Systematic green processing method of smoked preserved meat reproducing traditional firewood flavor

Abstract

The invention discloses a systematic green processing method of smoked preserved meat capable of reproducing a traditional firewood flavor. The systematic green processing method comprises the following steps: performing low-temperature fermentation pretreatment on raw material meat by using a specific compound leavening agent added with Chinese prickly ash and Baijiu; a multi-layer composite smoking material composed of a core flavor layer, a middle reaction layer, a slow-release regulation and control layer and an outer functional layer is used for generating smoke in an open-fire-free electric heating cracking device; programmed smoking is carried out through three stages of adsorption, dynamic reaction and fragrance fixation, wherein intermittent smoking is adopted in the dynamic reaction stage, and periodic oxygen concentration regulation and control are combined; sequentially carrying out primary low-temperature airing, secondary stage smoking, secondary low-temperature airing and low-temperature controlled atmosphere storage on the smoked meat to complete circulating ripening and dry storage. Through systematic synergy of the smoking material structure, the flavor raw materials and the circulating smoking process, the core flavor characteristics of traditional firewood smoked preserved meat can be stably reproduced, residues and salt content of harmful substances such as benzo [a] pyrene and nitrite are remarkably reduced, and green and standardized industrial production of traditional flavor is achieved.

Description

Technical Field

[0001] This invention belongs to the field of meat product processing technology, specifically relating to a systematic green processing method for smoked bacon that can systematically reproduce the core flavor characteristics of traditional wood-fired smoked bacon under clean industrial production conditions, and significantly reduce the residues of harmful substances such as nitrite and polycyclic aromatic hydrocarbons. Background Technology

[0002] Cured pork, especially wood-fired cured pork, is a traditional and distinctive meat product with a long history in my country, and its unique flavor is loved by consumers. The traditional process of making wood-fired cured pork typically includes steps such as selecting raw materials, marinating, air-drying, and smoking. Taking the methods used in Hunan and Sichuan as examples, fresh meat is usually marinated for several days with salt, Sichuan peppercorns, and white wine, and then smoked for a long time using smoke generated from pine branches, fruitwood chips, and other materials. The complex smoky flavor and dry texture developed in this process are the soul of traditional cured pork.

[0003] However, this traditional process, which relies on experience, has several insurmountable flaws and has become a bottleneck for industrial modernization and upgrading: First, safety issues are prominent. Open flame or incomplete combustion during the smoking process can easily produce highly carcinogenic polycyclic aromatic hydrocarbons such as benzo[a]pyrene. At the same time, to ensure preservation and an appealing color, traditional or some modern processes often require the use of high levels of salt and nitrite additives, posing a risk of high salt intake and excessive nitrite levels.

[0004] Secondly, flavor formation is uncontrollable, resulting in unstable products. Traditional smoking relies on specific firewood and natural climate, and the generation and adsorption of flavor substances are highly accidental, leading to large batch-to-batch differences and making it difficult to achieve standardized production.

[0005] Third, it is environmentally unfriendly and inefficient. Traditional smoking methods pose fire hazards, generate large amounts of smoke pollution, and have a long production cycle, failing to meet the high-efficiency and cleanliness requirements of the modern food industry.

[0006] To address the above problems, existing technologies have made some improvements, mainly including: Smoking-free processes: such as baking or soaking in smoking liquid instead of smoking. While baking avoids polycyclic aromatic hydrocarbons, the product completely loses the traditional smoky flavor; the flavor imparted by smoking liquid is singular, dull, lacking in complexity and richness, and often still relies on chemical colorants.

[0007] Improved smoking equipment and processes: Using low-temperature curing combined with a temperature-controlled smoking chamber can improve hygiene and safety to some extent. Some studies have also used ordinary fruitwood chips for electric smoking. However, these improvements mostly focus on localized optimization of process parameters and fail to systematically address the fundamental issues of flavor chemistry formation. Ordinary electric smoking processes use a single type of smoking material (only wood), and the process is mostly constant temperature and humidity, lacking effective stimulation and simulation of flavor generation pathways such as the Maillard reaction. The resulting products have a bland flavor, poor complexity, and still cannot completely solve the problem of harmful substance formation.

[0008] Therefore, there is an urgent need in this field for an innovative, systematic, and green processing method for cured meat. Summary of the Invention

[0009] In view of the shortcomings of traditional and existing cured meat processing techniques described in the background art in terms of safety, flavor authenticity, and standardized production, the purpose of this invention is to provide a systematic green processing method for smoked cured meat that reproduces the traditional wood-fired flavor. This method, under the strict constraints of completely eliminating open-flame smoking, not using chemical nitrites, and controlling low-salt addition, actively guides and completes a series of complex flavor-forming reactions similar to those that occur in traditional processes through industrially precise controllable processes. This results in the stable and efficient production of cured meat products with highly traditional wood-fired smoking flavor characteristics and extremely low harmful residues.

