Split type dynamic inoculation machine and dynamic inoculation method for biomass fungus-based particles

Abstract

The invention belongs to the technical field of mushroom cultivation, and discloses a split type dynamic inoculation machine and a dynamic inoculation method.The equipment comprises a sealed feeding section, a sterilization cooling unit, an inclined rotating inoculation section and a sterile butt joint device which are sequentially connected, and the sterilization cooling unit is provided with a sterile air injection system and a water cooling jacket; the inoculation section is matched with fungus-based particles with omega-shaped grooves through a multidirectional fan-shaped jet orifice, and the inoculation method comprises a complete flow of sterilization, cooling and precise jet inoculation. According to the method, the problem of high breakage rate of large fungus pellets during inoculation is solved, the single-batch treatment period is shortened, whole-process sterile control is realized to reduce pollution, various raw materials such as bamboo sawdust and different site conditions are adapted, the inoculation efficiency and the fungus pellet planting rate are improved, and support is provided for large-scale cultivation of soil-covered fungi.

Description

Technical Field

[0001] This invention belongs to the field of mushroom cultivation technology, specifically relating to a biomass mycelium-based granule split-type dynamic inoculation machine and a dynamic inoculation method. Background Technology

[0002] Currently, the field of mycelial substrate inoculation relies on two mainstream technologies. One is the decentralized inoculation mode centered on the Japanese bag cultivation method. In this mode, the mycelial substrate must first be sterilized in a bag and allowed to cool naturally before inoculation is carried out manually or with simple equipment. Each step is decentralized and relies on multiple independent devices, which is not only cumbersome and inefficient, but also prone to contamination by other microorganisms due to exposure during the process. At the same time, for the large mycelial balls used for soil-covering fungi such as bamboo fungus and gastrodia elata, it is difficult to accurately control the attachment position of the mycelial balls during manual inoculation, resulting in a high rate of mycelial ball detachment after inoculation, and it is impossible to achieve large-scale processing.

[0003] Another type is the centralized seed production equipment represented by the American Scherphon V-type machine. Although it can integrate sterilization and inoculation, it is only suitable for small mycelial balls such as button mushrooms. When using a stirring inoculation mechanism, the breakage rate of large mycelial balls exceeds 90%, which cannot meet the inoculation requirements of rare mushrooms such as bamboo fungus and gastrodia elata. Moreover, this equipment does not adopt a modular design, and the linkage between sterilization and cooling is poor. The processing cycle for a single batch is as long as 8 hours or more, and the processing capacity is only 1-2 tons, which is difficult to adapt to the large-scale inoculation scenario of mycelial substrates using bamboo chips and sawdust as raw materials in my country. In addition, existing inoculation equipment generally lacks a design adapted to mycelial substrates with special structures. During inoculation, the mycelial balls cannot be accurately planted in the tank, resulting in uneven mycelial growth, which further affects the fruiting efficiency and quality. At the same time, the cooling process after sterilization mostly relies on natural cooling, which can easily prolong the production cycle due to slow cooling and increase the risk of mycelial substrate contamination. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a biomass-based microbial granule split-type dynamic inoculation machine and a dynamic inoculation method, providing an automated large-scale inoculation system with high efficiency and good inoculation stability.

[0005] The technical solution adopted in this invention is as follows: In a first aspect, the present invention discloses a split-type dynamic inoculation machine for biomass microbial granules, used for sterilizing, cooling, and inoculating biomass microbial granules, comprising: [the following components are connected in sequence] The feeding section includes a sealed screw conveyor for conveying biomass microbial granules. The sealed screw conveyor has a conveying capacity of 5 tons / hour and a pressure resistance of not less than 0.3 MPa. The sterilization and cooling unit is connected to the feeding section and receives the conveyed biomass microbial particles, including a rotary pressure tank loaded with biomass microbial particles, and a sterile air injection system and an outer water-cooling jacket installed on the rotary pressure tank. The inoculation section, connected to the discharge end of the sterilization and cooling unit, has a rotating cylinder containing several nozzles that spray liquid inoculum towards the inoculation section; and The discharge section is a sterile docking device located at the end of the feeding section to receive the biomass microbial granules. The sterile docking device is sealed to the culture bag.

[0006] In conjunction with the first aspect, the present invention provides a first embodiment of the first aspect, wherein the rotary pressure tank has a volume of 6m³, a rotation speed of 5r / min, and is equipped with a temperature sensor and a pressure sensor inside.

[0007] In conjunction with the first aspect, the present invention provides a second embodiment of the first aspect, wherein the air volume of the sterile air jet system is 100 m³ / h and the air filtration accuracy is 0.1 μm; the water temperature of the outer water-cooling jacket is controlled at 15°C and the flow rate is 20 m³ / h.

