Ultrasonic wave and pulse combined tremella polysaccharide extraction device

Abstract

The invention discloses a device for extracting tremella polysaccharide through combination of ultrasonic waves and pulses. The device comprises a pretreatment tank (1), a wall breaking treatment machine (2), an ultrasonic generator (21), a high-voltage pulse electric field device (22), a centrifugal machine (3), a high-pressure homogenizer (4), a membrane separation device (5), a liquid conveying pipeline and a liquid conveying pump, wherein the liquid conveying pipeline and the liquid conveying pump are connected. A temperature sensor and a double-layer jacket can be arranged in a container cavity of the wall breaking processor, and when the temperature rises to a preset value in the extraction process, circulating cooling water or chilled water is introduced into the middle of the container. According to the device, ultrasonic waves and a high-voltage pulse electric field are creatively combined for use, and temperature monitoring and cooling functions are set in the extraction container, so that the device is a high-extraction-rate extraction device suitable for easily inactivated active ingredients at high temperature.

Description

Technical Field

[0001] This invention relates to the field of food processing technology, specifically to a device for extracting polysaccharides from Tremella fuciformis using a combination of ultrasound and pulse. Background Technology

[0002] Tremella fuciformis polysaccharide is a natural high-molecular-weight compound with important biological activities (such as immunomodulation and anticancer effects). Its biological activity is highly dependent on its higher-order spatial structure (such as the triple helix structure) and molecular weight, and it is highly sensitive to temperature. Its inactivation is not a fixed "melting point" but a gradual degradation process. It is generally recommended to control the extraction temperature below 80℃ to maximize the preservation of its biological activity. Therefore, its extraction efficiency and extraction temperature are crucial for its application in the food and pharmaceutical fields. Currently, hot water extraction is commonly used industrially to extract Tremella fuciformis polysaccharide. Although this method is simple to operate, it has significant drawbacks, including high extraction temperature, long extraction time, low efficiency, and the possibility that high temperatures may cause polysaccharide chain degradation and loss of some biological activity. To overcome these shortcomings, some physical field-assisted extraction technologies, such as ultrasonic-assisted extraction, have been gradually applied.

[0003] Ultrasonic extraction technology utilizes the mechanical force generated by cavitation to effectively break down cell walls, thereby shortening extraction time and increasing yield. However, strong cavitation can sometimes lead to localized excessive shear degradation of polysaccharides and has limited selectivity on cell membranes. Furthermore, prolonged ultrasonic treatment can cause solution temperatures to exceed 80°C, resulting in partial inactivation of the bioactive components of *Tremella fuciformis*. Existing technologies, besides single ultrasonic extraction, include hot water extraction and enzymatic hydrolysis. However, these methods have not effectively solved the technical challenge of overcoming the dual mass transfer barriers of cell walls and cell membranes while maintaining low temperature and high efficiency.

[0004] Patent CN202222602420.X discloses an ultrasonic cell-wall breaking device for processing Tremella fuciformis polysaccharide extract. It improves upon existing ultrasonic cell-wall breaking devices by adding a stirring function to enhance the breaking effect and prevent localized overheating. However, it does not address the negative impact of overall solution temperature rise on active substances. Patent CN201520653820.0 discloses an extraction device for buckwheat dietary fiber. While it improves upon the ultrasonic device and incorporates a Peltier element for temperature regulation of the reaction vessel, it also has significant drawbacks: relatively low efficiency, especially in applications requiring high-power cooling, resulting in high energy consumption; and the need for heat dissipation of the element, otherwise it will overheat and damage, drastically reducing the cooling effect. Considering these two drawbacks, this cooling solution is not suitable for extracting active ingredients that are easily deactivated at high temperatures. Existing technologies typically focus on improving ultrasonic devices by addressing stirring techniques or selecting appropriate ultrasonic devices to ensure uniform solution reaction, neglecting the temperature rise caused by ultrasonic treatment.

[0005] Therefore, developing an extraction device that can utilize the advantages of ultrasonic physical fields while avoiding the disadvantages of ultrasonic waves, achieve higher extraction efficiency of Tremella fuciformis polysaccharides, extract Tremella fuciformis polysaccharides at relatively low temperatures, and better maintain the activity of the product has become an urgent technical problem to be solved in this field. Summary of the Invention

[0006] To overcome the shortcomings of the existing technology, and taking into account the characteristics of Tremella polysaccharide, a device for extracting Tremella polysaccharide by combining ultrasound and pulse is provided.

