Optimization system for relieving biochemical resistance of dietary fibers through steam explosion

Abstract

The invention relates to the technical field of food engineering, and discloses an optimization system for relieving biochemical resistance of dietary fibers through steam explosion, which comprises a material pretreatment module, an explosion control module, a flash evaporation treatment module, a fiber modification module, an analysis detection module, an intelligent optimization module and a product integration module, by accurately regulating and controlling the bursting pressure, temperature, pressure maintaining time and instantaneous pressure releasing rate, the crystallinity of cellulose is weakened, and a fiber structure and a hemicellulose-lignin connecting bond are broken, so that a biochemical reaction interface is optimized, sufficient deconstruction of the fiber structure is ensured, a foundation is laid for improving the bioavailability of fibers, and the application prospect is broad. Through cooperative control of material pretreatment moisture content, rapid cooling after blasting and a flash drying process, physical relaxation and chemical modification of fiber components are promoted, the solubility, fermentability and digestibility of fibers are improved, and a final product is endowed with better functional characteristics and processing adaptability.

Description

Technical Field

[0001] This invention relates to the field of food engineering technology, specifically to an optimized system for using steam explosion to remove biochemical resistance to food fiber. Background Technology

[0002] Steam explosion, also known as steam blasting, is a technology that uses the principle of steam catapults to achieve an explosion process for the pretreatment of biomass. Its essence is to release the steam molecules that have penetrated into the plant tissue instantaneously, so that the internal energy of the steam is converted into mechanical energy and acts on the intercellular layers of the biomass tissue. This allows the raw materials to be decomposed with less energy. Because it avoids the secondary pollution problem of chemical treatment and solves the problem of low efficiency of biological treatment, it is the most promising pretreatment technology in the field of biomass conversion.

[0003] Currently, while steam explosion technology is widely used in the processing of materials rich in dietary fiber, it has several shortcomings in practical applications: insufficient reduction in cellulose crystallinity, inadequate fiber structure breakage, and poor hemicellulose-lignin bond breaking, all of which affect the optimization of the biochemical reaction interface. Furthermore, in the material pretreatment moisture content control, post-explosion cooling rate control, and flash drying stages, the physical relaxation and chemical modification of fiber components are insufficient, resulting in limited improvement in fiber solubility, fermentability, and digestibility. Moreover, the functional characteristics and processing adaptability of the final product are difficult to meet high-standard requirements. In continuous production, there are issues with large fluctuations in processing effects and poor batch-to-batch consistency, severely restricting the industrial application of high-value-added fiber products.

[0004] Therefore, an optimized system for steam explosion to remove biochemical resistance of food fiber is proposed to solve the above problems. Summary of the Invention

[0005] (0) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides an optimized system for steam explosion to remove biochemical resistance of food fibers, thus solving the problems mentioned in the background section.

[0006] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: an optimized system for steam explosion to remove biochemical resistance of food fiber, comprising: Material pretreatment module: The macroscopic structure of the raw material is broken down by a twin-screw crusher, the moisture content is adjusted to 25%-45% by a buffer atomizer, and the porous material is output through a constant temperature balance chamber; Explosion control module: Receives the porous material, implements step-by-step pressurization through a multi-stage steam injection device, performs instantaneous pressure relief operation using a piston-type pressure relief valve, and outputs micro-crack structure via a pressure sensor array; Flash evaporation module: Receives the microcracked structure, achieves rapid deep cooling through a liquid nitrogen supply system, locks the pore conformation using an infrared temperature monitor, and outputs a shaped fiber matrix; Fiber modification module: Receives the shaped fiber matrix, performs surface modification through an airflow vortex dryer, controls the moisture content to ≤8% using a humidity feedback controller, and outputs high water-holding capacity fibers; Analysis and detection module: Receives the high water-holding capacity fiber, analyzes the crystallinity reduction using an X-ray diffractometer, detects the bond breaking rate using a Fourier transform infrared spectroscopy, and outputs structure-function correlation data via an enzymatic hydrolysis reactor; Intelligent optimization module: Receives the structure-function association data, generates control instructions through an industrial computer equipped with a parameter adjustment algorithm library, and reversely links the moisture content of the material pretreatment module, the pressure maintenance time of the burst control module, the cooling rate of the flash evaporation module, and the wind speed parameters of the fiber modification module. Product integration module: Receives optimized fibers, standardizes particle size through an ultra-fine pulverizer, inactivates microorganisms using an electron beam sterilizer, and outputs soluble dietary fiber products that meet the standards via an automated packaging line.