[0008] In conjunction with the first aspect, the present invention provides a third embodiment of the first aspect, wherein the rotating cylinder is tilted and rotates at an angle of 15° and a rotation speed of 8 r / min, and the rotating cylinder has at least eight fan-shaped spray nozzles evenly distributed on it, wherein the spray pressure of the spray nozzles is 0.1 MPa and the spray angle is 45°.

[0009] In conjunction with the first aspect, the present invention provides a fourth embodiment of the first aspect, wherein the tank door of the rotary pressure tank adopts a sealing and locking structure, and the pressure inside the tank is stably maintained at 0.1 MPa after locking.

[0010] In conjunction with the first aspect, the present invention provides a fifth embodiment of the first aspect, wherein the diameter of the injection port is 2-3 mm, the arc length between adjacent injection ports is equal, and the injection direction is all directed obliquely downwards from the central axis of the rotating cylinder.

[0011] In conjunction with the first aspect, the present invention provides a sixth embodiment of the first aspect, wherein the aseptic docking device includes an annular sealing ring and a pneumatic clamping assembly.

[0012] Secondly, the present invention provides a dynamic inoculation method, employing a biomass-based microbial granule split-type dynamic inoculation machine as described in any of the above claims, comprising the following steps: S1. First, feed the biomass microbial granules into the rotary pressure tank via a sealed screw conveyor, then close and seal the tank door; S2. Then, saturated steam is introduced into the horizontal rotary pressure tank to raise the temperature inside the tank to 121°C and the pressure to 0.1MPa. This state is maintained for 3 hours, while the tank body is controlled to rotate at a speed of 5r / min. S3. After sterilization, start the sterile air injection system and the outer water-cooling jacket to introduce sterile air with a 0.1μm filtration precision into the tank, and at the same time cool it down through the water-cooling jacket to reduce the particle temperature to 20-25℃ within 1.5 hours. S4. The cooled granules are fed into an inclined rotating cylinder, which is rotated at 8 r / min. Liquid inoculum containing bacterial balls is sprayed into the granules through the spray nozzle. The inoculation amount for each granule is 0.5 ml. S5. Using an aseptic docking device, the inoculated particles are loaded into aseptic culture bags, 20 kg per bag, and sealed to complete the inoculation.

[0013] In conjunction with the second aspect, the present invention provides a first embodiment of the second aspect, wherein the liquid bacterial culture in step S4 contains large bacterial balls with a diameter of 1 cm, and the bacterial ball concentration is 1.2 × 10⁻⁶. 7 cells / mL; In step S2, the temperature fluctuation range of the horizontal rotary pressure tank is less than 2°C, and the pressure fluctuation range is less than 0.01 MPa. In step S3, the sterile air injection system works in conjunction with the outer water-cooled jacket, performing sterile air cooling for the first hour and water-cooled jacket cooling for the next 30 minutes.

[0014] In conjunction with the second aspect, the present invention provides a second embodiment of the second aspect, wherein the biomass microbial granules have an Ω-shaped planting trough, and in step S4, liquid microbial inoculum containing microbial balls is sprayed into the Ω-shaped planting trough through a spray nozzle.

[0015] The beneficial effects of this invention are as follows: This invention integrates sterilization, cooling, and inoculation modules into one unit through a split functional design, effectively solving the problems of cumbersome traditional decentralized inoculation procedures and easy contamination due to exposed connections. The collaborative work of each module not only simplifies the operation process but also reduces the probability of contamination by other microorganisms. This invention addresses the problem of high breakage rate in large fungal pellet inoculation. It employs a non-destructive inoculation mechanism that combines particle rolling and multi-directional spraying, enabling the fungal pellets to be precisely filled into the Ω-value groove of the fungal substrate, with the breakage rate controlled below 5%, thus meeting the inoculation requirements of soil-covering fungi such as bamboo fungus and gastrodia elata. This invention also uses a dual-system synergistic cooling design that combines high-pressure sterilization with sterile air evaporative cooling and jacketed water cooling to compress the total sterilization and cooling time, making it shorter than the cycle of traditional equipment and significantly improving production efficiency. At the same time, the design of a single-batch sealed spiral conveyor and sterile docking device not only meets the needs of large-scale production, but also ensures a sterile environment throughout the bacterial substrate inoculation process, avoiding external contamination. This invention can be directly adapted to Ω-groove substrates made from bamboo shavings and wood chips, breaking through the limitations of raw materials and mycelial ball types, and better matching the characteristics of raw materials in the edible fungi industry. It improves the distributed and large-scale inoculation of casing fungi, and further enhances the subsequent mycelial full-bag rate and fruiting quality. Attached Figure Description

[0016] Figure 1 This is a front view of the inoculation machine in an embodiment of the present invention; Figure 2 This is an isometric view of the inoculation machine in an embodiment of the present invention; Figure 3 This is a top view of the inoculation machine in an embodiment of the present invention; Figure 4 This invention is based on Figure 3 The isometric view of the rotating pressure tank after being sectioned by the AA section line.

