Halogen pig trotters non-thermal sterilization and texture regulation synergistic fresh-keeping production system and method

Abstract

The application discloses a kind of halogen pig trotter non-thermal sterilization and texture control coordination's lock fresh production system and method, the system includes: raw material pretreatment equipment, texture control equipment, marinating equipment, precooling equipment, drying equipment, non-thermal sterilization equipment, modified atmosphere packaging equipment and industrial control panel computer;The method includes: by using texture control, vacuum precooling, cold air drying and non-thermal sterilization process in halogen pig trotter production process realizes halogen pig trotter flavor, fresh and tender, juicy, locks the unique aroma of marinating flavor and attractive color, effectively kills pathogenic bacteria and spoilage bacteria while retaining the original nutritional ingredients, flavoring substances and sensory characteristics of halogen pig trotter, through intelligent, collaborative control strategy ensures the product "safe, delicious, long-acting" trinity high quality, at the same time, realizes the standardization, lean and self-adapting optimization of production, with strong market competitiveness and broad industrialization application prospect.

Description

Technical Field

[0001] This invention relates to the field of braised pig's trotters production technology, and in particular to a freshness-locking production system and method for braised pig's trotters that combines non-thermal sterilization and texture regulation. Background Technology

[0002] As consumers demand higher quality pre-prepared meat products, traditional braised pig's trotters processing methods face significant challenges: high-temperature sterilization can easily lead to fibrous texture and a tougher mouthfeel, and conventional vacuum tumbling is insufficient to achieve uniform penetration of the braising liquid; modified atmosphere packaging, if disconnected from the sterilization process, can easily result in a shortened shelf life due to residual microorganisms. In existing technologies, insufficient equipment synergy makes it difficult to balance textural properties with sterilization effectiveness. For example, if ultra-high pressure processing parameters are not dynamically matched with the tumbling penetration depth, it may lead to incomplete sterilization or excessive hardening in certain areas. Furthermore, parameter transfer between processes relies on manual experience and lacks a real-time feedback mechanism, affecting product consistency.

[0003] With the development of science and technology, automated and intelligent production control methods have emerged in the production and processing of braised pig's trotters. For example, Chinese patent CN120585047A discloses an automated tumbling and marinating industrial control method and system for braised pig's trotters, which realizes dynamic control during the tumbling and marinating process and ensures the uniformity of brine absorption. However, the differences in multiple processes such as braising, sterilization, and packaging during the processing of braised pig's trotters still affect the final flavor, quality, and shelf life of the product.

[0004] To address these issues, this invention innovatively integrates non-thermal sterilization with texture control technology. Through closed-loop control of an industrial control tablet computer, it achieves synergistic optimization of sterilization intensity and meat tenderness, ensuring the high quality of braised pig trotters in three aspects: safety, deliciousness, and long-lasting freshness. This provides a new solution for the efficient preservation of freshness in braised meat products. Summary of the Invention

[0005] In view of the shortcomings in the prior art, the purpose of this invention is to propose a freshness-locking production system and method for braised pig trotters that combines non-thermal sterilization and texture regulation, so as to solve the problem of the contradiction between the taste, flavor and quality and the shelf life of existing braised pig trotters.

[0006] To achieve the above objectives, the technical solution of the present invention is implemented as follows:

[0007] On the one hand, the present invention provides a freshness-locking production system for braised pig trotters that combines non-thermal sterilization and texture regulation, including raw material pretreatment equipment, texture regulation equipment, braising equipment, precooling equipment, drying equipment, non-thermal sterilization equipment, modified atmosphere packaging equipment, and industrial control tablet computer.

[0008] The raw material pretreatment equipment is used for the thawing, hair removal, cleaning and chopping processes in the production and processing of braised pig trotters;

[0009] The texture control equipment is connected to the raw material pretreatment equipment via a production line and is used to perform texture control treatment on the pretreated pig trotters.

[0010] The braising equipment is connected to the texture control equipment via a production line and is used to braise the texture-controlled pig trotters.

[0011] The precooling equipment is connected to the braising equipment via a production line and is used to cool down the braised pig's trotters.

[0012] The drying equipment is connected to the precooling equipment via a production line and is used to dry the cooled braised pig trotters with cold air.

[0013] The non-thermal sterilization equipment is connected to the drying equipment via a production line and is used to perform non-thermal physical field sterilization on the braised pig trotters after cold air drying.

[0014] The modified atmosphere packaging equipment is connected to the non-thermal sterilization equipment via a production line and is used to package sterilized braised pig trotters in a sterile or semi-sterile environment.

