas require different cleaning difficulties and areas. The inner wall has a large area, requiring a higher flow rate to ensure comprehensive coverage. The bottom of the tank has a lot of material deposits, requiring a greater impact force of the water flow. The agitator shaft 52 is relatively small and positioned in a special way, so a smaller flow rate can be used for precise cleaning. Therefore, the size and flow rate of the outer ring 77, middle ring 75, and inner ring 71 are designed to increase in a step-by-step manner. Through the coordinated operation of three nozzles in different directions, the interior of the fermenter is cleaned from multiple angles, ensuring that the agitator shaft 52, the tank interior, and every part of the inner wall are covered by the cleaning liquid. This effectively eliminates the blind spots that may exist in traditional cleaning methods and greatly improves the comprehensiveness and reliability of the cleaning effect. The step-by-step increase design allows the cleaning liquid to be precisely distributed according to the needs of different areas, ensuring cleaning results while avoiding unnecessary waste. Compared with a uniform flow cleaning method, this differentiated design can complete the cleaning task in a shorter time, reducing the amount of cleaning liquid used and cleaning time, lowering energy consumption and production costs. It also extends the overall service life of the fermenter and related equipment, and reduces equipment maintenance and replacement costs.

[0070] Thoroughly remove residual materials and microorganisms in the tank, effectively avoiding contamination and interference of the previous batch of fermentation residues on the new batch, providing a stable and pure environment for each batch of fermentation, and helping to improve the quality stability and consistency of fermentation products such as theaflavins.

[0071] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the protection scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A theaflavin preparation system based on a continuous fermentation structure, characterized in that: include: The fermentation equipment (1) comprises an early fermentation tank (11), a mid-fermentation tank (12), and a late fermentation tank (13) arranged in series, wherein the interior of the early fermentation tank (11) is a suitable environment for the early fermentation, the interior of the mid-fermentation tank (12) is a suitable environment for the mid-fermentation, and the interior of the late fermentation tank (13) is a suitable environment for the late fermentation, thereby avoiding the production interruption problem caused by the need to stop and clean different batches of mixed liquid in a traditional single tank fermentation, and achieving continuous fermentation; A connector (2), wherein adjacent ones of the early fermentation tank (11), the mid-fermentation tank (12), and the late fermentation tank (13) are connected via the connector (2), and mixed liquids at different fermentation stages are transmitted via the connector (2); A stirring member (5), wherein the stirring member (5) is located inside the early fermentation tank (11), the middle fermentation tank (12) and the late fermentation tank (13), and rotates at different speeds; A feed opening (6), wherein the feed opening (6) is located at the top of the early fermentation tank (11), the middle fermentation tank (12) and the late fermentation tank (13); A cleaning member (7), the cleaning member (7) being located at the top of the early fermentation tank (11), the middle fermentation tank (12) and the late fermentation tank (13), and the cleaning member (7) being located at a lower position relative to the feed port (6); Wherein, the connecting member (2) includes a movable ring (25) for stirring the mixed liquid during the transmission process.

2. The theaflavin preparation system based on continuous fermentation structure according to claim 1, characterized in that: The stirring member (5) arranged inside the pre-fermentation tank (11) is composed of a motor (51), a stirring shaft (52) and a rotary blade group (53). The motor (51) is located at the top of the pre-fermentation tank (11). The output end of the motor (51) is connected to the stirring shaft (52) in a transmission manner. The bottom end of the stirring shaft (52) is sleeved with the rotary blade group (53).

3. The theaflavin preparation system based on continuous fermentation structure according to claim 1, characterized in that: The stirring member (5) arranged inside the fermentation mid-term tank (12) is composed of a motor (51), a stirring shaft (52), a rotary blade group (53) and a stirring blade (55). The motor (51) is located at the top of the fermentation mid-term tank (12). The output end of the motor (51) is connected to the stirring shaft (52) in a transmission manner. The stirring blade (55) is sleeved on the upper part of the stirring shaft (52), and the rotary blade group (53) is sleeved on the bottom end of the stirring shaft (52).

4. The theaflavin preparation system based on a continuous fermentation structure according to claim 1, characterized in that: The stirring member (5) arranged inside the late fermentation tank (13) is composed of a motor (51), a stirring shaft (52), a rotary blade group (53) and a second stirring blade (56). The motor (51) is located at the top of the late fermentation tank (13). The output end of the motor (51) is connected to the stirring shaft (52) in a transmission manner. The rotary blade group (53) is sleeved on the lower part of the stirring shaft (52). The bottom end of the stirring shaft (52) is fixedly connected to the second stirring blade (56). The second stirring blade (56) is located inside a cone (131) fixedly connected to the bottom end of the late fermentation tank (13).

5. The theaflavin preparation system based on continuous fermentation structure according to claim 2, characterized in that: The connecting member (2) further comprises a connecting port 1 (22) located at the liquid outlet position of the early fermentation tank (11) and the mid-fermentation tank (12); the outer wall of the connecting port 1 (22) is rotatably connected to the inner wall of the movable ring (25); the outer wall of the movable ring (25) is evenly fixed with a damping block (26); the top end of the damping block (26) contacts the outer wall of the rotary blade group (53); the inner wall of the movable ring (25) is fixedly connected with a guide plate (27) with an inclined surface design; the outer wall of the connecting port 1 (22) is fixedly connected to a pipe (21); the other end of the pipe (21) is fixedly connected to a connecting port 2 (24); the connecting port 2 (24) is fixedly connected to the liquid inlet position of the mid-fermentation tank (12) and the late fermentation tank (13).

6. The theaflavin preparation system based on continuous fermentation structure according to claim 5, characterized in that: The rotary blade group (53) comprises a fixed ring (531) fixedly connected to the stirring shaft (52); the outer wall of the fixed ring (531) is symmetrically fixed with fan blades (532); the upper surface of the fan blades (532) adopts a symmetrical tilting design; the other end of the fan blades (532) is fixedly connected to a round block (533); the outer wall of the round block (533) is provided with a clamping block (535); the top of the round block (533) is rotatably connected to a rotary blade (536).

7. The theaflavin preparation system based on continuous fermentation structure according to claim 1, characterized in that: The cleaning member (7) comprises an inner ring (71) fixedly connected to the outer wall of the top end of the stirring shaft (52); a nozzle group 1 (72) is provided at the bottom end of the inner ring (71); a fixing frame (73) is fixedly connected to the outer wall of the inner ring (71); a middle ring (75) and an outer ring (77) are fixed at the bottom end of the fixing frame (73) at intervals; and a nozzle group 2 (76) is provided at the bottom end of the outer ring (77).

8. The theaflavin preparation system based on continuous fermentation structure according to claim 4, characterized in that: The outer wall of the cone (131) is provided with a discharge port (3) for fully discharging the liquid.

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