[0010] The objective of this invention is achieved through the following technical solution: This invention provides a systematic and green processing method for reproducing the traditional flavor of smoked bacon, comprising the following steps: S1. Raw Material Pretreatment: The trimmed raw meat is mixed with a compound fermentation agent containing Staphylococcus xylose, Pediococcus pentosaceus, and Lactobacillus plantarum, salt, natural compound colorant, Sichuan pepper powder, and baijiu (Chinese white liquor), and fermented at 15-20℃ for 36-72 hours. This step utilizes a specific ratio of compound fermentation agent (Staphylococcus xylose, Pediococcus pentosaceus, and Lactobacillus plantarum) to utilize microbial metabolism to produce acid, naturally lowering the pH value of the meat embryo and inhibiting the growth of spoilage bacteria, thus achieving biological preservation. During fermentation, proteins and fats are simultaneously and gently hydrolyzed, generating free amino acids, small peptides, and other rich flavor precursors, laying the foundation for the Maillard reaction and other processes in the subsequent smoking stage. Furthermore, chemical sodium nitrite is completely eliminated; a safe and stable natural coloring is achieved through a scientific blend of red yeast rice red and sorghum red. The amount of salt added is strictly controlled at 2.2%-2.6%, far lower than traditional high-salt processes, meeting the demands of modern healthy eating.

[0011] Sichuan pepper powder not only provides the signature numbing and fragrant flavor of traditional cured meat, but its volatile essential oil components also have broad-spectrum antibacterial effects, which synergize with the biological preservative effect of the fermentation agent.

[0012] The addition of baijiu (preferably with an alcohol content of 52% vol or higher) serves three purposes: firstly, its high permeability promotes the diffusion of pickling components inward and aids in dehydration; secondly, ethanol acts as a solvent to extract and blend flavor compounds, while also participating in esterification reactions during subsequent smoking, enriching the flavor profile. The combination of these three elements further strengthens the preservation system under low-salt conditions and establishes a richer, more authentic traditional flavor base.

[0013] S2. Stage Smoking: The meat processed in step S1 is placed in a smoking room and smoked in stages using composite smoking materials. The specific steps are as follows: S21. Adsorption stage: Smoking is carried out continuously for 1-3 hours in a smokehouse with a temperature of 40-50℃ and a relative humidity of 75-85%; a low temperature (40-50℃) and high humidity (75-85%) environment is created. Under these conditions, the surface of the meat is moist, which is conducive to the maximum physical adsorption and dissolution of various flavor components in the smoke, including phenols and reaction layer products, thus providing a sufficient "raw material reserve" for subsequent reactions.

[0014] S22. Dynamic Reaction Stage: The smoking chamber temperature is controlled at 55-68℃, and the relative humidity at 60-75% for intermittent smoking. Smoking is repeated for 30-50 minutes, followed by a 10-20 minute pause in smoke supply. This cycle is repeated, with a total smoking time of 3-8 hours. This step raises the internal temperature of the smoking chamber to 55-68℃, entering the optimal window for Maillard reaction and fat oxidation. The intermittent smoking (smoking / stopping cycle) and the periodic oxygen fluctuations (16%-18%) caused by the introduction of controlled humid airflow precisely simulate the natural fluctuations in temperature, smoke, and oxygen concentration caused by adding firewood and suppressing the fire in traditional wood-fired smoking. This dynamic, oxygen-rich environment greatly drives and promotes the complex interactive reactions (Maillard reaction, Streckel degradation, esterification, etc.) between various substances adsorbed on the surface of the meat in the previous stage, and between these substances and the internal components of the meat (amino acids, reducing sugars, fats), synergistically constructing a full and rich traditional flavor profile. The sprayed heat-resistant Kluyveromyces maculae works synergistically at this stage to synthesize additional aroma components such as esters.

[0015] S23. Aroma Fixation Stage: After the dynamic reaction stage is completed, the temperature of the smoking chamber is controlled at 70-80℃ and the relative humidity is controlled at less than 60%. Smoke supply is stopped, and the residual heat is circulated for 0.5-2 hours. The purpose of this stage is to promote the penetration and fixation of the volatile flavor molecules that have been formed into the meat under the high temperature (70-80℃) and low humidity (<60%) conditions when smoke supply is stopped. At the same time, the surface dehydration and final color solidification are completed, and the surface water activity is further reduced.

[0016] S3. Cyclic Aging and Dry Storage: The smoked meat undergoes the following steps in sequence: S31. Low-temperature sun drying: Place the meat in a clean environment with a temperature of 10-15℃, relative humidity of 60-70%, and wind speed of 0.5-1.0 m / s for 1-2 days to allow the surface to dry moderately and form a preliminary protective film.

[0017] S32. Secondary Smoking: The meat that has been sun-dried once is placed back in the smoking chamber, and the secondary smoking process of step S2 is repeated, but the total time is controlled to be 1 / 3 to 1 / 2 of the initial smoking time (S2). This step aims to enhance the depth and uniformity of the smoky flavor penetration through secondary smoking, and to promote the further integration of the inner fat and flavor substances by utilizing the secondary heat effect.

[0018] S33. Secondary low-temperature drying: Place the smoked meat in an environment with a temperature of 8-12℃, relative humidity of 55-65%, and wind speed of 0.2-0.5 m / s for 3-5 days to allow the water activity (Aw) to drop steadily to below 0.80 and the texture to become firm.

[0019] S34. Low-temperature storage: After the meat has been dried twice, it shall be stored for more than 7 days in a clean warehouse with a temperature of ≤4℃, relative humidity of 70-75% and carbon dioxide volume concentration of 1-3% to achieve final flavor integration and stabilization.

[0020] The composite smoked material is a physical structure composite comprising at least a core flavor layer, an intermediate reaction layer and an outer functional layer, and a slow-release regulating layer composed of edible hydrophilic colloids is provided between the intermediate reaction layer and the outer functional layer.

[0021] Furthermore, the composite fumigation material, from the inside out, consists of: Core flavor layer: accounting for 50-65 parts by weight, the raw material is apple wood, jujube wood or walnut wood chips; the core flavor layer is mainly used to provide phenolic substances (such as guaiacol and 4-methylguaiacol) produced by the electrothermal decomposition of lignin at 300-360℃, to build the "skeleton" of traditional smoked flavor.