[0015] The industrial control tablet computer is connected to the texture control equipment, brining equipment, precooling equipment, drying equipment, non-thermal sterilization equipment, and modified atmosphere packaging equipment via RS485 port using the Modbus protocol. It is used to coordinate the control of texture control parameters, brining parameters, precooling parameters, cold air drying parameters, non-thermal sterilization parameters, and packaging environment parameters to achieve synergistic optimization of sterilization and texture and freshness preservation control.

[0016] Preferably, the texture control equipment is a vacuum tumbler, which has a built-in pressure sensor, temperature sensor and PLC controller, used to control the vacuum tumbling and penetration of pig trotters soaked in brine for 10 to 60 minutes under the conditions of processing pressure of -0.06 to -0.08 MPa and processing temperature of 4 to 15°C.

[0017] The braising equipment is a fully automatic hoisted honeycomb braising pot, which is equipped with a temperature sensor, pressure sensor, weighing sensor, liquid level sensor, pH sensor and PLC controller. It is used to collect data on temperature, pressure, weight of pig trotters, liquid level of braising liquid and pH value during the braising process, and control the pig trotters to be braised at 90 to 100℃ for 60 to 120 minutes to fully absorb the flavor.

[0018] The precooling equipment is a vacuum precooling machine, which has a built-in temperature sensor and PLC controller to control the cooling of pig trotters with a temperature of 85 to 98°C after braising to a core temperature of 10 to 25°C within 3 to 10 minutes.

[0019] The drying equipment is a vertical cold air drying cabinet, which is equipped with a temperature sensor, humidity sensor, wind speed sensor and PLC controller. It is used to control the temperature of the pre-cooled braised pig trotters at 18±2℃ and the humidity at ≤40%RH for 2 to 3 hours to achieve rapid dehydration of the pig trotter surface, inhibit oil seepage and microbial growth.

[0020] Preferably, the non-thermal sterilization equipment is an ultra-high pressure sterilizer, which has a built-in pressure sensor, temperature sensor and PLC controller, used to control the pressure holding time of the cold-air dried braised pig trotters at a processing pressure of 300 to 600 MPa and a processing temperature of 20 to 45°C for 3 to 15 minutes to complete the sterilization process;

[0021] The modified atmosphere packaging equipment is a modified atmosphere packaging machine, which has built-in pressure sensors, temperature sensors, nitrogen sensors, carbon dioxide sensors, oxygen sensors and PLC controllers. It is used to control the filling of 70% to 80% nitrogen and 20% to 30% carbon dioxide into the box after sterilization and vacuuming, and then sealing it.

[0022] Preferably, the industrial control tablet PC is pre-set with multiple sets of collaborative process recipes. Each recipe is associated with at least one set of pressure-temperature-time parameters for texture regulation, one set of brining temperature-time parameters, one set of precooling temperature-time parameters, one set of cold air drying temperature-humidity-wind speed-time parameters, and one set of non-thermal sterilization pressure-time parameters. The industrial control tablet PC is used to send instructions to each device according to the selected recipe, and to receive sensor data from each device in real time, and to perform closed-loop feedback control using a rolling strategy optimization algorithm.

[0023] On the other hand, the present invention provides a method for using a freshness-locking production system for braised pig trotters that combines non-thermal sterilization and texture regulation, comprising the following steps:

[0024] S1. Thaw, remove hair, clean, and chop fresh pig trotters into predetermined sizes;

[0025] S2. Transfer the pretreated pig trotters to the texture control equipment. At the same time, use the industrial control tablet computer to call the initial process formula and set the initial parameters according to the target product type.

[0026] S3. The industrial control tablet computer performs the first rolling strategy optimization, determines the pressure, temperature and time parameters of vacuum tumbling and sends them to the texture control equipment, and controls the texture control equipment to use vacuum low-temperature tumbling to allow the brine to penetrate the pig's trotters;

[0027] S4. Transfer the texture-controlled pig trotters to the braising equipment for braising. At the same time, receive real-time data from the sensors of the braising equipment through the industrial control tablet. If a significant deviation is detected, trigger the optimization and recalculation of the subsequent pre-cooling, drying or sterilization process for feedforward compensation.

[0028] S5. Quickly transfer the braised pig's trotters to the pre-cooling equipment. Cool the braised pig's trotters using the pre-cooling equipment according to the latest pre-cooling parameters. After cooling, use the drying equipment according to the latest cold air drying parameters to control the surface water activity Aw of the cooled braised pig's trotters to below 0.85.