[0007] This invention is achieved through the following technical solution: an apparatus for extracting polysaccharides from Tremella fuciformis using a combination of ultrasound and pulse, comprising: a pretreatment tank for pretreating Tremella fuciformis, a cell wall breaking machine, an ultrasonic generator, a high-voltage pulse electric field device, a centrifuge, a high-voltage homogenizer, a membrane separation device, and infusion pipelines and infusion pumps. The pretreatment tank is sequentially connected to the cell wall breaking machine, the ultrasonic generator, the high-voltage pulse electric field device, the centrifuge, the high-voltage homogenizer, the membrane separation device, a vacuum freeze dryer (first type), a vacuum freeze dryer (second type), and a vacuum freeze dryer (third type). The pretreatment tank is equipped with a feed inlet, a water inlet, a crushing blade, and a cutting blade. The centrifuge is connected to a Tremella fuciformis fiber storage tank. The outlet of the high-voltage homogenizer is connected to the membrane separation device and a Tremella fuciformis polysaccharide stock solution collection device.

[0008] Furthermore: The aforementioned cell wall breaking machine has a double-layer jacket design, with circulating cooling water or chilled water flowing through the middle of the jacket. The cell wall breaking machine is equipped with a temperature sensor, a drive motor B, and a stirring paddle.

[0009] The ultrasonic generator has an ultrasonic frequency of 20–100 kHz.

[0010] The high-voltage pulsed electric field has an intensity of 10–80 kV / cm and a pulse width of 1–100 μs.

[0011] The centrifuge used is a specialized food (beverage) centrifuge. A centrifuge is a machine that uses centrifugal force to accelerate the separation of different materials, primarily to remove coarse fibers from a solution. Preferably, the rotation speed is set to approximately 1000 rpm.

[0012] The homogenizing pressure of the high-pressure homogenizer is 20~30MPa.

[0013] The membrane separation device has a first separation membrane with a molecular weight cutoff of 80,000 to 200,000 micrometers for polysaccharides; a second separation membrane with a molecular weight cutoff of 20,000 to 80,000 micrometers for polysaccharides; and a third separation membrane with a molecular weight cutoff of 5,000 to 20,000 nanometers for polysaccharides.

[0014] The extraction process of Tremella polysaccharides using the ultrasonic and pulse combined extraction device of the present invention includes the following steps: S1: Add raw materials and pure water to the pretreatment tank through the feed inlet and the first infusion pump, and crush them to a particle size ≤2mm to form a tremella suspension; S2: The tremella suspension is pumped to the cell wall breaking machine via a second infusion pump. An ultrasonic generator and a high-voltage pulse electric field device perform ultrasonic and high-voltage pulse treatment on the suspension. During the process, a stirring paddle can be activated simultaneously to ensure more uniform ultrasonic treatment and prevent localized overheating. The temperature is monitored throughout the process by a built-in temperature sensor. If the temperature exceeds a preset value (usually preset to be below the temperature at which the active ingredients are deactivated), the cooling system is activated, using condensate and ice in the jacket to cool the solution. Once the temperature drops by more than 10°C, ultrasonic treatment continues until the preset ultrasonic treatment time is completed. S3: The cell wall-breaking liquid is pumped into the centrifuge via the third infusion pump. The supernatant after centrifugation is pumped into the high-pressure homogenizer via the fourth infusion pump. The lower sediment is collected through the tremella fiber storage tank.

[0015] S4: After processing by the high-pressure homogenizer, it can be directly packaged into a pulp by the Tremella polysaccharide raw liquid collection device, or it can be further subdivided into products of different molecular weights by the membrane separation device, and then packaged into various products such as macromolecular Tremella polysaccharide dry powder, medium molecular weight Tremella polysaccharide dry powder, and small molecular weight Tremella polysaccharide dry powder by the vacuum freeze dryer I, vacuum freeze dryer II, and vacuum freeze dryer III respectively.

[0016] The three vacuum freeze dryers mentioned above can be replaced by a single integrated vacuum freeze dryer.

[0017] The advantages of this invention are: 1. The process and apparatus employing a combined ultrasonic and high-voltage pulsed electric field extraction method for Tremella fuciformis polysaccharide extraction, a dual physical cell disruption method, can improve cell disruption rate and extraction rate. Simultaneously, this dual physical disruption method reduces ultrasonic reaction time while maintaining high disruption and extraction rates, thereby inhibiting the inactivation of effective substances caused by solution heating above 70°C. The physical cell disruption processor is equipped with a temperature sensor and a double-jacket design with condensate water flowing through it, allowing for real-time temperature monitoring during the reaction to prevent the solution temperature from exceeding 60°C, thus maximizing the protection of the extract's bioactivity.