[0022] Intermediate reaction layer: comprising 25-40 parts by weight, the raw material is a homogeneous mixture of dried tangerine peel powder, hawthorn powder, jujube powder, and yeast extract, wherein the mass ratio of dried tangerine peel powder, hawthorn powder, and yeast extract is (4-6):(2-4):1. Unlike traditional single-wood smoked materials, the intermediate reaction layer is rich in reducing sugars from dried tangerine peel powder and hawthorn powder, as well as free amino acids from yeast extract. During smoking and heating, this layer can undergo Maillard reactions in situ, directly generating key flavor compounds such as furans (e.g., furfural) and pyrazines. These substances are important contributors to the complexity of traditional cured meat flavor. This invention, through the "active synthesis" and release of the smoked material, directly compensates for the insufficient surface reaction intensity of the meat in clean, short-time smoking processes.

[0023] Slow-release regulating layer: Coated or pressed onto the outside of the intermediate reaction layer, accounting for 3-8% of the total weight of the composite smoke material, it is composed of one or a mixture of guar gum and kerogen gum; the slow-release regulating layer is composed of hydrophilic colloids with humidity-responsive properties. It swells rapidly in high humidity environments, promoting the release of substances; in low humidity environments, the swelling rate decreases, and the release slows down. This characteristic can intelligently simulate the natural release dynamics of traditional firewood combustion smoke from strong to weak, making the flavor formation process more layered and precisely matching the temperature and humidity changes in stages S21 and S22.

[0024] Outer functional layer: comprising 10-20 parts by weight, the raw materials are a mixture of celery powder, rosemary extract powder, tea polyphenols, and food-grade calcium chloride. The outer functional layer integrates safety and quality control functions. Lactic acid-pretreated celery powder provides a more stable plant-derived nitrogen source; rosemary extract and tea polyphenols, as potent natural antioxidants, significantly inhibit the formation of harmful polycyclic aromatic hydrocarbons such as benzo[a]pyrene during the thermal decomposition of fumigant materials from the source; food-grade calcium chloride helps improve product texture.

[0025] Furthermore, the swelling rate of the controlled-release layer at a relative humidity above 70% is at least 80% higher than that at a relative humidity below 50%; in the outer functional layer, celery powder accounts for 50%-65% of the total weight of the layer, the weight ratio of rosemary extract powder to tea polyphenols is (1.5:1) to (2.5:1), and food-grade calcium chloride accounts for 1%-3% of the total weight of the layer.

[0026] Further, in step S1, the natural compound colorant is a compound of red yeast rice red and sorghum red in a mass ratio of (2.5:1) to (3.5:1), and its total addition amount is 0.02%-0.04% of the weight of the raw meat; the amount of salt added is 2.2%-2.6% of the weight of the raw meat; the amount of Sichuan pepper powder added is 0.2%-0.5% of the weight of the raw meat; the liquor is liquor with an alcohol content ≥52%vol, and its addition amount is 0.8%-2.0% of the weight of the raw meat, and no sodium nitrite or sodium nitrate is added.

[0027] Furthermore, in step S2, the composite fumigant generates smoke in a flameless electrothermal pyrolysis device, with the pyrolysis temperature controlled at 300-360℃.

[0028] Furthermore, in the dynamic reaction stage of step S2, during the interval when the smoke supply is stopped, a stream of humid air with a temperature of 50-60°C that has been sterile filtered is introduced into the fumigation chamber at a flow rate of 0.1-0.3 m / s for a duration of 5-15 minutes, so that the oxygen concentration in the fumigation chamber fluctuates periodically within the range of 16%-18% (v / v) to maintain the stability of the reaction environment and promote the surface reaction.

[0029] Further, in step S1, the ratio of viable bacteria of Staphylococcus xylose: Pediococcus pentosus: Lactobacillus plantarum in the compound fermentation agent is (1.8-2.2):(1.1-1.3):1; and before the start of the dynamic reaction stage in step S2, a suspension containing Kluyveromyces martensii is sprayed onto the surface of the meat product at a spraying amount of 5×104-8×104 CFU / cm².

[0030] Furthermore, in the outer functional layer of the composite fumigation material, celery powder is pre-wetted with a lactic acid solution of 1-3% concentration, dried at 40-50℃ until the moisture content is ≤8%, and then mixed with other components, wherein the amount of lactic acid solution is 10-20% of the weight of celery powder.

[0031] Furthermore, the ambient air after the mild drying process described in step S3 undergoes slow horizontal convection at a speed of 0.05-0.15 m / s, and the volume concentration of carbon dioxide in the ambient air is maintained at 0.5%-2.0%.

[0032] The present invention also provides a method for preparing the above-mentioned composite fumigant, comprising the following steps: (a) Fill the bottom of the mold with the core flavor layer ingredients evenly and compact them initially.

[0033] (b) The uniformly mixed intermediate reaction layer material is spread on the outside of the preliminary compacted layer in step (a), and then pressurized again to form a dense preform; (c) The aqueous solution of edible hydrophilic colloid is uniformly sprayed or brushed onto the outer surface of the embryo obtained in step (b) to form a wet control layer.

[0034] (d) The uniformly mixed and pretreated outer functional layer raw material is coated on the control layer, placed under a pressure of 8-12MPa for 20-40 seconds, pressed into shape, and then dried at 40-50℃ until the overall moisture content is ≤12% to obtain the composite fumigation material.