[0029] S6. The industrial control tablet computer performs a second rolling strategy optimization, collaboratively solving for the optimal ultra-high pressure processing parameters and modified atmosphere packaging parameters, and then sends the ultra-high pressure processing parameters and modified atmosphere packaging parameters determined by the second rolling strategy optimization to the non-thermal sterilization equipment and the modified atmosphere packaging equipment, respectively.

[0030] S7. Pack the dried braised pig's trotters into flexible packaging bags and place them in a non-thermal sterilization device. The dried braised pig's trotters are then sterilized using the non-thermal sterilization device according to the latest ultra-high pressure processing parameters.

[0031] S8. Immediately after non-thermal sterilization, braised pig trotters are modified atmosphere packaged in an aseptic environment using modified atmosphere packaging equipment according to the latest modified atmosphere packaging parameters.

[0032] S9. Store the packaged braised pig's trotters at 0 to 4°C.

[0033] S10. After refrigeration for 24 hours, sample the packaged braised pig's trotters and test them. The measured quality data is then fed back to the industrial control tablet computer for model parameter calibration and learning.

[0034] Compared with existing technologies, the non-thermal sterilization and texture regulation synergistic freshness-locking production system and method for braised pig trotters provided by this invention have the following beneficial effects:

[0035] (1) In the production process of braised pig's trotters, a texture control process was used to promote the uniform penetration of braising liquid into the muscle fibers under low temperature and negative pressure. This not only improved the uniformity of flavor but also improved the tenderness and juiciness of the product through physical action, avoiding the possibility of overly mushy or dry meat due to traditional processes.

[0036] (2) After the braising process of pig trotters, vacuum precooling and cold air drying processes are added, which can quickly reduce the product temperature, inhibit the volatilization of flavor substances and excessive Maillard reaction caused by excessive heat reaction, and at the same time form a protective layer through surface dehydration, locking in the unique aroma and attractive color formed by braising.

[0037] (3) The ultra-high pressure non-thermal sterilization technology only acts on the biomacromolecules of microorganisms without damaging their valence bonds. Therefore, it can effectively kill pathogenic bacteria and putrefactive bacteria without using high temperature or adding too many chemical preservatives, while almost perfectly preserving the original nutrients, flavor substances and sensory characteristics of braised pig trotters.

[0038] (4) A freshness-locking production system for braised pig trotters with non-thermal sterilization and texture regulation was designed. The rolling strategy optimization algorithm was used to perform two rolling strategy optimizations to ensure the high quality of the product in three aspects: "safety, deliciousness and long-lasting effect". At the same time, through intelligent and collaborative control strategies, the standardization, lean production and adaptive optimization of production were achieved, which has strong market competitiveness and broad industrial application prospects. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0040] Figure 1 This is a schematic diagram of the freshness-locking production system for braised pig trotters that combines non-thermal sterilization and texture regulation according to the present invention.

[0041] Figure 2 This is a flowchart illustrating the process of using the non-thermal sterilization and texture regulation synergistic freshness-locking production system for braised pig trotters according to the present invention. Detailed Implementation

[0042] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0043] Example 1: As Figure 1 As shown, this embodiment of the invention provides a freshness-locking production system for braised pig trotters that combines non-thermal sterilization and texture control, including raw material pretreatment equipment, texture control equipment, braising equipment, precooling equipment, drying equipment, non-thermal sterilization equipment, modified atmosphere packaging equipment, and an industrial control panel computer, wherein:

[0044] Raw material pretreatment equipment is used for thawing, dehairing, cleaning, and chopping processes in the production and processing of braised pig trotters;

[0045] The texture control equipment is connected to the raw material pretreatment equipment via a production line and is used to perform texture control treatment on pretreated pig trotters.

[0046] The braising equipment, connected to the texture control equipment via a production line, is used to braise pig trotters after texture control.

[0047] The pre-cooling equipment is connected to the braising equipment via a production line drive and is used to cool down the pig's trotters after braising.

[0048] The drying equipment, connected to the precooling equipment via a production line, is used to dry the cooled braised pig trotters with cold air.

[0049] The non-thermal sterilization equipment is connected to the drying equipment via a production line and is used to perform non-thermal physical field sterilization on braised pig trotters after cold air drying.

[0050] Modified atmosphere packaging equipment, connected to non-thermal sterilization equipment via a production line, is used to package sterilized braised pig trotters in a sterile or semi-sterile environment.