[0017] In the diagram: 1-feed screen, 2-feed chute, 3-feed conveyor, 4-rotary pressure tank, 5-rotary cylinder, 6-aseptic docking device. Detailed Implementation

[0018] The present invention will be further explained below with reference to the accompanying drawings and specific embodiments.

[0019] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0021] Example 1: This embodiment discloses a split-type dynamic inoculation machine for biomass microbial-based granules, which is a device for processing and inoculating microbial-based granules with grooved structures, and is suitable for large-scale aseptic inoculation scenarios, as detailed below: Including those connected sequentially: The feeding section includes a screw conveyor 3 for conveying biomass microbial granules. The sealed screw conveyor 3 has a conveying capacity of 5 tons / hour and a pressure resistance of not less than 0.3 MPa. The sterilization and cooling unit is connected to the feeding section and receives the conveyed biomass microbial particles. It includes a rotary pressure tank 4 loaded with biomass microbial particles, and a sterile air injection system and an outer water-cooling jacket installed on the rotary pressure tank 4. The inoculation section, connected to the discharge end of the sterilization and cooling unit, has a rotating cylinder 5, the rotating cylinder 5 having several spray nozzles that spray liquid inoculum toward the inoculation section; and The discharge section is a sterile docking device 6 located at the end of the feeding section to receive the biomass microbial base particles. The sterile docking device 6 is sealed to the culture bag.

[0022] Furthermore, in this embodiment, preferred specifications are provided for each part of the inoculation machine.

[0023] 1. Feeding section structure The feeding section mainly includes a sealed screw conveyor 3, with a feeding screen 1 at the front end for controlling the feed rate. The feeding screen 1 is connected to the screw conveyor 3 via a feeding chute 2. It connects the pre-buffered bin and the post-sterilization and cooling unit to achieve sealed conveying of the particles.

[0024] This conveyor features an inclined arrangement with an adjustable angle between 15-45° to accommodate varying site height requirements. The conveyor is 3m long and has a double-layered conveying pipe structure. The inner layer houses stainless steel spiral blades and a main shaft; the outer layer is a sealed protective cover with a 5-8mm gap between the cover and the blades. This design ensures efficient conveying while preventing particles from becoming stuck between the cover and blades, thus avoiding equipment malfunctions.

[0025] The conveyor drive system uses an asynchronous motor of 4-7.5 kW. The motor power is matched according to the conveying capacity of 5 tons / hour. The motor is connected to the main shaft through a coupling. The main shaft speed can be adjusted by frequency conversion, ranging from 10-30 r / min, to ensure that the feeding speed matches the processing capacity of the sterilization and cooling unit, and to avoid the situation where the unit is overloaded due to feeding too fast or idled due to feeding too slow.

[0026] In terms of connection, the conveyor inlet is connected to the star-shaped discharge valve outlet of the pre-storage silo via a flexible sealing sleeve, which has good sealing performance and corrosion resistance; the conveyor outlet is connected to the inlet of the sterilization and cooling unit via a flange interface, with a silicone rubber sealing ring embedded in the flange joint surface and bolts tightened at the interface to ensure that the entire conveying process is sealed and leak-free, preventing external bacteria from entering.

[0027] For situations where site height is limited, a combination of belt elevator and horizontal receiving trough can be used as an alternative solution.

[0028] The horizontal receiving trough is made of stainless steel and is equipped with a low-speed screw feeder with a rotation speed of 8 r / min, which is used to smoothly push the particles in the trough to the elevator. The elevator uses a skirted conveyor belt to prevent the particles from slipping during the lifting process. The conveyor belt is 500 mm wide and has a linear speed of 0.3-0.5 m / s. The discharge port at the top of the elevator is connected to the sterilization and cooling unit through a chute. The inner wall is polished to ensure that no particles are left during the conveying process.

[0029] 2. Sterilization cooling unit structure The sterilization and cooling unit is based on a horizontal rotary pressure tank 4, which integrates the sterilization and cooling of particles. The rotary pressure tank 4 is made of 316L stainless steel, which has good corrosion resistance and high temperature resistance. The tank is supported on a concrete foundation at both ends by heavy-duty bearing seats, and the support legs are equipped with leveling bolts to adjust the tank's levelness.

[0030] One end of the tank is connected to a rotary drive device, which consists of a variable frequency motor, a worm gear reducer and a gear transmission pair. It can drive the tank to rotate at a uniform speed of 5r / min, ensuring that the particles inside the tank are evenly agitated and avoiding incomplete sterilization in certain areas.

[0031] The internal structure of the tank is specially designed, with lifting plates welded along the axial direction on the inner wall, forming a 15° angle with the tank's generatrix. When the tank rotates, the lifting plates can lift the particles to a height of 0.5m before dropping them, forming a uniform material curtain that ensures full contact between the particles and the sterilization medium, thus improving the sterilization effect.