[0035] The beneficial effects of this invention are as follows: (1) By using open flame-free electric fumigation and built-in antioxidants in the fumigation material, the content of benzo[a]pyrene is reduced to an extremely low level from the source; by combining compound fermentation with plant coloring technology, chemical nitrites are completely eliminated, achieving safe coloring and corrosion prevention with high safety.

[0036] (2) Under clean and short-term industrial conditions, the traditional firewood flavor is accurately reproduced. By producing aroma in situ through the smoking materials and using a gradient process that simulates natural smoking fluctuations, the key flavor components of the product are highly similar to those of traditional products.

[0037] (3) Transforming experience-based operations into standardized production with full process control, resulting in high product consistency. The entire process is flameless and smoke is controllable, achieving a fundamental transformation from traditional high-energy-consuming and high-emission processes to green industrial manufacturing.

[0038] (4) By introducing Sichuan pepper powder and liquor, the complex aroma (numbing and liquor aroma) of traditional cured meat is further enriched without relying on chemical additives, and the antiseptic and antibacterial effect of the low-salt formula is enhanced, making the product flavor closer to the authentic tradition.

[0039] (5) Through the cyclical aging process of “smoking-drying-smoking again-drying again”, the essence of repeated “sun and dew” or “intermittent smoking” in traditional production is simulated, so that the smoked flavor penetrates more evenly from the surface to the inside, the meat is dry but not moist, and the flavor is more varied. Furthermore, the final low-temperature modified atmosphere preservation ensures the long-term stability and safety of the product. Attached Figure Description

[0040] Figure 1 This is a complete process flow diagram of the systematic green processing method for reproducing the traditional flavor of smoked cured meat described in this invention. Detailed Implementation

[0041] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The described embodiments are merely 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. Example 1

[0042] like Figure 1 As shown in the figure, this embodiment presents a systematic green processing method for reproducing the traditional flavor of smoked bacon, including the following steps: S1. Raw material pretreatment: S11. Select 10kg of skin-on pork belly (raw meat), trim and cut into strips; separately take 2.4% salt by weight of the raw meat, 0.03% natural compound colorant (red yeast rice: sorghum red = 3:1), 0.3% Sichuan pepper powder, 1.0% 52% vol baijiu (Chinese white liquor), and compound fermentation agent (Staphylococcus xylose: Pediococcus pentosaceus: Lactobacillus plantarum live bacteria ratio = 2:1.2:1, total live bacteria count 10 6 (CFU / g) for later use.

[0043] The trimmed raw meat is mixed with all the above ingredients, tumbled under vacuum (-0.08MPa) for 20 minutes, and then fermented at 18℃ and 80% relative humidity (RH) for 48 hours.

[0044] S12. Preparation of composite fumigation material: The composite fumigant consists of, from the inside out: a core flavor layer, an intermediate reaction layer, a slow-release regulating layer, and an outer functional layer. Among these, The core flavor layer is made from 620g of jujube wood chips.

[0045] The raw material for the intermediate reaction layer is a mixture of 180g dried tangerine peel powder, 90g hawthorn powder, 60g jujube powder, and 30g yeast extract (in a ratio of 6:3:1).

[0046] The raw material for the slow-release regulating layer is a 5% (5% by weight) aqueous solution of kerogen gum from the composite fumigant.

[0047] The raw materials for the outer functional layer are a mixture of 100g celery powder, 45g rosemary extract powder, 30g tea polyphenols and 5g food-grade calcium chloride. To prepare this mixture, 100g celery powder is first soaked in a 2% lactic acid solution at 15% of its weight and dried at 45℃ until the moisture content is ≤8%. Then, the pretreated celery powder is mixed evenly with 45g rosemary extract powder, 30g tea polyphenols and 5g food-grade calcium chloride.

[0048] The preparation steps of the composite fumigant are as follows: (a) Fill the bottom of the mold with the core flavor layer ingredients evenly and compact them initially.

[0049] (b) The uniformly mixed intermediate reaction layer material is spread on the outside of the initial compacted layer in step (a) and then pressed again to form a dense embryo.

[0050] (c) The aqueous solution of edible hydrophilic colloid is uniformly sprayed onto the outer surface of the embryo obtained in step (b) to form a wet control layer.

[0051] (d) The uniformly mixed and pretreated outer functional layer raw material is coated on the control layer, placed under a pressure of 10 MPa for 30 seconds, pressed into shape, and then dried at 45°C until the overall moisture content is 10.5% to obtain the composite fumigation material.

[0052] S2. Stage Smoking: The meat processed in step S1 is placed in a smoking chamber, and composite smoking material is used. The composite smoking material is placed in an electrothermal pyrolysis smoke generator (a conventional device), and the pyrolysis temperature is set to 330℃ for stage smoking. The specific steps are as follows: S21. Adsorption stage: In a fumigation chamber with a temperature of 45℃ and a relative humidity of 82%, continuous fumigation is carried out for 2 hours. S22. Dynamic Reaction Stage: The smokehouse temperature is controlled at 62℃ and the relative humidity at 70%. First, a Kluyveromyces macrocephala suspension is sprayed onto the surface of the meat (spraying amount: 6.5 × 10⁴ CFU / cm²). Then, intermittent smoking is carried out, with smoke supply stopped for 20 minutes after smoking for 40 minutes, and the cycle is repeated. During smoking, the oxygen concentration in the smokehouse is maintained within the range of 17% ± 1% (v / v) through the fresh air system. At the third smoke supply stop interval, a stream of humid air (flow velocity 0.2 m / s, lasting 10 minutes) that has been sterile filtered, is at a temperature of 55℃ and a relative humidity of 70%. The total duration of this stage is 6.5 hours.