[0051] The industrial control tablet PC is connected to the texture control equipment, brining equipment, precooling equipment, drying equipment, non-thermal sterilization equipment, and modified atmosphere packaging equipment via RS485 port using the Modbus protocol. It is used to coordinate the control of texture control parameters, brining parameters, precooling parameters, cold air drying parameters, non-thermal sterilization parameters, and packaging environment parameters to achieve synergistic optimization of sterilization and texture and freshness preservation control.

[0052] Specifically, the texture control equipment is a vacuum tumbler, which has a built-in pressure sensor, temperature sensor and PLC controller, used to control the vacuum tumbling and penetration of pig trotters soaked in brine for 10 to 60 minutes under the conditions of processing pressure of -0.06 to -0.08 MPa and processing temperature of 4 to 15℃.

[0053] Specifically, the braising equipment is a fully automatic suspended honeycomb braising pot, which is equipped with temperature sensors, pressure sensors, weighing sensors, liquid level sensors, pH sensors and PLC controllers. These are used to collect data on temperature, pressure, weight of pig trotters, liquid level of braising liquid and pH value during the braising process, and to control the braising process of pig trotters at 90 to 100℃ for 60 to 120 minutes to ensure that they are fully flavored.

[0054] Specifically, the precooling equipment is a vacuum precooling machine, which has a built-in temperature sensor and PLC controller to control the cooling of pig trotters, which are at a temperature of 85 to 98°C after braising, to a core temperature of 10 to 25°C within 3 to 10 minutes.

[0055] Specifically, the drying equipment is a vertical cold air drying cabinet, which is equipped with a temperature sensor, humidity sensor, wind speed sensor and PLC controller. It is used to control the temperature of the pre-cooled braised pig trotters at 18±2℃ and the humidity at ≤40% RH for 2 to 3 hours to achieve rapid dehydration of the surface of the pig trotters, inhibit oil seepage and microbial growth.

[0056] Specifically, the non-thermal sterilization equipment is an ultra-high pressure sterilizer, which has a built-in pressure sensor, temperature sensor and PLC controller. It is used to control the sterilization process of the braised pig trotters after cold air drying, and to maintain the pressure for 3 to 15 minutes under the conditions of processing pressure of 300 to 600 MPa and processing temperature of 20 to 45℃.

[0057] Specifically, the modified atmosphere packaging equipment is a modified atmosphere packaging machine, which has built-in pressure sensors, temperature sensors, nitrogen sensors, carbon dioxide sensors, oxygen sensors and PLC controllers. It is used to control the filling of 70% to 80% nitrogen and 20% to 30% carbon dioxide into the box after sterilization and vacuuming, and then sealing it.

[0058] Specifically, the industrial control tablet PC is pre-set with multiple sets of collaborative process recipes. Each recipe is associated with at least one set of pressure-temperature-time parameters for texture control, one set of brining temperature-time parameters, one set of precooling temperature-time parameters, one set of cold air drying temperature-humidity-wind speed-time parameters, and one set of non-thermal sterilization pressure-time parameters. The industrial control tablet PC can send instructions to each device according to the selected recipe and receive sensor data from each device in real time, and use a rolling strategy optimization algorithm for closed-loop feedback control.

[0059] More specifically, the preferred vacuum tumbling machine is the fully automatic JY-1000L model vacuum tumbling machine manufactured by Guangzhou Jiuying Machinery Equipment Co., Ltd.

[0060] More specifically, the fully automatic hoisting honeycomb braising pot is preferably a continuous honeycomb braising pot produced by Weifang Longchuang Machinery Equipment Co., Ltd.

[0061] More specifically, the vacuum precooling machine is preferably a fully automatic vacuum precooling machine produced by Shandong Jieshima Machinery Technology Co., Ltd.

[0062] More specifically, the preferred choice for vertical cold air drying cabinets is the vertical cold air drying cabinet manufactured by Zhucheng Furuide Machinery Co., Ltd.

[0063] More specifically, the preferred ultra-high pressure sterilizer is the fully automatic ultra-high pressure sterilizer manufactured by Xifa (Shanghai) Hydraulic Technology Co., Ltd.

[0064] More specifically, the preferred modified atmosphere packaging machine is the XL-380 model manufactured by Shanghai Xilu Electromechanical Equipment Co., Ltd.

[0065] More specifically, the preferred industrial control panel PC is the Yidao EM-I10J 10-inch Win11 industrial panel PC.