[0007] Preferably, it includes the following steps: S1. Material pretreatment: Crush raw materials containing food fiber into particles with a particle size ≤5mm, adjust the moisture content to 25%-45%, and perform constant temperature equilibrium treatment. S2, Steam Explosion Loading: The pretreated material is placed in a pressure-resistant explosion tank and heated to 160-240℃ at a rate of 5-8℃ / s, while a saturated steam pressure of 0.8-2.8MPa is applied simultaneously. S3, Dynamic pressure control: Maintain the target pressure within a fluctuation range of ±0.15MPa, with a pressure maintenance time of 15-240 seconds; S4. Instantaneous pressure relief operation: The pressure relief of the rupture tank is completed within 0.05-0.5 seconds through a high-speed solenoid valve, with a pressure relief rate ≥8MPa / s; S5. Flash cooling treatment: After the explosion, the material is immediately poured into a vacuum freezing chamber at -15℃ to -30℃, and the core temperature of the material is reduced to below 40℃ within ≤10 seconds. S6. Fiber structure modification: Place the cooled material in an airflow vortex dryer and treat it with an air velocity of 60-90m / s for 5-15 minutes to make the moisture content of the fiber components ≤8%; S7. Resistance index detection: X-ray diffraction was used to determine the change in cellulose crystallinity, and infrared spectroscopy was used to analyze the hemicellulose-lignin bond breaking rate. S8. Soluble conversion: The fiber is treated with a complex enzyme using an enzymatic hydrolysis reactor, and the amount of soluble dietary fiber generated is detected. S9. Functional characteristic optimization: Based on the detection results, dynamically adjust the combination of parameters from S2 to S6 to make the product water holding capacity ≥800% and swelling force ≥12mL / g; S10. Product Integration and Output: The optimized fibers are ultra-finely pulverized, sterilized, and then packaged into food additives and functional base materials.

[0008] Preferably, the S1 material pretreatment includes the following sub-steps: S11. A twin-screw extruder is used to shear and crush plant-based raw materials such as wheat bran and brown rice, as well as edible fungi such as Ganoderma lucidum. The screw speed is 1200 rpm and the screen aperture is 2 mm. S12. Spray a pH 6.8 citrate-disodium hydrogen phosphate buffer solution using a high-pressure atomizing spray system at a spray intensity of 8 L / min·m². S13. Equilibrate in a 35℃ constant humidity chamber for 3 hours, with a humidity control accuracy of 2%RH; S14. The formula for calculating the porosity of the pretreated material is: in For the bulk density of the material, The true density of the material; S15. Near-infrared moisture meter is used to monitor moisture content online and adjust the spray volume accordingly.

[0009] Preferably, the S2 steam explosion loading and S4 instantaneous depressurization include the following coordinated control: S21. A three-stage steam ejector is used to achieve stepped pressurization, with a pressure gradient of 0.8MPa→1.6MPa→2.8MPa; S22, the standard deviation of the temperature field distribution inside the tank is less than 1.5℃, and the pressure fluctuation is 0.05MPa; S23. The material loading coefficient shall be controlled at 70% of the rupture tank volume; S41. A blasting force of 18kN is achieved through a hydraulically driven piston-type pressure relief device; S42. The ratio of the pressure relief valve orifice diameter to the tank volume is 1:10, and the surface finish Ra of the pressure relief channel is less than 0.8μm; S43. After depressurization, the residual pressure inside the tank is less than 0.05 MPa, and the time constant τ is equal to 0.05 s.

[0010] Preferably, the S5 flash cooling process specifically includes: S51. The pressure in the vacuum freezing chamber is maintained at 75Pa, and the vacuum establishment time is less than 3s. S52, adopts a -196℃ liquid nitrogen injection system, with a nozzle layout density of 4 nozzles / m³; S53, the material freezing rate is greater than 25℃ / min, and the average ice crystal size is less than 30μm; S54, The sublimation interface movement rate is controlled at 1.2 mm / h during the ice crystal sublimation process; S55. Distributed thermocouples are used to monitor the material temperature gradient, with a maximum temperature difference of less than 5℃. S56, cooling medium circulation flow rate 120m³ / h, heat exchange area coefficient 8m² / m³.

[0011] Preferably, the S7 resistance index detection includes: S71. Cellulose crystallinity is detected using a radiation source with a diffraction angle range up to 40°. S72, hemicellulose-lignin bond breaking rate passed 1735 Calculation of characteristic peak area change rate, resolution 4 ; S73. Fiber structure change parameters: crystallinity decreases by more than 35%, hydrogen bond breakage rate exceeds 80%. - Glycosidic bond cleavage greater than 0.8 mmol / g, pore size change rate +120%, pore volume increase +150%, degree of polymerization decrease greater than 40%; S74. Simultaneous determination of hydration capacity index: water holding rate greater than 850%, expansion volume greater than 15 mL / g; S75. Observe the changes in the surface topology of the fiber using an atomic force microscope.

[0012] Preferably, the S8 soluble conversion includes: S81, the enzymatic hydrolysis formula is xylanase:cellulase:pectinase in a ratio of 3:2:1, with enzyme activities of 8000U / g, 5000U / g, and 3000U / g, respectively. S82, react at 50℃ and pH 5.2 for 120 minutes with a stirring rate of 120 rpm; S83, Enzymatic hydrolysis kinetic model: in This refers to the concentration of soluble dietary fiber. For time differential units, The reaction rate constant is... Enzyme concentration, Substrate concentration, , The reaction order is [number]. S84. Immediately after the conversion is terminated, raise the temperature to 85℃ to inactivate the enzyme for 15 minutes. S85. Uses ultrafiltration membrane separation technology to concentrate soluble components; S86. Conversion rate requirements: Soluble dietary fiber content greater than 40%, reducing sugar yield less than 5%.