[0053] S23. Fragrance Fixation Stage: After the dynamic reaction stage is completed, stop the smoke supply, raise the temperature of the fumigation chamber to 76℃, reduce the relative humidity to 55%, and use the waste heat circulation system to circulate the hot air for 1 hour (extract the hot air from the fumigation chamber and then send it back into the fumigation chamber to circulate the hot air).

[0054] S3. Cyclic maturation and dry storage: S31. Low-temperature drying: Hang the smoked meat in a clean drying room with a temperature of 12℃, relative humidity of 65%, and wind speed of 0.8 m / s for 1.5 days.

[0055] S32. Secondary smoking stage: The meat is placed back in the smoking chamber, and the process of step S2 is completely repeated, but the total time of the three stages of adsorption, dynamic reaction, and aroma fixation is controlled to 3 hours. The adsorption stage lasts 0.8 hours; the total time of this stage is 2 hours, and the residual heat circulation treatment lasts 0.2 hours.

[0056] S33. Secondary low-temperature drying: Place the smoked meat in an environment with a temperature of 10℃, relative humidity of 60%, and wind speed of 0.3 m / s for 4 days.

[0057] S34. Low-temperature preservation: Transfer the meat to a cold storage at a temperature of 2-4℃, relative humidity of 72%, and carbon dioxide volume concentration of 2.0% and store for 10 days to obtain the finished cured meat. Example 2

[0058] This embodiment is used to verify the effect of a milder combination of process parameters within the scope of the claims. The difference between this embodiment and Embodiment 1 is: In step S1, the fermentation temperature is 15℃ and the fermentation time is 72 hours.

[0059] In step S2, the pyrolysis temperature of the fumigation material is 300℃.

[0060] In step S21, the smoke is continuously emitted for 3 hours in a fumigation chamber with a temperature of 40°C and a relative humidity of 85%.

[0061] In step S22, the smoking chamber temperature is controlled at 55℃ and the relative humidity at 75%. First, a Kluyveromycin suspension is sprayed onto the surface of the meat (spraying amount is 5×10⁴ CFU / cm²). Then, intermittent smoking is carried out, with smoking stopped for 20 minutes after smoking for 30 minutes, and the cycle is repeated. The total duration of this stage is 3 hours.

[0062] In step S23, after the dynamic reaction stage is completed, the smoke supply is stopped, the temperature of the fumigation chamber is raised to 70°C, the relative humidity is reduced to 55%, and the waste heat is circulated using the hot air circulation system for 0.5 hours. Example 3

[0063] This embodiment is used to verify the effect of a relatively drastic combination of process parameters within the scope of the claims. The difference between this embodiment and Embodiment 1 is: In step S1, the fermentation temperature is 20℃ and the fermentation time is 36 hours.

[0064] In step S2, the pyrolysis temperature of the fumigation material is 360℃.

[0065] In step S21, the smoke is continuously emitted and smoked for 1 hour in a fumigation chamber with a temperature of 50°C and a relative humidity of 75%.

[0066] In step S22, the smoking chamber temperature is controlled at 68℃ and the relative humidity at 60%. First, a Kluyveromycin suspension is sprayed onto the surface of the meat (spraying amount is 8×10⁴ CFU / cm²). Then, intermittent smoking is carried out, with the smoke supply stopped for 10 minutes after smoking for 50 minutes, and the cycle is repeated. The total duration of this stage is 8 hours.

[0067] In step S23, after the dynamic reaction stage is completed, the smoke supply is stopped, the temperature of the fumigation chamber is raised to 80°C, the relative humidity is reduced to 50%, and the waste heat is circulated and treated for 2 hours using the hot air circulation system. Example 4

[0068] This embodiment is used to verify the feasibility of using different types of wood as the core flavor layer. The only difference between this embodiment and Embodiment 1 is that, in preparing the composite smoky material, the core flavor layer raw material is replaced by an equal mass of apple wood chips instead of jujube wood chips; all other steps and parameters are exactly the same as in Embodiment 1. Example 5

[0069] This embodiment is used to verify the effect of a specific ratio range in the intermediate reaction layer. The only difference between this embodiment and Embodiment 1 is that, except for adjusting the mass ratio of tangerine peel powder, hawthorn powder and yeast extract in the intermediate reaction layer of the composite fumigation material to 4:2:1 (lower limit of claims), all other steps and parameters are exactly the same as in Embodiment 1.

[0070] Comparative Example 1 (Comparison of Mixed Smoking Materials) This comparative example is used to verify the necessity of the "functionalized layered structure" of the composite smoked material. The only difference between this comparative example and Example 1 is that the smoked material preparation is changed to a simple physical mixing of all the raw materials used in Example 1 for the core flavor layer, intermediate reaction layer and outer functional layer (without distinguishing the layers), and then pressing them into shape in one step using the same mold and pressure.

[0071] Comparative Example 2 (Comparison of Constant Temperature Smoking Processes) This comparative example is used to verify the necessity of the "programmed gradient fumigation process". The only difference between this comparative example and Example 1 is that the entire fumigation process is changed to keep the fumigation chamber constant at 60°C and 70% relative humidity, continuously generate smoke for 6.5 hours, and then turn off the smoke generation and raise the temperature of the fumigation chamber to 75°C for hot air circulation for 1 hour (that is, it is not divided into S21-S23 stages, and there is no intermittent mode and oxygen concentration control).