[0066] The present invention provides a production system for preserving freshness of braised pig trotters through synergistic non-thermal sterilization and texture regulation. This system comprises raw material pretreatment equipment, texture regulation equipment, braising equipment, pre-cooling equipment, drying equipment, non-thermal sterilization equipment, modified atmosphere packaging equipment, and an industrial control tablet computer. It achieves synergistic freshness preservation through non-thermal sterilization and texture regulation of braised pig trotters. Specifically, the system utilizes texture regulation, vacuum pre-cooling, cold air drying, and non-thermal sterilization processes in the production of braised pig trotters to ensure the trotters are flavorful, tender, and juicy, locking in the unique aroma and appealing color of the braised flavor. It effectively kills pathogenic and spoilage bacteria while preserving the original nutrients, flavor compounds, and sensory characteristics of the braised pig trotters. Through intelligent and collaborative control strategies, it ensures the product achieves a high-quality goal of "safety, deliciousness, and long-lasting effects." Through design, simulation, and verification, a modular product is formed, enabling rapid portability between different platforms and accelerating the product development process.

[0067] Example 2: As Figure 2 As shown, this embodiment of the invention provides a method for using a fresh-locking production system for braised pig's trotters that combines non-thermal sterilization and texture regulation. Specifically, it employs the fresh-locking production system for braised pig's trotters that combines non-thermal sterilization and texture regulation as described in Example 1, and includes the following steps:

[0068] S1. Thaw, remove hair, clean, and chop fresh pig trotters into predetermined sizes;

[0069] S2. Transfer the pretreated pig trotters to the texture control equipment. At the same time, use the industrial control tablet computer to call the initial process formula and set the initial parameters according to the target product type.

[0070] S3. The industrial control tablet computer performs the first rolling strategy optimization, determines the pressure, temperature and time parameters of vacuum tumbling and sends them to the texture control equipment, and controls the texture control equipment to use vacuum low-temperature tumbling to allow the brine to penetrate the pig's trotters;

[0071] S4. Transfer the texture-controlled pig trotters to the braising equipment for braising. At the same time, receive real-time data from the sensors of the braising equipment through the industrial control tablet. If a significant deviation is detected, trigger the optimization and recalculation of the subsequent pre-cooling, drying or sterilization process for feedforward compensation.

[0072] S5. Quickly transfer the braised pig's trotters to the pre-cooling equipment. Cool the braised pig's trotters using the pre-cooling equipment according to the latest pre-cooling parameters. After cooling, use the drying equipment according to the latest cold air drying parameters to control the surface water activity Aw of the cooled braised pig's trotters to below 0.85.

[0073] S6. The industrial control tablet computer performs a second rolling strategy optimization, collaboratively solving for the optimal ultra-high pressure processing parameters and modified atmosphere packaging parameters, and then sends the ultra-high pressure processing parameters and modified atmosphere packaging parameters determined by the second rolling strategy optimization to the non-thermal sterilization equipment and the modified atmosphere packaging equipment, respectively.

[0074] S7. Pack the dried braised pig's trotters into flexible packaging bags and place them in a non-thermal sterilization device. The dried braised pig's trotters are then sterilized using the non-thermal sterilization device according to the latest ultra-high pressure processing parameters.

[0075] S8. Immediately after non-thermal sterilization, braised pig trotters are modified atmosphere packaged in an aseptic environment using modified atmosphere packaging equipment according to the latest modified atmosphere packaging parameters.

[0076] S9. Store the packaged braised pig's trotters at 0 to 4°C.

[0077] S10. After refrigeration for 24 hours, sample the packaged braised pig's trotters and test them. The measured quality data is then fed back to the industrial control tablet computer for model parameter calibration and learning.

[0078] Specifically, the first optimization of the rolling strategy in S3 includes the following steps:

[0079] L1. The industrial control panel PC establishes a dynamic mathematical model of the vacuum tumbling process based on the target product type and initial process formula;

[0080] L2. The MPC model predictive control algorithm is adopted to optimize the multi-objective rolling strategy within a finite time domain, with brine penetration uniformity and textural properties as optimization objectives.

[0081] L3. Optimize variables, including vacuum pressure, tumbling temperature, and tumbling time;

[0082] L4. Real-time monitoring of pressure and temperature inside the tumbling chamber, and dynamic adjustment of tumbling speed and interval ratio based on sensor feedback.

[0083] Specifically, the feedforward compensation in S4 includes the following steps:

[0084] M1. During the braising process, the temperature, pressure, and pH of the brine are monitored in real time;

[0085] M2. When the temperature deviation of the brine exceeds ±2℃ or the pH value deviation exceeds ±0.3, it is determined to be a significant deviation, triggering the compensation algorithm to recalculate the precooling time, cold air drying time or ultra-high pressure treatment intensity based on the degree and direction of the deviation.