[0013] Preferably, the parameter adjustment rules for optimizing the S9 functional characteristics include: S91. When the crystallinity decreases by less than 30%, increase the pressure release rate of S4 by 20%, extend the pressure holding time of S3 by 15%, and increase the final temperature of S2 by 10℃. S92. When the water holding capacity is less than 700%: increase the cooling rate of S5 by 25%, decrease the drying temperature of S6 by 10℃, and extend the drying time by 20%; S93. When the expansion force is less than 10 mL / g: increase the steam pressure of S2 by 0.5 MPa, shorten the equilibrium time of S1 by 30%, and increase the fineness of the pulverization by 15%. S94. When the hemicellulose-lignin bond breaking rate is less than 70%, adjust the steam composition and add 0.3% acetic acid catalyst. S95, when - When the amount of glycosidic bond cleavage is less than 0.6 mmol / g: increase the pressure holding time by 25% and increase the burst pressure by 0.3 MPa.

[0014] Preferably, the S10 product integration output includes: S104. Use an impact crusher to crush the fiber to D50=20μm, and the particle size distribution Span value is less than 1.2; S105, using electron beam sterilization with a dose of 10 kGy and irradiation uniformity greater than 85%; S106. Standardized product formula: dietary fiber content 85±2%, protein less than 5%, ash content less than 3%, heavy metal Pb less than 0.5ppm; S107. Packaging environment control: Oxygen content less than 0.5%, humidity less than 10%RH; S108, Shelf life index: 12 months at 25℃, soluble component retention rate greater than 90%; S109. Establish a quality tracking system: link each batch of products to a database of process parameters.

[0015] Preferably, it also includes a bioavailability optimization step: S110. A three-compartment continuous in vitro digestion model is adopted: gastric phase pH 2.0 → intestinal phase pH 6.5 → colonic phase pH 7.0; S111. Determine the amount of short-chain fatty acids produced: acetic acid > 1.2 mmol / g, propionic acid > 0.4 mmol / g, butyric acid > 0.8 mmol / g; S112. Probiotic proliferation rate determination: Bifidobacterium CFU increased by more than 2.0 log, and Lactobacillus CFU increased by more than 1.5 log; S113. When butyric acid yield is less than 0.8 mmol / g: increase the vortex intensity of S6 by 25% and add 0.2% inulin; S114. Metagenomic sequencing was used to analyze the gut microbiota α diversity index. S115. Establish an in vitro fermentation kinetic model: the maximum gas production rate is greater than 3.5 mL / h, and the lag period is less than 0.5 h.

[0016] (III) Beneficial Effects Compared with existing technologies, the present invention provides an optimized system for steam explosion to remove biochemical resistance of food fiber, which has the following beneficial effects: 1. In this invention, by setting a precise control module for steam explosion parameters, the crystallinity of cellulose, the broken fiber structure, and the hemicellulose-lignin linkage are weakened by precisely controlling the explosion pressure, temperature, pressure holding time, and instantaneous pressure release rate during food fiber processing. This optimizes the biochemical reaction interface, ensures the full deconstruction of the fiber structure, and lays the foundation for improving the bioavailability of fiber.

[0017] 2. In this invention, by setting up a process coordination and control module, during the fiber processing, the physical relaxation and chemical modification of fiber components are promoted by coordinating the control of the moisture content of material pretreatment, rapid cooling after explosion, and flash drying process, thereby improving the solubility, fermentability and digestibility of the fiber, and at the same time giving the final product better functional characteristics and processing adaptability.

[0018] 3. In this invention, by setting up a real-time fiber structure monitoring and dynamic adjustment module, the process parameters are dynamically adjusted based on the real-time monitoring of fiber structure changes during continuous production, thereby solving the problem of fluctuations in processing effect, ensuring the consistency of product performance between batches, and providing a reliable guarantee for the industrial application of high value-added fiber products. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the optimized system for removing biochemical resistance of food fiber by steam explosion according to the present invention. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Please see Figure 1 This optimized system for steam explosion to degrade biochemical resistance of dietary fiber includes: Material pretreatment module: The macroscopic structure of the raw material is broken down by a twin-screw crusher, the moisture content is adjusted to 25%-45% by a buffer atomizer, and the porous material is output through a constant temperature balance chamber; Explosion control module: Receives the porous material, implements step-by-step pressurization through a multi-stage steam injection device, performs instantaneous pressure relief operation using a piston-type pressure relief valve, and outputs micro-crack structure via a pressure sensor array; Flash evaporation module: Receives the microcracked structure, achieves rapid deep cooling through a liquid nitrogen supply system, locks the pore conformation using an infrared temperature monitor, and outputs a shaped fiber matrix; Fiber modification module: Receives the shaped fiber matrix, performs surface modification through an airflow vortex dryer, controls the moisture content to ≤8% using a humidity feedback controller, and outputs high water-holding capacity fibers; Analysis and detection module: Receives the high water-holding capacity fiber, analyzes the crystallinity reduction using an X-ray diffractometer, detects the bond breaking rate using a Fourier transform infrared spectroscopy, and outputs structure-function correlation data via an enzymatic hydrolysis reactor; Intelligent optimization module: Receives the structure-function association data, generates control instructions through an industrial computer equipped with a parameter adjustment algorithm library, and reversely links the moisture content of the material pretreatment module, the pressure maintenance time of the burst control module, the cooling rate of the flash evaporation module, and the wind speed parameters of the fiber modification module. Product integration module: Receives optimized fibers, standardizes particle size through an ultra-fine pulverizer, inactivates microorganisms using an electron beam sterilizer, and outputs soluble dietary fiber products that meet the standards via an automated packaging line.