[0032] The tank inlet is located at the top near the drive end. A short pipe is welded to the outer edge of the inlet, and a quick-opening sealing door is installed at the end of the short pipe. The sealing door is connected to the short pipe by a hinge. When closed, the high-temperature resistant asbestos gasket is pressed by an eccentric locking mechanism to ensure that the sealing pressure reaches 0.3MPa, which meets the pressure requirements of the sterilization process.

[0033] The heating and cooling systems of the sterilization and cooling unit work together to ensure thorough sterilization and efficient cooling. During the sterilization stage, a sterile air injection system is installed inside the tank. This system has a main air duct running along the tank's axis, penetrating both ends of the tank. The end extending out of the tank is connected to an external air source via a rotary joint, ensuring an uninterrupted air supply while the tank rotates. Several air holes are spaced apart on the main air duct, facing the lower inner side of the tank. Branch pipes are vertically welded to both sides of the main air duct, with small holes in their walls pointing towards the particle accumulation area. The external air source can provide 100 m³ / h of sterile hot air with a filtration accuracy of 0.1 μm, a temperature of 121℃, and a pressure of 0.15-0.2 MPa. This hot air is maintained inside the tank for 3 hours to ensure thorough particle sterilization.

[0034] One approach involves a two-step cooling process. First, a sterile air jet system is activated, introducing sterile air at room temperature at a rate of 100 m³ / h. This air evaporation cools the particles, reducing their temperature to 40-50°C within 30-40 minutes. Next, the outer water-cooling jacket is activated, creating a 20mm gap between the jacket and the tank wall. Annular seals at both ends of this gap prevent cooling water leakage. A cooling water inlet is located at the bottom of the jacket, connected to a circulating water pump at a flow rate of 20 m³ / h. This pump introduces 15°C cooling water into the jacket, further reducing the particle temperature to 20-25°C within 30 minutes, meeting the temperature requirements for subsequent inoculation. An insulation layer is applied to the outside of the water-cooling jacket to reduce heat loss during cooling and improve cooling efficiency.

[0035] 3. Inoculation segment structure The inoculation section employs an inclined rotating cylinder 5 to achieve precise inoculation of the particles, ensuring uniform adhesion of the bacterial solution to the particle surface. The rotating cylinder 5 is inclined at 15° and fixed to the ground by a support frame. The support height is adjustable according to actual needs, and shock-absorbing pads are installed at the bottom of the support frame to reduce the impact of vibration during equipment operation on surrounding components. The rotating cylinder 5 is made of 304 stainless steel with a smooth, burr-free inner wall to prevent scratching of the particles or residual bacterial solution.

[0036] The higher end of the rotating cylinder 5 is connected to the outlet of the sterilization and cooling unit through a flexible sealing sleeve. A transition chamber is set at the connection point to effectively prevent particles from directly impacting the inner wall of the cylinder and to play a buffering role. The lower end is equipped with a guide plate with an inclination angle of 45°, which is used to smoothly guide the inoculated particles to the aseptic docking device 6.

[0037] The drive of the rotating cylinder 5 works in conjunction with the spray system to ensure the inoculation effect.

[0038] The cylinder is driven by a variable frequency motor, which drives the cylinder to rotate via a chain drive, with the rotation speed stabilized at 8 r / min. Several fan-shaped spray nozzles are evenly spaced along the circumference of the inner wall of the cylinder. The nozzles are made of stainless steel, with a spray angle of 45° and a spray pressure of 0.1 MPa. The spray nozzles are evenly distributed in three groups along the axial direction of the cylinder to ensure that the particles can come into full contact with the bacterial solution during rotation inside the cylinder.

[0039] The bacterial solution supply system provides a stable source of bacterial solution for the injection nozzle. This system includes a storage tank, a metering pump, and delivery pipelines. The storage tank is made of 316 stainless steel and is equipped with an agitator that rotates at 30 rpm to prevent the sedimentation of large bacterial pellets (1 cm in diameter) in the solution and ensure uniform bacterial concentration.

[0040] The metering pump, installed at the outlet of the storage tank, precisely controls the inoculation amount of each particle, maintaining the bacterial concentration at 1.2 × 10⁻⁶. 7 The inoculation rate is maintained at 1 / mL to ensure stable inoculation results.

[0041] 4. Aseptic docking device with 6-fold structure The aseptic docking device 6 mainly realizes the quantitative bagging and sealing of particles after inoculation. It adopts a design that combines a fixed operating table with a quantitative bagging system to ensure accurate bagging and reliable sealing.

[0042] The work surface is flat and smooth, facilitating cleaning and disinfection. Several positioning grooves are cut into the work surface, with the groove dimensions matching the sterile culture bags. The grooves are 100mm deep and 200mm apart. Each groove can hold one open sterile culture bag. The culture bags are made of polyethylene, which meets the requirements of subsequent sterilization and culture processes.