[0086] The M3 compensation algorithm considers the deviation propagation model and inter-process coupling effects to ensure the consistency of final product quality.

[0087] Specifically, the second rolling strategy optimization in S6 includes the following steps:

[0088] N1. Establish a synergistic optimization model for ultra-high pressure treatment and modified atmosphere packaging, with microbial inactivation rate, color retention and shelf life as multiple objective functions;

[0089] N2. Optimization variables include ultra-high pressure, holding time, holding temperature, and the proportion of gas components in modified atmosphere packaging;

[0090] N3. A multi-objective genetic algorithm is used to solve for the Pareto optimal solution set, and the optimal parameter combination is selected according to actual needs.

[0091] Specifically, the calibration learning of model parameters in S10 includes the following steps:

[0092] Q1. Collect quality data such as total microbial count, Aw value, textural properties, and color parameters from the samples;

[0093] Q2. Compare the prediction error and model confidence with the output value of the prediction model;

[0094] Q3. When the confidence level is lower than the preset threshold, the incremental learning algorithm in machine learning is used to update the model parameters;

[0095] Q4. The updated model parameters are used for optimization calculations in the next batch of production, enabling adaptive improvement of the model.

[0096] like Figure 2 As shown, after pre-processing fresh pig trotters, the industrial control tablet computer calls the initial process formula and sets the initial parameters according to the target product type. During texture control, the parameters are optimized using a first rolling strategy. During braising, deviations are detected and feedforward compensation is performed to optimize subsequent pre-cooling, drying, or sterilization processes based on the deviations. After vacuum pre-cooling, the parameters are optimized using a second rolling strategy to determine the ultra-high pressure processing parameters and modified atmosphere packaging parameters. After product packaging, sampling tests are conducted for model parameter calibration and learning, ensuring the product's three-in-one high-quality goal of "safety, deliciousness, and long-lasting effects".

[0097] The non-thermal sterilization and texture regulation synergistic freshness-locking production system and method for braised pig trotters provided in this embodiment adopts a modular design approach. It utilizes raw material pretreatment equipment, texture regulation equipment, braising equipment, precooling equipment, drying equipment, non-thermal sterilization equipment, modified atmosphere packaging equipment, and industrial control tablet computer to realize the non-thermal sterilization and texture regulation synergistic freshness-locking production system for braised pig trotters. By using texture regulation, vacuum precooling, cold air drying, and non-thermal sterilization processes in the production process of braised pig trotters, the system achieves flavorful, tender, and juicy braised pig trotters, locking in the unique aroma and appealing color of braised food. It effectively kills pathogenic and spoilage bacteria while preserving the original nutrients, flavor substances, and sensory characteristics of braised pig trotters. Through intelligent and collaborative control strategies, it ensures the three-in-one high-quality goal of "safety, deliciousness, and long-lasting effect" of the product.

[0098] To further illustrate the usage of the non-thermal sterilization and texture regulation synergistic freshness-locking production system for braised pig trotters provided by the present invention, a specific application example is used below to explain how the non-thermal sterilization and texture regulation synergistic freshness-locking production system for braised pig trotters provided by the present invention is specifically operated.

[0099] In this specific application embodiment, the industrial control tablet PC's database pre-stores various product recipes such as "Spicy and Chewy" and "Five-Spice Crispy and Soft," and each recipe is a structured data table. For example, the "Spicy and Chewy" recipe includes:

[0100] 1. Texture control: vacuum degree -0.08MPa, temperature 4℃, total time 50 minutes (intermittent mode: 12 minutes of rotation / 3 minutes of rest).

[0101] 2. Braising: Temperature 98℃, time 75 minutes.

[0102] 3. Pre-cooling: Target center temperature 12℃, maximum time 8 minutes.

[0103] 4. Drying: Temperature 17℃, humidity 30%, wind speed 2.0m / s, time 3 hours.

[0104] 5. Non-thermal sterilization: Pressure 550MPa, temperature 30℃, pressure holding for 8 minutes.

[0105] 6. Modified atmosphere packaging: gas ratio N2:CO2 = 70:30.

[0106] Before production, the operator selects the appropriate recipe on the industrial control tablet computer interface according to the actual needs, such as the "spicy and chewy" recipe or the "five-spice and tender" recipe. Then, the pre-treated pig trotters are transferred to the texture control equipment (i.e., the vacuum tumbler) and production is started.