[0072] Comparative Example 3 (Traditional Process) This comparison is based on traditional wood-fired smoking. The traditional process involves dry-curing the raw meat with 3.0% of its weight in salt and spices for 5 days (at an ambient temperature of 8°C), followed by ventilated hanging to air-dry for 36 hours, and finally smoking it over a smoldering fire using a mixture of cypress branches and fruitwood chips. The smoking chamber temperature naturally fluctuates between 35-60°C, and the smoking process continues for 4 days.

[0073] Comparative Example 4 (comparison of sustained-release control layer omitted) This comparative example is used to verify the specific technical contribution of the "slow-release regulating layer" in the composite fumigant. The only difference between this comparative example and Example 1 is that: when preparing the composite fumigant, the slow-release regulating layer is not set, that is, after the mixed intermediate reaction layer raw materials are compacted, the outer functional layer raw materials are directly coated and pressed.

[0074] Comparative Example 5 (Dynamic oxygen control comparison omitted) This comparative example is used to verify the specific technical contribution of "oxygen concentration control" in the dynamic reaction stage of step S22. The only difference between this comparative example and Example 1 is that in the dynamic reaction stage of S22, only the intermittent fumigation mode is executed, but the introduction of humid air flow is stopped, and the oxygen concentration in the fumigation chamber is not actively controlled (allowing it to fluctuate naturally).

[0075] Comparative Example 6 (comparison of post-ripening CO2 environment omitted) This comparative example is used to verify the specific auxiliary role of "maintaining a low CO2 concentration environment" in the S3 post-ripening stage. The only difference between this comparative example and Example 1 is that the carbon dioxide concentration in the environment is not controlled in the S4 mild drying post-ripening stage (approximately 0.04% of the atmospheric background value).

[0076] Verification Experiment Verification Experiment 1: 1. Experimental objective: To verify whether the composite smoking material and staged smoking are necessary conditions for achieving the objectives of this invention (high safety and high flavor authenticity), and whether there is a synergistic effect of "1+1>2".

[0077] 2. Experimental Design: Four sets of comparisons were set up, namely Example 1, Comparative Example 1, Comparative Example 2, and Comparative Example 3. Example 1 fully implemented the present invention. Comparative Example 1 used the same raw materials but with mixed structures of smoking materials to verify the necessity of "functionalized structure of smoking materials". Comparative Example 2 used the smoking materials of the present invention but adopted a constant temperature smoking process to verify the necessity of "gradient smoking procedure". Comparative Example 3 simulated the traditional process as a benchmark for flavor authenticity and a safety risk control. In the company's laboratory, the nitrite residue, benzo[a]pyrene content, total amount of key characteristic flavor compounds, flavor spectrum similarity, and sensory score data of the cured meats prepared in Example 1, Comparative Example 1, Comparative Example 2, and Comparative Example 3 were tested and recorded respectively (each sample was prepared and tested in parallel n=3 times, and the sensory evaluation review panel consisted of 10 trained tasters, and a scoring system was used for evaluation, with scores ranging from 0 to 10). The results are shown in Table 1.

[0078] Table 1: Comparison Table of the Necessity and Synergistic Effect of Composite Fumigating Materials and Stage Fumigation

[0079] 3. The data analysis based on the test results in Table 1 is as follows: (1) Safety: Example 1 (the present invention) achieved optimal levels in both nitrite and benzo[a]pyrene, significantly surpassing the safety of traditional processes (Comparative Example 3). Comparative Examples 1 and 2, inheriting the green processes of open flame fumigation and bio-fermentation of the present invention, also showed significantly better safety than traditional processes, but neither was as good as the complete scheme of Example 1. It is worth noting that the benzo[a]pyrene content of Comparative Example 2 (constant temperature fumigation) was higher than that of Comparative Example 1, suggesting that the static process may have locally aggravated the risk of harmful substance formation.

[0080] (2) Flavor Authenticity: The flavor indicators (total flavor components, spectral similarity, and sensory score) of Example 1 are closest to the traditional process benchmark. The flavor indicators of Comparative Example 1 (mixed smoking materials) are significantly reduced, with the total flavor components decreasing by about 27% compared to Example 1, proving that destroying the functionalized layered structure of the smoking materials will severely weaken its "in-situ aroma production" and "slow-release regulation" efficacy. The flavor indicators of Comparative Example 2 (constant temperature smoking) are the worst, indicating that even with the same smoking materials, the lack of a process environment with gradient temperature and dynamic oxygen control cannot effectively drive the formation of a complete and layered traditional flavor.

[0081] (3) Synergy: The overall effect of safety and flavor achieved by Example 1 is far superior to either the improvement of smoking material (Comparative Example 1) or the improvement of process (Comparative Example 2). This proves that the "structured smoking material" and "gradient dynamic process" of the present invention are a deeply coupled and mutually reinforcing technical whole, and the technical effect (superior safety and flavor) produced by the synergy of the two has outstanding inventiveness. Verification Experiment 2:

[0082] 1. Experimental Objective Based on the establishment of the core solution (the necessity and synergy of composite fumigation materials and staged fumigation), further verification of specific key technical features (slow-release regulation layer, dynamic oxygen control, and post-ripening CO2) is conducted. 2 The specific contribution of the environment to the quality of the final product.

[0083] 2. Experimental Design Using Example 1 as a complete comparison, three comparative examples with omitted features are set up: Comparative Example 4: No slow-release regulating layer was set when preparing the composite fumigant.

[0084] Comparative Example 5: During fumigation, no dynamic oxygen control was performed (intermittent fumigation but no humid air flow was introduced).