[0018] 2. The apparatus for combined ultrasonic and pulse extraction of Tremella fuciformis polysaccharides described in this invention can be further homogenized after centrifugation of the above-mentioned Tremella fuciformis polysaccharide-containing liquid for different applications. The Tremella fuciformis polysaccharide stock solution can then be further subjected to membrane separation to obtain Tremella fuciformis polysaccharides of different molecular weights. The membrane separation device employs a three-layer membrane: the first layer is a micron-sized membrane with a molecular weight cutoff of 50,000–200,000 for polysaccharides; the second layer is a micron-sized membrane with a molecular weight cutoff of 15,000–50,000 for polysaccharides; and the third layer is a nano-sized membrane with a molecular weight cutoff of 5,000–15,000 for polysaccharides. This allows for applications in various fields. If clogging occurs after prolonged membrane separation, it can be flushed with distilled water.

[0019] 3. Advantages of the device for combined ultrasonic and pulse extraction of tremella polysaccharides described in this invention: (1) High extraction efficiency: The unique physical properties of ultrasonic waves can cause plant cell tissue to break or deform, making the extraction of effective components of tremella more complete, and the extraction rate is significantly improved by 50-500% compared with the traditional hot water extraction process; (2) Short extraction time: Ultrasonic waves can usually obtain the best extraction rate in 20-40 minutes, and the extraction time is shortened by more than 2 / 3 compared with the traditional method; (3) Low extraction temperature: The optimal temperature for ultrasonic extraction of Chinese medicinal materials is 40-80℃, which has a protective effect on the effective components in tremella, and at the same time saves energy; (4) Fewer impurities after extraction (no chemical interference from chemical extraction methods, and no enzymes that are difficult to remove), and the effective components are easy to separate and purify; (5) Low operating cost of extraction process and significant comprehensive economic benefits; (6) Simple and easy to operate, and convenient to maintain and care for the device.

[0020] 4. This invention is the first to combine a device that combines ultrasonic cavitation effect with high-voltage pulse electroporation effect, and applies it to the breaking of the cell wall of Tremella fuciformis. Through energy field coupling and parameter optimization, the cell breaking rate of Tremella fuciformis is over 96%, shortening the extraction time. It can achieve a 40-60% increase in the dissolution rate of polysaccharides extracted from Tremella fuciformis compared to traditional methods, overcoming the technical bottleneck of low efficiency of single physical cell breaking and providing a solution for the efficient utilization of functional components of Tremella fuciformis. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall invention; The component names in the diagram are as follows: 1-Pretreatment tank; 11-Drive motor A; 12-Pulverizing blade; 13-Cutting blade; 14-Feed inlet; 15-Pure water; 16-First infusion pump; 17-Second infusion pump; 2-Wall-breaking machine; 21-Ultrasonic generator; 22-High-voltage pulse electric field device; 23-Third infusion pump; 24-Jacket; 25-Drive motor B; 26-Agitator; 3-Centrifuge; 31-Supernatant; 32-Tremella fuciformis fiber precipitate; 33-Tremella fuciformis fiber storage tank; 34-Fourth infusion pump; 4-High-pressure homogenizer; 41-Tremella fuciformis polysaccharide stock solution collection device; 5-Membrane separation device; 61-Vacuum freeze dryer one; 62-Vacuum freeze dryer two; 63-Vacuum freeze dryer three; 71-Large molecule Tremella fuciformis polysaccharide dry powder; 72-Medium molecule Tremella fuciformis polysaccharide dry powder; 73-Small molecule Tremella fuciformis polysaccharide dry powder. Detailed Implementation

[0023] Example 1

[0024] As shown in the figure, an apparatus for extracting polysaccharides from Tremella fuciformis using a combination of ultrasound and pulse extraction includes: a pretreatment tank 1 for pretreating Tremella fuciformis, a cell wall breaking machine 2, an ultrasonic generator 21, a high-voltage pulse electric field device 22, a centrifuge 3, a high-voltage homogenizer 4, and a membrane separation device 5; the pretreatment tank 1 is sequentially connected to the cell wall breaking machine 2, the ultrasonic generator 21, the high-voltage pulse electric field device 22, the centrifuge 3, the high-voltage homogenizer 4, the membrane separation device 5, a vacuum freeze dryer 61, a vacuum freeze dryer 62, and a vacuum freeze dryer 63; the pretreatment tank 1 is equipped with a feed inlet 14, a water inlet 15, a crushing blade 12, a cutting blade 13, a motor 11, a first infusion pump 16, and a second infusion pump 17; the cell wall breaking machine 2 has a double-jacketed design. The interlayer 24 allows for the passage of condensate or ice, and contains a temperature sensor, a stirring paddle 26, and is connected to an ultrasonic generator 21, a high-voltage pulse electric field device 22, and a third infusion pump 23. It also contains a centrifuge 3 connected to a tremella fiber storage tank 33 and a fourth infusion pump 34. The outlet of the high-pressure homogenizer 4 is connected to a membrane separation device 5 and a tremella polysaccharide raw material collection device 41. The membrane separation device 5 is connected to a vacuum freeze dryer 61, a vacuum freeze dryer 62, and a vacuum freeze dryer 63.