[0022] Includes the following steps: S1. Material pretreatment: Crush raw materials containing food fiber into particles with a diameter of less than 5mm, adjust the moisture content to 45%, and perform constant temperature equilibrium treatment. S2, Steam Explosion Loading: The pretreated material is placed in a pressure-resistant explosion tank and heated to 240°C at a rate of 8°C / s, while a saturated steam pressure of 0.8-2.8MPa is applied simultaneously. S3, Dynamic Pressure Control: Maintains the target pressure within a fluctuation range of ±0.15MPa for 240 seconds; S4. Instantaneous pressure relief operation: The pressure relief of the rupture tank is completed within 0.5 seconds through a high-speed solenoid valve, with a pressure relief rate greater than 8MPa / s; S5. Flash cooling treatment: After the explosion, the material is immediately poured into a -30℃ vacuum freezing chamber, and the core temperature of the material is reduced to below 40℃ in less than 10 seconds. S6. Fiber structure modification: Place the cooled material in an airflow vortex dryer and treat it for 15 minutes at a wind speed of 90m / s to make the moisture content of the fiber components less than 8%; S7. Resistance index detection: X-ray diffraction was used to determine the change in cellulose crystallinity, and infrared spectroscopy was used to analyze the hemicellulose-lignin bond breaking rate. S8. Soluble conversion: The fiber is treated with a complex enzyme using an enzymatic hydrolysis reactor, and the amount of soluble dietary fiber generated is detected. S9. Functional characteristic optimization: Based on the detection results, dynamically adjust the combination of parameters from S2 to S6 to make the product water holding capacity greater than 800% and the swelling force greater than 12mL / g. S10. Product Integration and Output: The optimized fibers are ultra-finely pulverized, sterilized, and then packaged into food additives and functional base materials.

[0023] S1 material pretreatment includes the following sub-steps: S11. A twin-screw extruder is used to shear and crush plant-based raw materials such as wheat bran and brown rice, as well as edible fungi such as Ganoderma lucidum. The screw speed is 1200 rpm and the screen aperture is 2 mm. S12. Spray a pH 6.8 citrate-disodium hydrogen phosphate buffer solution using a high-pressure atomizing spray system at a spray intensity of 8 L / min·m². S13. Equilibrate in a 35℃ constant humidity chamber for 3 hours, with a humidity control accuracy of 2%RH; S14. The formula for calculating the porosity of the pretreated material is: in For the bulk density of the material, The true density of the material; S15. Near-infrared moisture meter is used to monitor moisture content online and adjust the spray volume accordingly.

[0024] S2 steam explosion loading and S4 instantaneous depressurization include the following coordinated control: S21. A three-stage steam ejector is used to achieve stepped pressurization, with a pressure gradient of 0.8MPa→1.6MPa→2.8MPa; S22, the standard deviation of the temperature field distribution inside the tank is less than 1.5℃, and the pressure fluctuation is 0.05MPa; S23. The material loading coefficient shall be controlled at 70% of the rupture tank volume; S41. A blasting force of 18kN is achieved through a hydraulically driven piston-type pressure relief device; S42. The ratio of the pressure relief valve orifice diameter to the tank volume is 1:10, and the surface finish Ra of the pressure relief channel is less than 0.8μm; S43. After depressurization, the residual pressure inside the tank is less than 0.05 MPa, and the time constant τ is equal to 0.05 s.

[0025] The S5 flash cooling process specifically includes: S51. The pressure in the vacuum freezing chamber is maintained at 75Pa, and the vacuum establishment time is less than 3s. S52, adopts a -196℃ liquid nitrogen injection system, with a nozzle layout density of 4 nozzles / m³; S53, the material freezing rate is greater than 25℃ / min, and the average ice crystal size is less than 30μm; S54, The sublimation interface movement rate is controlled at 1.2 mm / h during the ice crystal sublimation process; S55. Distributed thermocouples are used to monitor the material temperature gradient, with a maximum temperature difference of less than 5℃. S56, cooling medium circulation flow rate 120m³ / h, heat exchange area coefficient 8m² / m³.