[0085] Comparative Example 6: During post-ripening, CO2 was not controlled. 2 Concentration. The benzo[a]pyrene content, total amount of key characteristic flavor compounds, flavor spectrum similarity, sensory score data, and final water activity of the cured meats prepared in Example 1, Comparative Example 4, Comparative Example 5, and Comparative Example 6 were tested and recorded in the company's laboratory. (Each sample was prepared and tested in parallel (n=3 times). The sensory evaluation review panel consisted of 10 trained tasters. Scoring was used during the evaluation, with a score range of 0-10.) The results are shown in Table 2.

[0086] Table 2: Key Technology Feature Verification Comparison Table

[0087] 3. The data analysis based on the test results in Table 2 is as follows: (1) The role of the sustained-release control layer: The flavor indicators (total amount, similarity, sensory score) of Comparative Example 4 (without sustained-release layer) showed a significant decrease, proving that the humidity response layer plays a key role in simulating the natural release rhythm of traditional flue gas "from strong to weak" and optimizing the release and reaction process of flavor substances at different stages, and is the core of forming a layered flavor.

[0088] (2) The role of dynamic oxygen regulation: The benzo[a]pyrene content in Comparative Example 5 (oxygen-free control) increased to 1.1 μg / kg, an increase of 83%, and its flavor index was the worst among all comparative examples. This strongly demonstrates that the periodic oxygen regulation (16%-18%) during the dynamic reaction stage not only creates the necessary conditions for the formation of beneficial flavor pathways such as the Maillard reaction, but also effectively inhibits the formation of harmful substances such as polycyclic aromatic hydrocarbons, thus possessing a dual core function.

[0089] (3) The role of CO2 environment in post-ripening: The core flavor and safety indicators of Comparative Example 6 (without CO2) were not significantly different from those of Example 1, but its final water activity (Aw) was significantly increased (0.81). This confirms that the low concentration of CO2 environment in the post-ripening stage mainly plays a role in inhibiting aerobic microorganisms and improving the storage stability of the product, which is an effective auxiliary feature to ensure long-term safety. Verification Experiment 3:

[0090] (1) Experimental Objective Verify whether the technical effects of the present invention can be stably achieved within the range of changes in the parameters and components of the present invention.

[0091] (2) Experimental Design Based on the best embodiment (Example 1), boundary and variant tests are performed: Parameter range verification: Example 2 (lower limit combination of each process parameter); Example 3 (upper limit combination of each process parameter).

[0092] Validation of core component variants: Example 4 (replacing jujube wood with apple wood in the core flavor layer); Example 5 (adjusting the ratio of the intermediate reaction layer to the lower limit of 4:2:1). The nitrite residue, benzo[a]pyrene content, total amount of key characteristic flavor compounds, flavor spectrum similarity, and sensory score data of the cured meats prepared in Examples 1, 2, 3, 4, and 5 were tested and recorded in the company's laboratory (each sample was prepared and tested in parallel n=3 times; the sensory evaluation review panel consisted of 10 trained tasters, and a scoring system was used, with scores ranging from 0 to 10). The results are shown in Table 3.

[0093] Table 3: Validation Table of Parameter and Component Variant Effects

[0094] 3. The data analysis based on the test results in Table 3 is as follows: (1) Feasibility of parameter range: Although the core indicators of Example 2 (lower limit combination of parameters) and Example 3 (upper limit combination of parameters) are slightly inferior to those of the best Example 1, the flavor similarity (R value) remains above 0.85, the sensory score is above 7.8, and the safety indicators are still far superior to those of traditional processes. This proves that implementing the present invention within the entire range of process parameters described in the claims can stably produce high-quality, safe, and flavor-close to traditional products, and the technical effect is stable and reliable.

[0095] (2) Inclusivity of component changes: The product quality of Example 4 (core flavor layer replaced with applewood) and Example 5 (lower limit of intermediate reaction layer ratio) remained excellent. Although some indicators fluctuated slightly due to changes in raw material characteristics or ratios, the overall effect was very close to that of the best example. This shows that the technical solution of the present invention has good versatility and robustness, and its technical effect does not depend on a single specific raw material or precise ratio.

[0096] Other aspects of this invention that are not detailed herein are all conventional techniques known to those skilled in the art.

[0097] It should be noted that the terms “comprising,” “including,” or any other variations are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0098] The scope of protection of this invention is not limited to the technical solutions disclosed in the specific embodiments. Any modifications, equivalent substitutions, improvements, etc., made to the above embodiments based on the technical essence of this invention shall fall within the scope of protection of this invention.