[0107] During production, the first rolling strategy optimization is performed: when the pig trotters enter the texture control equipment (i.e., the vacuum tumbler), the industrial control panel initiates the first MPC optimization (i.e., rolling strategy optimization); the specific optimization process is as follows:

[0108] (1) Model establishment: Call the dynamic model f1(P, T, t, ω, r) of the tumbling process. Where P is the pressure, T is the temperature, t is the time, ω is the rotation speed, and r is the interval ratio. The model outputs the predicted values ​​of penetration uniformity U and tenderness Tender.

[0109] (2) Optimization objective: Maximize J1 = α×U + β×Tender, while constraining the total time to ≤60 minutes and the temperature to ≤15℃. α is the weight of penetration uniformity and β is the weight of tenderness.

[0110] (3) Rolling implementation:

[0111] ①The industrial control panel uses the current initial parameters from the recipe as a starting point to predict the state within the next 20 minutes;

[0112] Solving the optimization problem yields a set of optimal future control sequences, such as: maintaining -0.08 MPa for the first 10 minutes and adjusting it to -0.06 MPa for the next 10 minutes to promote internal and external pressure balance; and gradually increasing the temperature from 6°C to 10°C.

[0113] The first control command in the sequence is sent to the PLC of the tumbler;

[0114] In the next sampling cycle, new actual pressure and temperature sensor data are read, the status is refreshed, and prediction and optimization are repeated to achieve "rolling time domain, feedback correction".

[0115] (4) Dynamic adjustment: During the process, if the pressure sensor feedback indicates that the vacuum level is established slowly, the industrial control tablet PC will dynamically extend the tumbling interval time of the vacuuming stage through the PLC to ensure that the target vacuum level is achieved.

[0116] Then, feedforward compensation is performed: that is, during the brining stage, the sensor network uploads data in real time; the specific compensation process is as follows:

[0117] (1) Scenario simulation: When the braising process reached the 40th minute, the pH sensor data showed that the pH value dropped rapidly from the preset 6.0 to 5.6, with a significant deviation exceeding the ±0.3 threshold, which may be due to the slightly higher acidity of this batch of pig trotters.

[0118] (2) Compensation trigger: The industrial control tablet PC determines whether to trigger the feedforward compensation algorithm and performs compensation calculation:

[0119] ① Deviation analysis: A decrease in pH may accelerate protein denaturation, resulting in a product that is ultimately too firm.

[0120] ② Compensation Decision: To offset this impact, the texture needs to be "softened" in subsequent processes. The industrial control tablet computer initiates a compensation algorithm, which incorporates a process coupling effect model.

[0121] (3) Compensation output:

[0122] ① Pre-cooling: Adjust the target core temperature from 12℃ to 18℃. A slower pre-cooling rate can reduce excessive contraction of myofibrils to some extent, helping to maintain tenderness.

[0123] ② Ultra-high pressure sterilization: The processing pressure is slightly reduced from 550MPa to 520MPa. Ultra-high pressure sterilizes proteins while also causing them to denature and gel to a moderate degree. The slight reduction in pressure helps to avoid excessive gelation when the proteins are already hardening, thus synergistically maintaining the target texture.

[0124] ③ Command issuance: New pre-cooling target temperature and ultra-high pressure parameters are calculated in real time and updated to the control command sequence of the corresponding equipment, and executed when the material arrives.

[0125] Next, a second round of rolling strategy optimization was performed: During the later stages of drying the pig trotters, the industrial control panel initiated a second round of MPC optimization, focusing on coordinating sterilization and packaging; the specific optimization process is as follows:

[0126] (1) Collaborative Model: Establishing a calling model f2(P) hpp , t hpp , T hpp The inputs are ultra-high pressure parameters and gas ratios, and the outputs are the predicted microbial survival rate Log(S), color change ΔE, and predicted shelf life Shelf. life .

[0127] (2) Multi-objective optimization: Establish a multi-objective optimization problem

[0128] Minimize J2= [Log(S), ΔE, Shelf life ]

[0129] (3) Solution and decision: The fast non-dominated sorting genetic algorithm NSGA-II is used to solve the problem. The search is conducted in the decision space: pressure, time, temperature and gas ratio to obtain a set of Pareto optimal solutions.

[0130] For example, the solution set might include: Solution A (600MPa, 3min, N2:CO2=80:20) offers the strongest sterilization but results in slightly greater color loss; Solution B (400MPa, 10min, N2:CO2=70:30) provides the best color but has slightly weaker sterilization intensity. The industrial control panel PC automatically selects Solution B as the final parameter based on the priority requirements of "shelf life" and "color" for this production order.