[0026] S7 resistance index testing includes: S71. Cellulose crystallinity is detected using a radiation source with a diffraction angle range up to 40°. S72, hemicellulose-lignin bond breaking rate passed 1735 Calculation of characteristic peak area change rate, resolution 4 ; S73. Fiber structure change parameters: crystallinity decreases by more than 35%, hydrogen bond breakage rate exceeds 80%. - Glycosidic bond cleavage greater than 0.8 mmol / g, pore size change rate +120%, pore volume increase +150%, degree of polymerization decrease greater than 40%; S74. Simultaneous determination of hydration capacity index: water holding rate greater than 850%, expansion volume greater than 15 mL / g; S75. Observe the changes in the surface topology of the fiber using an atomic force microscope.

[0027] S8 soluble conversion includes: S81, the enzymatic hydrolysis formula is xylanase:cellulase:pectinase in a ratio of 3:2:1, with enzyme activities of 8000U / g, 5000U / g, and 3000U / g, respectively. S82, react at 50℃ and pH 5.2 for 120 minutes with a stirring rate of 120 rpm; S83, Enzymatic hydrolysis kinetic model: in This refers to the concentration of soluble dietary fiber. For time differential units, The reaction rate constant is... Enzyme concentration, Substrate concentration, , The reaction order is [number]. S84. Immediately after the conversion is terminated, raise the temperature to 85℃ to inactivate the enzyme for 15 minutes. S85. Uses ultrafiltration membrane separation technology to concentrate soluble components; S86. Conversion rate requirements: Soluble dietary fiber content greater than 40%, reducing sugar yield less than 5%.

[0028] The parameter adjustment rules for S9 feature optimization include: S91. When the crystallinity decreases by less than 30%, increase the pressure release rate of S4 by 20%, extend the pressure holding time of S3 by 15%, and increase the final temperature of S2 by 10℃. S92. When the water holding capacity is less than 700%: increase the cooling rate of S5 by 25%, decrease the drying temperature of S6 by 10℃, and extend the drying time by 20%; S93. When the expansion force is less than 10 mL / g: increase the steam pressure of S2 by 0.5 MPa, shorten the equilibrium time of S1 by 30%, and increase the fineness of the pulverization by 15%. S94. When the hemicellulose-lignin bond breaking rate is less than 70%, adjust the steam composition and add 0.3% acetic acid catalyst. S95, when - When the amount of glycosidic bond cleavage is less than 0.6 mmol / g: increase the pressure holding time by 25% and increase the burst pressure by 0.3 MPa.

[0029] S10 product integration outputs include: S104. Use an impact crusher to crush the fiber to D50=20μm, and the particle size distribution Span value is less than 1.2; S105, using electron beam sterilization with a dose of 10 kGy and irradiation uniformity greater than 85%; S106. Standardized product formula: dietary fiber content 85±2%, protein less than 5%, ash content less than 3%, heavy metal Pb less than 0.5ppm; S107. Packaging environment control: Oxygen content less than 0.5%, humidity less than 10%RH; S108, Shelf life index: 12 months at 25℃, soluble component retention rate greater than 90%; S109. Establish a quality tracking system: link each batch of products to a database of process parameters.

[0030] It also includes bioavailability optimization steps: S110. A three-compartment continuous in vitro digestion model is adopted: gastric phase pH 2.0 → intestinal phase pH 6.5 → colonic phase pH 7.0; S111. Determine the amount of short-chain fatty acids produced: acetic acid > 1.2 mmol / g, propionic acid > 0.4 mmol / g, butyric acid > 0.8 mmol / g; S112. Probiotic proliferation rate determination: Bifidobacterium CFU increased by more than 2.0 log, and Lactobacillus CFU increased by more than 1.5 log; S113. When butyric acid yield is less than 0.8 mmol / g: increase the vortex intensity of S6 by 25% and add 0.2% inulin; S114. Metagenomic sequencing was used to analyze the gut microbiota α diversity index. S115. Establish an in vitro fermentation kinetic model: the maximum gas production rate is greater than 3.5 mL / h, and the lag period is less than 0.5 h.

[0031] Example 1: High-value conversion scheme for wheat bran fiber This embodiment uses wheat bran as raw material for steam explosion treatment. First, wheat bran with a moisture content of 12% is fed into a twin-screw extruder for crushing. The screen aperture is precisely controlled to 5 mm. After crushing, the material is uniformly sprayed with a pH 6.8 citrate-disodium hydrogen phosphate buffer solution through a high-pressure atomizing spray system. The spray intensity is maintained at a constant level of 8 liters per square meter per minute, increasing the material's moisture content to 35%. The treated material is then transferred to a 35°C constant humidity chamber for equilibration treatment for 3 hours. During this period, the moisture content change is monitored in real time using a near-infrared moisture meter to ensure that the bulk density remains stable at 0.45 grams per cubic centimeter, and the porosity meets the technical specifications.