Claims

1. A systematic green processing method of bacon with traditional charcoal fire flavor reproduced, characterized in that, The method comprises the following steps: S1. Raw material pretreatment: mix the trimmed raw material meat with a compound starter culture comprising Staphylococcus xylosus, Pediococcus pentosaceus and Lactobacillus plantarum, salt, natural compound colorant, Sichuan pepper powder and baijiu, and ferment at 15-20°C for 36-72 hours; S2. Stage smoking: place the meat product treated in step S1 in a smoking room, use a compound smoking material, and perform stage smoking, the steps of which are as follows: S21. Adsorption stage: continuously smoke in a smoking room with a temperature of 40-50°C and a relative humidity of 75-85% for 1-3 hours; S22. Dynamic reaction stage: control the temperature of the smoking room at 55-68°C and the relative humidity at 60-75% to perform intermittent smoking, stop smoking for 10-20 minutes after smoking for 30-50 minutes, and repeat the cycle, and the total time of this stage is 3-8 hours; S23. Fragrance fixing stage: after the dynamic reaction stage is completed, control the temperature of the smoking room at 70-80°C and the relative humidity at less than 60%, stop smoking, and use the residual heat to circulate for 0.5-2 hours; S3. Circulating aging and dry storage: after smoking, the meat product is subjected to the following steps in sequence: S31. First low-temperature airing: place the meat product in a clean environment with a temperature of 10-15°C and a relative humidity of 60-70% for 1-2 days; S32. Second stage smoking: place the meat product subjected to the first airing in a smoking room again, and repeat the stage smoking process of step S2, and the total time is 1 / 3 to 1 / 2 of the total time of step S2; S33. Second low-temperature airing: place the meat product subjected to the second smoking in an environment with a temperature of 8-12°C and a relative humidity of 55-65% for 3-5 days; S34. Low-temperature storage: store the meat product subjected to the second airing in a clean warehouse with a temperature of ≤4°C, a relative humidity of 70-75%, and a carbon dioxide volume concentration of 1-3% for more than 7 days; The compound smoking material is a physical structure complex comprising at least a core flavor layer, an intermediate reaction layer, and an outer functional layer, and a slow-release control layer composed of edible hydrophilic colloid is arranged between the intermediate reaction layer and the outer functional layer.

2. The bacon processing method according to claim 1, wherein The compound smoking material comprises, from inside to outside: Core flavor layer: 50-65 parts by weight of applewood, jujube wood or walnut sawdust; Intermediate reaction layer: 25-40 parts by weight of a uniform mixture of orange peel powder, hawthorn powder, red date powder and yeast extract, wherein the mass ratio of orange peel powder, hawthorn powder and yeast extract is (4-6):(2-4):1; Slow-release control layer: coated or pressed on the outside of the intermediate reaction layer, accounting for 3-8% of the total weight of the compound smoking material, composed of one or a mixture of guar gum and gum ghatti; Outer functional layer: 10-20 parts by weight of a mixture of celery powder, rosemary extract powder, tea polyphenol and food-grade calcium chloride.

3. The green process for smoked meat system according to claim 2, characterized in that: The swelling rate of the slow-release regulating layer at relative humidity higher than 70% is at least 80% higher than that at relative humidity lower than 50%; in the outer functional layer, celery powder accounts for 50%-65% of the total weight of the layer, the weight ratio of rosemary extract powder to tea polyphenol is (1.5:1) to (2.5:1), and food-grade calcium chloride accounts for 1%-3% of the total weight of the layer.

4. The smoked meat systemized green processing method according to claim 1, characterized in that: In step S1, the natural compound colorant is a compound of red koji red and sorghum red at a mass ratio of (2.5:1) to (3.5:1), and the total amount of addition is 0.02%-0.04% of the weight of the raw meat; the amount of addition of the salt is 2.2%-2.6% of the weight of the raw meat, the amount of addition of the pepper powder is 0.2%-0.5% of the weight of the raw meat, the white wine is a white wine with an alcohol content of ≥52%vol, and the amount of addition is 0.8%-2.0% of the weight of the raw meat, and no sodium nitrite or sodium nitrate is added.

5. The smoked meat systemized green processing method according to claim 1, characterized in that: In step S2, the composite smoking material is smoked in a non-flame electric pyrolysis device, and the pyrolysis temperature is controlled at 300-360℃.

6. The smoked meat systemized green processing method according to claim 5, characterized in that, In the dynamic reaction stage of step S2, during the interval period when the smoke supply is stopped, sterile-filtered humid air with a temperature of 50-60℃ is introduced into the smoking house at a flow rate of 0.1-0.3 m / s, and the duration is 5-15 minutes, so that the oxygen concentration in the smoking house periodically fluctuates within the range of 16%-18% (v / v).

7. The smoked meat systemized green processing method according to claim 1, characterized in that: In step S1 the ratio of viable cell counts of S. xylosus : P. pentosaceus : L. plantarum in the complex starter culture is (1.8-2.2):(1.1-1.3):1; and before the start of the dynamic reaction phase of step S2, a suspension comprising K. marxianus is sprayed onto the surface of the meat in an amount of 5x10 4 -8x10 4 CFU / cm2.

8. The smoked meat systemized green processing method according to claim 2, characterized in that: In the outer functional layer of the composite smoking material, the celery powder is pretreated by soaking in a lactic acid solution with a concentration of 1-3%, and then dried at 40-50℃ until the water content is ≤8%, and then mixed with other components, wherein the amount of lactic acid solution is 10-20% of the weight of the celery powder.

9. The smoked meat systemized green processing method according to claim 1, characterized in that: In the drying environment of steps S31 and S33, the air is forced to flow at a speed of 0.2-1.0 m / s.

10. The smoked meat systemized green processing method according to claim 1, characterized in that, The preparation steps of the composite smoking material are as follows: (a) uniformly fill the core flavor layer raw materials into the bottom of the mold and preliminarily compact; (b) cover the uniformly mixed intermediate reaction layer raw materials on the outside of the preliminarily compacted layer of step (a), and press again to form a dense embryo; (c) uniformly spray or brush the aqueous solution of edible hydrophilic colloid on the outer surface of the embryo obtained in step (b) to form a wet regulating layer; (d) coat the uniformly mixed and pretreated outer functional layer raw materials outside the regulating layer, and press under a pressure of 8-12 MPa for 20-40 seconds, and then dry at 40-50℃ until the total water content is ≤12%, to obtain the composite smoking material.

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