[0043] An electronic scale is embedded at the bottom of each positioning groove to monitor the weight of the granules inside the bag in real time, ensuring that the weight of each bag of granules is precisely controlled at around 20kg. The opening of the cultivation bag is fixed to the edge of the groove by an elastic retainer ring. The elastic retainer ring keeps the bag opening open, making it easy to load the granules and preventing the bag opening from shifting during the filling process.

[0044] Pneumatic clamping assemblies are installed on both sides of the operating table. These assemblies consist of cylinders and sealing blocks. When the electronic scale detects that the weight of the granules inside the bag reaches 20kg, it immediately sends a signal to the control system. The control system stops the granule supply and simultaneously activates the pneumatic clamping assembly. The cylinder drives the sealing block downward to press and seal the sealing film at the mouth of the culture bag. The sealing edge width is 1cm to ensure a firm seal and prevent external bacteria from entering.

[0045] A conveyor belt is installed on one side of the operating table. The sealed culture bags are transferred to the conveyor belt manually or by a robotic arm, and then transported to the culture workshop by the conveyor belt, realizing the efficient transfer of particles after inoculation.

[0046] Furthermore, in this embodiment, a raw material pre-buffer module is also provided before the feeding section. Because the bacterial granules are in a dry state after preparation, with a moisture content controlled at 12-15%, and a particle diameter of 3-4 cm and a length of 4-6 cm, a pre-buffer structure is specially set up to achieve stable feeding to the feeding section.

[0047] The main structure is a closed storage silo, using a vertical cylindrical structure made of 304 stainless steel. The inner wall is polished to prevent particles from remaining inside the silo. The top of the silo has an openable feeding port with a sealing cap that remains closed when not feeding to isolate external impurities. The bottom of the silo is designed as a discharge port.

[0048] A star-shaped discharge valve is installed at the discharge port. The speed of the discharge valve can be adjusted by frequency conversion, with an adjustment range of 5-15 r / min, thereby achieving a quantitative feeding of 5 tons / hour.

[0049] A rotary paddle level switch is installed on the side wall of the storage silo. When the material level in the silo is lower than the low-level switch, the upstream feeding equipment automatically starts to replenish material; when the material level is higher than the high-level switch, the feeding equipment stops operating to prevent particle overflow. A breather valve is also installed on the top of the storage silo to maintain pressure balance inside the silo and prevent material supply interruption due to negative pressure caused by falling particles. The outside of the storage silo is covered with an insulation layer to reduce the impact of changes in ambient humidity on the moisture content of the particles and ensure stable particle condition.

[0050] Example 2: This embodiment provides a preferred structure for the feeding section and sterilization cooling unit of the inoculation machine based on Embodiment 1, taking into account different site conditions and process requirements.

[0051] One implementation method is to use a screw conveyor 3 with two feed inlets as the feed section.

[0052] This solution adds a preheating function to the conventional screw conveyor 3, shortening the subsequent sterilization time. The main body adopts a horizontal screw conveyor 3. A main feed inlet is set in the middle of the conveyor, which connects to the star-shaped discharge valve of the pre-storage silo to receive the bacterial substrate particles; an auxiliary feed inlet is set at the front end of the conveyor near the sterilization and cooling unit, and the auxiliary feed inlet is connected to the Roots blower through a pipeline.

[0053] The Roots blower has an air volume of 300-500 m³ / h and an air pressure of 0.05 MPa, which can stably deliver air. An electric heater with a power of 15 kW is installed at the blower outlet, which can heat the air to 100-120℃.

[0054] As the particles are conveyed forward in the screw conveyor 3, hot air is blown into the conveyor pipe in the opposite direction through the auxiliary feed port. The hot air comes into full contact with the particles, preheating and drying them. The preheating time is 15 minutes, raising the particle temperature to 80-90℃. At this temperature, the surface moisture of the particles evaporates, and some microorganisms are initially killed, reducing the burden on the subsequent sterilization process.

[0055] To prevent external bacteria from entering with the air, exhaust vents are provided in the section of the conveying pipeline corresponding to the auxiliary feed inlet. Air filters with a filtration accuracy of 0.1μm are installed in the exhaust vents to ensure that the discharged air is clean and sterile, while maintaining pressure balance within the pipeline to avoid excessive pressure affecting particle conveying.

[0056] One implementation method is to use a mobile trough and a belt conveyor.

[0057] The solution involves a movable material trough on the ground, with casters at the bottom for easy repositioning according to production needs. Particles can be replenished manually or with a small loader. The trough outlet connects to a belt conveyor with anti-slip ridges to prevent particles from slipping during transport; sealing baffles are installed on both sides of the conveyor to prevent particles from spilling from the sides.

[0058] The belt conveyor operates at a speed of 0.3 m / s. The end of the conveyor connects to the inlet of the sterilization and cooling unit via a chute. The inner wall is polished to ensure smooth, residue-free particle transport. This solution eliminates the need for fixed storage silos, is easy to install and disassemble, and is suitable for small-batch, multi-batch temporary production tasks.