[0032] The pre-treated material is loaded into a 500-liter pressure-resistant bursting tank, with the loading factor controlled at 70%. Precise pressure control is achieved through a three-stage steam injection system: an initial pressure of 0.8 MPa is maintained for 30 seconds, the second stage increases to 1.6 MPa and maintains it for 45 seconds, and the final stage reaches the target pressure of 2.8 MPa. The entire heating process is strictly controlled at a rate of 6.5 degrees Celsius per second, and the temperature distribution uniformity within the tank meets technical standards. The pressure maintenance phase lasts for 90 seconds, with pressure fluctuations controlled within allowable errors. After pressure maintenance, a hydraulically driven piston-type pressure relief device completes instantaneous pressure release within 0.2 seconds, with a pressure relief rate of 10 MPa per second. The pressure relief valve diameter is maintained in a specific ratio to the tank volume.

[0033] The blasted material is immediately poured into a vacuum freezing chamber at -25 degrees Celsius. The pressure inside the chamber builds up to the set value within 3 seconds. A cryogenic medium injection system is used for flash cooling, with nozzles arranged at a specific density. The cooling medium maintains a constant flow rate, ensuring the material freezing rate meets technical standards and ice crystal size is controlled within the required range. A distributed temperature monitoring system ensures the overall temperature uniformity of the material. The interface movement rate is strictly controlled during the ice crystal sublimation process, achieving a core temperature reduction to the target value within a specified time.

[0034] After cooling, the material is transferred to an airflow vortex drying device and treated at a specific wind speed for 10 minutes. The humidity control system maintains precise adjustment, ultimately bringing the moisture content of the fiber components to the predetermined standard. Analysis using advanced detection equipment shows that the crystallinity of cellulose is reduced and the area of ​​characteristic peaks is significantly reduced, indicating that key chemical bonds are broken efficiently. Microscopic observation shows that a porous structure is formed on the fiber surface, with a significant increase in pore size and pore volume.

[0035] The enzymatic hydrolysis stage employs a specific ratio of compound enzymes, catalyzing the reaction under strictly controlled temperature and pH conditions. Soluble components are concentrated using membrane separation technology. Testing shows that the proportion of soluble dietary fiber reaches an ideal level, reducing sugar production is maintained at a low range, and the final product meets high-quality dietary fiber standards in terms of water-holding capacity and swelling volume, with improved bioactivity indicators.

[0036] Example 2: Continuous Production Scheme for Soybean Residue Fiber Soybean residue, a byproduct of soybean processing, is used as raw material. After dehydration to adjust the moisture content to 35%, 0.3% food-grade acetic acid catalyst is added. The material enters the pretreatment zone at a uniform speed through a conveying system, and the bulk density is monitored and controlled in real time to 0.43 g / cm³. After pretreatment, the soybean residue enters a series of explosion tanks for four-stage pressure control: 0.5 MPa → 1.2 MPa → 2.0 MPa → 2.8 MPa. During the pressure maintenance stage, the temperature fluctuation is less than 1.2℃, the pressure relief system response is less than 50 ms, and the pressure relief rate is 12 MPa / s.

[0037] The blasted material is conveyed to a three-section freezing chamber: pre-cooling zone → deep-cooling zone → equilibrium zone. The intensity of liquid nitrogen injection is controlled in each zone, and the material freezing rate is greater than 28℃ / min. Infrared monitoring ensures that the temperature difference is less than 3℃. The vertical vortex drying tower adopts gradient wind speed control: 60m / s at the bottom → 85m / s in the middle → 70m / s at the top. After drying for 12 minutes, the moisture content is 5.8%.

[0038] A dynamic optimization mechanism was established: when the water holding capacity was less than 720%, the wind speed was automatically increased by 10%; when the hemicellulose breakage rate was less than 75%, the pressure was extended by 20%; the enzymatic hydrolysis adopted a continuous flow reactor with temperature zone control: 45℃ in the front section → 55℃ in the middle section → 50℃ in the back section; when the online monitoring showed that the conversion rate reached 40%, instantaneous inactivation was initiated; and the molecular weight was stabilized at 30kDa.

[0039] After being ultra-finely pulverized to D50=18μm, the product is sterilized with a 10kGy electron beam. The final product has a dietary fiber content of 85%, and the oxygen content is less than 0.3% in nitrogen-filled packaging. The raw material batch is traced back to the process parameters through a blockchain system. The butyric acid yield is verified to be 0.85mmol / g in vitro, and the shelf life is 18 months.

[0040] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply the existence of any such actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article, or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article, or device. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of other identical elements in the process, method, article, or device comprising the element.