[0025] This invention involves pretreatment tank 1 processing a mixture of tremella and water into a suspension, which is then pumped into a cell-wall breaking machine 2 via a second infusion pump 17. The suspension undergoes ultrasonic and pulsed electric field cell-wall breaking treatment. The cell-wall breaking machine 2 is equipped with a temperature sensor that monitors the temperature in real time and intelligently controls it during ultrasonic treatment. If the temperature exceeds a preset value (which is lower than the inactivation temperature of the active substance), the ultrasonic treatment is paused. Cooling water and ice are introduced into the jacket 24 of the cell-wall breaking machine 2 to cool the solution. Once the temperature drops by more than 10°C, ultrasonic treatment resumes until the preset ultrasonic treatment time is completed. The broken liquid is then pumped into a centrifuge 3 via a third infusion pump 23. The lower sediment 32 after centrifugation is sent to a tremella fiber storage tank 33, which is subsequently bottled to produce product 1: tremella dietary fiber. The supernatant 31 is sent to the high-pressure homogenizer 4 by the fourth infusion pump 34. The liquid after high-pressure homogenization can be directly packaged into product 2: Tremella polysaccharide stock solution through the Tremella polysaccharide stock solution collection device 41, or it can be sent to the membrane separation device 5 for membrane separation to form products of different molecular weights. Finally, it is packaged into three types of products: macromolecular Tremella polysaccharide dry powder 71, medium-molecular Tremella polysaccharide dry powder 72, and small-molecular Tremella polysaccharide dry powder 73 by the vacuum freeze dryer 61, the vacuum freeze dryer 62, and the vacuum freeze dryer 63.

Claims

1. A device for extracting polysaccharides from Tremella fuciformis using a combination of ultrasound and pulse, characterized in that: The device includes a pretreatment tank (1) for pretreatment of tremella, a cell wall breaking machine (2), an ultrasonic generator (21), a high-voltage pulse electric field device (22), a centrifuge (3), a high-voltage homogenizer (4), and a membrane separation device (5); the pretreatment tank (1) is sequentially connected to the cell wall breaking machine (2), the ultrasonic generator (21), the high-voltage pulse electric field device (22), the centrifuge (3), the high-voltage homogenizer (4), the membrane separation device (5), a vacuum freeze dryer I (61), a vacuum freeze dryer II (62), and a vacuum freeze dryer III (63); as well as connected infusion pipelines and infusion pumps; The pretreatment tank (1) is equipped with a feed inlet (14), a water inlet (15), a crushing blade (12), a cutting blade (13), a motor (11), a first infusion pump (16), and a second infusion pump (17); the centrifuge (3) is connected to a silver ear fiber storage tank (33) and a fourth infusion pump (34); the outlet of the high pressure homogenizer (4) is connected to a membrane separation device (5) and a silver ear polysaccharide raw liquid collection device (41); the membrane separation device (5) is connected to a vacuum freeze dryer one (61), a vacuum freeze dryer two (62), and a vacuum freeze dryer three (63).

2. The apparatus for combined ultrasonic and pulse extraction of Tremella polysaccharides as described in claim 1, characterized in that: The aforementioned cell wall breaking machine (2) is a double-layer jacket design, with a temperature sensor and a stirring paddle (26) inside. The jacket (24) can be used to condense ice and / or condensate water.

3. The apparatus for combined ultrasonic and pulse extraction of Tremella polysaccharides as described in claim 1, characterized in that: The cell wall breaking machine (2) is made of stainless steel, the ultrasonic generator is made of titanium alloy ultrasonic plate, and the pulse electric field electrode plate is made of platinum electrode.

4. The apparatus for combined ultrasonic and pulse extraction of Tremella polysaccharides as described in claim 1, characterized in that: The three vacuum freeze dryers (61), (62), and (63) are replaced by a single integrated vacuum freeze dryer.

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