[0059] One implementation method is to use a vertical rotary pressure tank 4 as a sterilization and cooling unit. This solution changes the horizontal rotary pressure tank 4 to a vertical structure, enabling continuous feeding and discharging of particles, which is suitable for large-scale production scenarios.

[0060] The vertical rotary pressure tank 4 is made of 316L stainless steel. The tank is divided into upper and lower sections by stainless steel partitions. The upper section is the sterilization zone and the lower section is the cooling zone.

[0061] The upper section is covered by a steam heating jacket, and saturated steam at 0.3 MPa is introduced into the jacket to keep the internal temperature of the upper section stable at 121℃, which meets the sterilization temperature requirements; the lower section is covered by a water cooling jacket, and cooling water at 15℃ is introduced into the jacket to achieve the cooling function.

[0062] A rotating shaft with a diameter of 60mm is set at the center of the tank. Helical blades are installed on the shaft with a pitch of 300mm. The rotating shaft rotates at a speed of 5r / min and is driven by a variable frequency motor.

[0063] The particles enter through the feed inlet at the top of the tank and descend slowly under the propulsion of the spiral blades, passing sequentially through the sterilization zone and the cooling zone. The particles remain in the sterilization zone for 3 hours to ensure thorough sterilization, and then remain in the cooling zone for 1.5 hours to cool down to 20-25°C. This system enables continuous feeding and discharging, eliminating the need for batch intervals and improving production efficiency.

[0064] One implementation method is to use an internal and external dual cooling system as the sterilization cooling unit.

[0065] Based on the horizontal rotating pressure tank 4 in Example 1, this scheme adds an internal cooling coil to form a coordinated internal and external cooling system, shortening the cooling time. The cooling coil is arranged in a spiral shape, closely attached to the inner wall of the tank. The coil diameter is 25mm, and the material is stainless steel. The coil inlet and outlet pass through the end caps at both ends of the tank and are connected by a sealed structure to ensure that the tank's sealing performance is not affected.

[0066] During the cooling process, the external water-cooling jacket normally circulates 15°C cooling water, while the internal cooling coils are activated, introducing -5°C ethylene glycol aqueous solution into the coils. The ethylene glycol aqueous solution improves heat transfer efficiency and accelerates heat conduction. The sterile air injection system blows ambient temperature sterile air outward from the center of the tank, forming a dual cooling mode of wall conduction and central convection. The cooling time can be shortened to 1 hour, improving cooling efficiency compared to the basic solution, while reducing particle temperature uniformity error and ensuring cooling quality.

[0067] Example 3: This embodiment provides an optimal design for the inoculation section and aseptic docking device 6 to meet different production scales and precision requirements, aiming at ensuring uniform inoculation and automating bagging. It can be combined with the feeding section and sterilization and cooling unit scheme in Embodiment 2.

[0068] One implementation method involves using a non-powered tilting cylinder, eliminating the external drive device for the rotating cylinder 5, and relying solely on the tilt angle to achieve particle rolling, thus reducing energy consumption. The rotating cylinder 5 is mounted on a bracket with a fixed tilt angle of 15°, and the bracket height is adjusted according to the actual site conditions. Helical guide vanes are welded to the inner wall of the cylinder, with a vane height of 50mm and a pitch of 500mm. These helical guide vanes guide the particles to roll along a fixed trajectory.

[0069] After the particles enter from the higher end of the cylinder, they slowly roll down along the spiral guide vanes under the action of gravity. The speed of sliding can be controlled by adjusting the cylinder tilt angle or the guide vane pitch, and is usually maintained at 0.1 m / s to ensure that the particles have enough time to contact the bacterial solution.

[0070] Three sets of spray nozzles, four in each set, are arranged axially along the inner side of the upper half of the cylinder. The nozzles are solid cone-shaped atomizing nozzles with a spray pressure of 0.1 MPa. The bacterial solution is atomized by the nozzles and evenly sprayed onto the surface of the particles. As the particles roll, they pass through the spray area, and their surface is evenly covered with the bacterial solution. The inoculation time is 3-5 minutes, and the energy consumption is reduced by 60% compared to the active rotation method, while ensuring the inoculation coverage rate.

[0071] One implementation method involves using a vertical rotary spray tower for inoculation. This method combines a material curtain with cross-spraying to achieve efficient inoculation, making it suitable for high-density inoculation scenarios. The top of the spray tower is closed, while the bottom has a conical discharge port for easy and concentrated discharge of inoculated particles. A rotary distributor with an umbrella-shaped structure is installed at the center of the tower, driven by a motor at a speed of 20-30 r / min.

[0072] The particles enter through the feed inlet at the top of the tower and fall onto the rotating distributor. Under centrifugal force, they are scattered around the tower wall, forming a uniform curtain of material that covers the entire cross-section of the tower, ensuring that every particle comes into contact with the bacterial solution. Four to six layers of spray nozzles are arranged along the height of the tower's inner wall, with six nozzles per layer. The nozzle spray pressure is 0.15 MPa. The bacterial solution is delivered to each layer of nozzles via a high-pressure pump with a flow rate of 50 L / h, ensuring an ample supply. The spray directions of the nozzles in each layer are staggered, forming a cross-spray network. During their free fall, the particles pass through the bacterial solution droplets multiple times, improving inoculation efficiency compared to the basic method.