[0041] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An optimized system for steam explosion to remove biochemical resistance of food fiber, characterized in that: include: Material pretreatment module: The macroscopic structure of the raw material is broken down by a twin-screw crusher, the moisture content is adjusted to 25%-45% by a buffer atomizer, and the porous material is output through a constant temperature balance chamber; Explosion control module: Receives the porous material, implements step-by-step pressurization through a multi-stage steam injection device, performs instantaneous pressure relief operation using a piston-type pressure relief valve, and outputs micro-crack structure via a pressure sensor array; Flash evaporation module: Receives the microcracked structure, achieves rapid deep cooling through a liquid nitrogen supply system, locks the pore conformation using an infrared temperature monitor, and outputs a shaped fiber matrix; Fiber modification module: Receives the shaped fiber matrix, performs surface modification through an airflow vortex dryer, controls the moisture content to ≤8% using a humidity feedback controller, and outputs high water-holding capacity fibers; Analysis and detection module: Receives the high water-holding capacity fiber, analyzes the crystallinity reduction using an X-ray diffractometer, detects the bond breaking rate using a Fourier transform infrared spectroscopy, and outputs structure-function correlation data via an enzymatic hydrolysis reactor; Intelligent optimization module: Receives the structure-function association data, generates control instructions through an industrial computer equipped with a parameter adjustment algorithm library, and reversely links the moisture content of the material pretreatment module, the pressure maintenance time of the burst control module, the cooling rate of the flash evaporation module, and the wind speed parameters of the fiber modification module. Product integration module: Receives optimized fibers, standardizes particle size through an ultra-fine pulverizer, inactivates microorganisms using an electron beam sterilizer, and outputs soluble dietary fiber products that meet the standards via an automated packaging line.

2. The optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 1, characterized in that: Includes the following steps: S1. Material pretreatment: Crush raw materials containing food fiber into particles with a particle size ≤5mm, adjust the moisture content to 25%-45%, and perform constant temperature equilibrium treatment. S2, Steam Explosion Loading: The pretreated material is placed in a pressure-resistant explosion tank and heated to 160-240℃ at a rate of 5-8℃ / s, while a saturated steam pressure of 0.8-2.8MPa is applied simultaneously. S3, Dynamic pressure control: Maintain the target pressure within a fluctuation range of ±0.15MPa, with a pressure maintenance time of 15-240 seconds; S4. Instantaneous pressure relief operation: The pressure relief of the rupture tank is completed within 0.05-0.5 seconds through a high-speed solenoid valve, with a pressure relief rate ≥8MPa / s; S5. Flash cooling treatment: After the explosion, the material is immediately poured into a vacuum freezing chamber at -15℃ to -30℃, and the core temperature of the material is reduced to below 40℃ within ≤10 seconds. S6. Fiber structure modification: Place the cooled material in an airflow vortex dryer and treat it with an air velocity of 60-90m / s for 5-15 minutes to make the moisture content of the fiber components ≤8%; S7. Resistance index detection: X-ray diffraction was used to determine the change in cellulose crystallinity, and infrared spectroscopy was used to analyze the hemicellulose-lignin bond breaking rate. S8. Soluble conversion: The fiber is treated with a complex enzyme using an enzymatic hydrolysis reactor, and the amount of soluble dietary fiber generated is detected. S9. Functional characteristic optimization: Based on the detection results, dynamically adjust the combination of parameters from S2 to S6 to make the product water holding capacity ≥800% and swelling force ≥12mL / g; S10. Product Integration and Output: The optimized fibers are ultra-finely pulverized, sterilized, and then packaged into food additives and functional base materials.

3. The optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 2, characterized in that: The S1 material pretreatment includes the following sub-steps: S11. A twin-screw extruder is used to shear and crush plant-based raw materials such as wheat bran and brown rice, as well as edible fungi such as Ganoderma lucidum. The screw speed is 1200 rpm and the screen aperture is 2 mm. S12. Spray a pH 6.8 citrate-disodium hydrogen phosphate buffer solution using a high-pressure atomizing spray system at a spray intensity of 8 L / min·m². S13. Equilibrate in a 35℃ constant humidity chamber for 3 hours, with a humidity control accuracy of 2%RH; S14. The formula for calculating the porosity of the pretreated material is: in For the bulk density of the material, The true density of the material; S15. Near-infrared moisture meter is used to monitor moisture content online and adjust the spray volume accordingly.

4. The optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 2, characterized in that: The S2 steam explosion loading and S4 instantaneous depressurization include the following coordinated control: S21. A three-stage steam ejector is used to achieve stepped pressurization, with a pressure gradient of 0.8MPa→1.6MPa→2.8MPa; S22, the standard deviation of the temperature field distribution inside the tank is less than 1.5℃, and the pressure fluctuation is 0.05MPa; S23. The material loading coefficient shall be controlled at 70% of the rupture tank volume; S41. A blasting force of 18kN is achieved through a hydraulically driven piston-type pressure relief device; S42. The ratio of the pressure relief valve orifice diameter to the tank volume is 1:10, and the surface finish Ra of the pressure relief channel is less than 0.8μm; S43. After depressurization, the residual pressure inside the tank is less than 0.05 MPa, and the time constant τ is equal to 0.05 s.