[0073] As one implementation method, a conveyor belt assembly line is preferred for the aseptic docking device 6.

[0074] This solution achieves full automation of bagging, sealing, and transfer without manual intervention, making it suitable for large-scale industrial production. The system consists of a conveyor belt, an automatic bag feeding mechanism, a quantitative feeder, and an automatic sealing mechanism. The conveyor belt is 600mm wide and operates at a speed of 0.1m / s. Multiple idlers are installed beneath the conveyor belt to ensure smooth operation.

[0075] An automatic bag feeding mechanism is installed at the beginning of the conveyor belt. It uses suction cups to grab stacked aseptic culture bags, automatically opening the bag openings and fitting them into positioning frames on the conveyor belt. These frames fix the culture bags in place, preventing displacement during transport. A quantitative feeder is installed at the filling station above the conveyor belt. Equipped with a weighing sensor, the feeder dispenses granules into the bag as it moves to the filling station, monitoring the weight in real time. Feeding stops immediately when the weight reaches 20kg. If a weight deviation occurs, it automatically replenishes or unloads the bag to ensure accurate weight for each bag.

[0076] The automatic sealing mechanism, located at the end of the conveyor belt, uses an ultrasonic sealing machine to quickly and securely seal the bag opening. After sealing, the conveyor belt transfers the culture bags to the subsequent conveyor belt in the culture workshop, achieving fully automated flow. This system is more efficient than semi-automatic solutions and avoids the risk of contamination from manual operation, further ensuring sterility.

[0077] This embodiment also discloses an inoculation method, as follows: Raw material preparation: The prepared and dried bacterial substrate granules with Ω-shaped planting grooves are fed into the pre-storage silo by a loader. The sealing cover of the silo feeding port is closed, the star-shaped unloading valve is started, and the speed is adjusted to 10 r / min. The material is fed to the sealed screw conveyor 3 of the feeding section at a speed of 5 tons / hour.

[0078] Feeding and Conveying: Start the sealed screw conveyor 3, adjust the motor speed to 20 r / min, and simultaneously open the flange seal between the conveyor outlet and the sterilization and cooling unit to ensure a leak-free interface. Driven by the screw blades, the particles move along the inclined conveyor towards the sterilization and cooling unit. During the conveying process, the conveyor's sealed cover isolates them from external impurities and bacteria.

[0079] Sterilization: The granules enter the horizontal rotary pressure tank 4 through the feed inlet. The quick-opening sealing door is closed, and the eccentric locking mechanism is activated to tighten the sealing gasket, ensuring a tight seal inside the tank. An external air source is activated to introduce sterile hot air at 121℃ and 0.15MPa into the tank. Simultaneously, the rotary drive is activated, causing the tank to rotate at a speed of 5 r / min. Temperature and pressure sensors inside the tank monitor parameters in real time, ensuring that temperature fluctuations are ≤2℃ and pressure fluctuations are ≤0.01MPa. This state is maintained for 3 hours to ensure thorough granule sterilization.

[0080] Cooling treatment: After sterilization, the sterile hot air supply is turned off, and the air source is switched to room temperature sterile air. The air volume is maintained at 100 m³ / h to evaporate and cool the particles. After 35 minutes, the particle temperature is monitored to drop to 45°C. Then, the circulating water pump is started to introduce 15°C cooling water into the water-cooling jacket and continue cooling for 30 minutes until the particle temperature drops to 22°C, which meets the inoculation temperature requirements.

[0081] Inoculation process: Open the outlet valve of the sterilization and cooling unit, and the cooled granules enter the inclined rotating cylinder 5. Start the cylinder drive motor and adjust the speed to 8 r / min. Simultaneously start the agitator and metering pump in the storage tank. The metering pump delivers granules at a concentration of 1.2 × 10⁻⁶. 7 The bacterial solution of 0.5 ml / particle is sprayed into the Ω-shaped colonization trough of the particles through the spray nozzle. The particles are inoculated in all directions as they rotate in the cylinder. After inoculation, the particles are guided to the aseptic docking device 6 through the guide plate.

[0082] Bagging, sealing, and transport: Place the aseptic culture bag into the positioning groove of the aseptic docking device 6, secure the bag opening with an elastic retaining ring, and zero the electronic scale. The inoculated particles fall into the culture bag. When the electronic scale displays a weight of 20 kg, the metering pump stops feeding, the pneumatic clamping assembly activates, and the cylinder drives the sealing block to seal the bag opening. After sealing, the culture bag is manually transferred to the conveyor belt and transported to the culture workshop, completing the entire dynamic inoculation process.