5. The optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 2, characterized in that: The S5 flash cooling process specifically includes: S51. The pressure in the vacuum freezing chamber is maintained at 75Pa, and the vacuum establishment time is less than 3s. S52, adopts a -196℃ liquid nitrogen injection system, with a nozzle layout density of 4 nozzles / m³; S53, the material freezing rate is greater than 25℃ / min, and the average ice crystal size is less than 30μm; S54, The sublimation interface movement rate is controlled at 1.2 mm / h during the ice crystal sublimation process; S55. Distributed thermocouples are used to monitor the material temperature gradient, with a maximum temperature difference of less than 5℃. S56, cooling medium circulation flow rate 120m³ / h, heat exchange area coefficient 8m² / m³.

6. The optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 2, characterized in that: The S7 resistance index detection includes: S71. Cellulose crystallinity is detected using a radiation source with a diffraction angle range up to 40°. S72, hemicellulose-lignin bond breaking rate passed 1735 Calculation of characteristic peak area change rate, resolution 4 ; S73. Fiber structure change parameters: crystallinity decreases by more than 35%, hydrogen bond breakage rate exceeds 80%. - Glycosidic bond cleavage greater than 0.8 mmol / g, pore size change rate +120%, pore volume increase +150%, degree of polymerization decrease greater than 40%; S74. Simultaneous determination of hydration capacity index: water holding rate greater than 850%, expansion volume greater than 15 mL / g; S75. Observe the changes in the surface topology of the fiber using an atomic force microscope.

7. The optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 2, characterized in that: The S8 soluble conversion includes: S81, the enzymatic hydrolysis formula is xylanase:cellulase:pectinase in a ratio of 3:2:1, with enzyme activities of 8000U / g, 5000U / g, and 3000U / g, respectively. S82, react at 50℃ and pH 5.2 for 120 minutes with a stirring rate of 120 rpm; S83, Enzymatic hydrolysis kinetic model: in This refers to the concentration of soluble dietary fiber. For time differential units, The reaction rate constant is... Enzyme concentration, Substrate concentration, , The reaction order is [number]. S84. Immediately after the conversion is terminated, raise the temperature to 85℃ to inactivate the enzyme for 15 minutes. S85. Uses ultrafiltration membrane separation technology to concentrate soluble components; S86. Conversion rate requirements: Soluble dietary fiber content greater than 40%, reducing sugar yield less than 5%.

8. The optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 2, characterized in that: The parameter adjustment rules for optimizing the S9 functional features include: S91. When the crystallinity decreases by less than 30%, increase the pressure release rate of S4 by 20%, extend the pressure holding time of S3 by 15%, and increase the final temperature of S2 by 10℃. S92. When the water holding capacity is less than 700%: increase the cooling rate of S5 by 25%, decrease the drying temperature of S6 by 10℃, and extend the drying time by 20%; S93. When the expansion force is less than 10 mL / g: increase the steam pressure of S2 by 0.5 MPa, shorten the equilibrium time of S1 by 30%, and increase the fineness of the pulverization by 15%. S94. When the hemicellulose-lignin bond breaking rate is less than 70%, adjust the steam composition and add 0.3% acetic acid catalyst. S95, when - When the amount of glycosidic bond cleavage is less than 0.6 mmol / g: increase the pressure holding time by 25% and increase the burst pressure by 0.3 MPa.

9. The optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 2, characterized in that: The S10 product integration output includes: S104. Use an impact crusher to crush the fiber to D50=20μm, and the particle size distribution Span value is less than 1.2; S105, using electron beam sterilization with a dose of 10 kGy and irradiation uniformity greater than 85%; S106. Standardized product formula: dietary fiber content 85±2%, protein less than 5%, ash content less than 3%, heavy metal Pb less than 0.5ppm; S107. Packaging environment control: Oxygen content less than 0.5%, humidity less than 10%RH; S108, Shelf life index: 12 months at 25℃, soluble component retention rate greater than 90%; S109. Establish a quality tracking system: link each batch of products to a database of process parameters.

10. An optimized system for steam explosion to remove biochemical resistance of food fiber according to claim 2, characterized in that: It also includes bioavailability optimization steps: S110. A three-compartment continuous in vitro digestion model is adopted: gastric phase pH 2.0 → intestinal phase pH 6.5 → colonic phase pH 7.0; S111. Determine the amount of short-chain fatty acids produced: acetic acid > 1.2 mmol / g, propionic acid > 0.4 mmol / g, butyric acid > 0.8 mmol / g; S112. Probiotic proliferation rate determination: Bifidobacterium CFU increased by more than 2.0 log, and Lactobacillus CFU increased by more than 1.5 log; S113. When butyric acid yield is less than 0.8 mmol / g: increase the vortex intensity of S6 by 25% and add 0.2% inulin; S114. Metagenomic sequencing was used to analyze the gut microbiota α diversity index. S115. Establish an in vitro fermentation kinetic model: the maximum gas production rate is greater than 3.5 mL / h, and the lag period is less than 0.5 h.

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