[0083] This invention is not limited to the optional embodiments described above, and anyone can derive other various forms of products based on the inspiration of this invention. The specific embodiments described above should not be construed as limiting the scope of protection of this invention; the scope of protection of this invention should be determined by the claims, and the specification can be used to interpret the claims.

Claims

1. A split-type dynamic inoculation machine for biomass microbial granules, used for sterilizing, cooling, and inoculating biomass microbial granules, characterized in that: It comprises the following sequentially connected parts: a feeding section comprising a sealed screw conveyor for conveying biomass substrate particles, the conveying capacity of the sealed screw conveyor being 5 tons / hour, and the pressure tolerance value being not less than 0.3 MPa; a sterilization and cooling unit connected to the feeding section and receiving the conveyed biomass substrate particles, comprising a rotating pressure tank for loading the biomass substrate particles, and a sterile air injection system and an outer water-cooled jacket provided on the rotating pressure tank; an inoculation section connected to the discharge end of the sterilization and cooling unit and having a rotating cylinder with a plurality of injection ports for spraying liquid inoculum towards the feeding section; and a discharge section being a sterile docking device provided at the end of the feeding section for receiving the biomass substrate particles, and being sealingly connected to a culture bag. The rotating pressure tank has a volume of 6 m³, a rotating speed of 5 r / min, and is internally provided with temperature and pressure sensors.

2. The split-type dynamic inoculator for biomass fungus-based granules according to claim 1, characterized in that: The sterile air injection system has an air volume of 100 m³ / h and an air filtration accuracy of 0.1 μm; the water temperature of the outer water-cooled jacket is controlled at 15 °C, and the water flow rate is 20 m³ / h.

3. The split-type dynamic inoculator for biomass fungus-based granules according to claim 1, characterized in that: The rotating cylinder is in an inclined rotating mode, has a rotating inclination of 15°, and a rotating speed of 8 r / min, and is uniformly provided with at least eight fan-shaped injection ports, the injection pressure of the injection ports being 0.1 MPa, and the injection angle being 45°.

4. The split-type dynamic inoculator for biomass fungus-based granules according to claim 1, characterized in that: The tank door of the rotating pressure tank is in a sealed locking structure, and the pressure in the tank is stably maintained at 0.1 MPa after locking.

5. The modular dynamic inoculator for biomass pellets according to claim 1, wherein: The injection ports have a hole diameter of 2-3 mm, the arc length between adjacent injection ports is equal, and the injection directions are all directed obliquely downward towards the central axis of the rotating cylinder.

6. The modular dynamic inoculator for biomass pellets according to claim 1, wherein: The sterile docking device comprises a ring-shaped sealing ring and a pneumatic pressing assembly.

7. The modular dynamic inoculator of biomass granules according to claim 1, characterized in that it comprises: The biomass substrate particle split-type dynamic inoculation machine comprises the following steps:

8. A dynamic inoculation method, characterized by: S1. First, the biomass substrate particles are fed into the rotating pressure tank through the sealed screw conveyor, and the tank door is closed and sealed; S2. Then, saturated steam is introduced into the horizontal rotating pressure tank to raise the temperature in the tank to 121 °C and the pressure to 0.1 MPa, and the state is maintained for 3 hours, while the tank body is controlled to rotate at a speed of 5 r / min; S3. After sterilization is completed, the sterile air injection system and the outer water-cooled jacket are started, sterile air with a filtration accuracy of 0.1 μm is introduced into the tank, and the particles are cooled through the water-cooled jacket, and the temperature of the particles is reduced to 20-25 °C within 1.5 hours; S4. The cooled particles are fed into the inclined rotating cylinder, the cylinder is controlled to rotate at a speed of 8 r / min, and liquid inoculum containing bacterial balls is sprayed onto the particles through the injection ports, and the inoculation amount of each particle is 0.5 ml; S5. The inoculated particles are loaded into sterile culture bags through the sterile docking device, 20 kg per bag, and the inoculation is completed after sealing. In the step S2, the temperature fluctuation range of the horizontal rotating pressure tank is less than 2 °C, and the pressure fluctuation range is less than 0.01 MPa; 9. A dynamic inoculation method according to claim 8, wherein: The liquid culture in step S4 contains large bacteria balls with a diameter of 1 cm, and the concentration of the bacteria balls is 1.2 x 10 7 / mL. In the step S3, the sterile air injection system and the outer water-cooled jacket work cooperatively, sterile air cooling is performed in the first hour, and water-cooled jacket cooling is performed in the last 30 minutes. ​ 10. The dynamic inoculation method of claim 8, wherein: The biomass fungus-based granule has an Ω-shaped colonization groove, and the liquid fungus containing fungus balls is sprayed into the Ω-shaped colonization groove through the spraying port in step S4. The biomass fungus-based granule has an Ω-shaped colonization groove, and the liquid fungus containing fungus balls is sprayed into the Ω-shaped colonization groove through the spraying port in step S4.

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