[0131] (4) Parameter distribution: The selected Scheme B parameters (400MPa, 10min, 25℃, 70:30) are distributed to the PLCs of the ultra-high pressure sterilizer and the modified atmosphere packaging machine respectively.

[0132] Finally, model calibration and self-learning are performed.

[0133] (1) Data collection: Samples are taken from the finished product warehouse according to AQL standards. The test items include: total bacterial count, Aw value (measured by water activity meter), texture (TPA test, measuring hardness, elasticity and chewiness), and color (measured by colorimeter).

[0134] (2) Feedback comparison: Compare the measured data, such as total colony count = 20 CFU / g, hardness = 8500 g, with the predicted values ​​under the corresponding parameters in the second optimization model: predicted total colony count = 15 CFU / g, predicted hardness = 8200 g.

[0135] (3) Model evaluation: Calculate the prediction error and model confidence. If the prediction error of texture hardness for multiple batches at the same process point continues to exceed 10% and the confidence is below 90%, then the model is updated.

[0136] (4) Incremental learning: The industrial control tablet computer calls the built-in random forest regression algorithm incremental learning module. The actual process parameters of this production are used as features and the measured quality data are used as labels as new data samples, which are added to the training set to partially retrain the sub-model of predicting the quality structure and update the node splitting rules or weights inside the model.

[0137] (5) Effect: The updated model can provide more accurate predictions in the first and second rolling optimizations of the next batch of production, thereby making better decisions and enabling the system to have the ability to continuously optimize and improve.

[0138] The following is the complete production process of the applicant's "Five-Spice Crispy and Soft" Fresh-Locking Braised Pig Trotters:

[0139] Production target: Produce 1,000 servings of "Five-Spice Crispy and Soft" Fresh-Locking Braised Pig Trotters.

[0140] Step S1, Raw material pretreatment: 1000kg of frozen pig trotters are thawed in circulating water, singed with flame, brushed, and chopped to obtain approximately 4000 standard pieces.

[0141] Step S2, Transfer and Recipe Call: First, the processed pig trotters are conveyed into the vacuum tumbler via a conveyor belt. Then, the operator selects the "Five-Spice Crispy and Soft" recipe on the industrial control tablet computer interface and starts the machine.

[0142] Step S3, First Optimization and Texture Control: Perform the first rolling strategy optimization using an industrial control tablet computer, determining and executing the following parameters: vacuum degree -0.06MPa, temperature 12℃, total time 30 minutes (intermittent mode: 8 minutes of rotation / 4 minutes of rest). After tumbling, the pig's trotters have evenly absorbed the braising liquid, and the meat texture is relaxed.

[0143] Step S4, Braising and Feedforward Monitoring: The pig's trotters are hoisted into the braising pot, and the industrial control tablet computer is set to 95℃ for 100 minutes for braising. During the braising process, the temperature and pH are stable and no significant deviation alarm is triggered, so feedforward compensation is not activated. Subsequent processes are prepared according to the original recipe parameters.

[0144] Step S5, Pre-cooling and drying: First, send the braised pig's trotters (center temperature about 97°C) into a vacuum pre-cooling machine. Within 7 minutes, the center temperature of the pig's trotters drops to 20°C. Then, transfer them to a cold air drying cabinet and dry them for 2 hours at 19°C, 38%RH, and a wind speed of 1.2m / s until the surface is dry and Aw=0.84.

[0145] Step S6, Second Collaborative Optimization: Execute the second rolling strategy optimization through the industrial control tablet computer. Based on the current material state and the goal of prioritizing "softness", select a solution from the Pareto solution set: ultra-high pressure processing pressure 450MPa, pressure holding for 6 minutes, temperature 35℃; modified atmosphere packaging ratio N2:CO2 = 75:25.

[0146] Step S7, Non-thermal sterilization: After the braised pig trotters are packaged, they are sent into an ultra-high pressure device and processed strictly according to the parameters of 450MPa / 35℃ / 6min.

[0147] Step S8, Modified Atmosphere Packaging: The sterilized packaging bag (i.e. the packaging bag containing braised pig's trotters) is placed in a sterile isolation hood, and the modified atmosphere packaging machine completes the vacuuming, filling with 75% N2 and 25% CO2, and heat sealing to ensure that the headspace residual oxygen content is <0.5%.

[0148] Step S9, Refrigeration: Quickly transfer the packaged braised pig's trotters to a cold storage at 2°C.

[0149] Step S10, Sampling and Learning: 24 hours later, 10 packages of product were randomly sampled. The test results were: total bacterial count <10 CFU / g, Aw=0.84, firmness (meets the target of being soft), and good color. The data was then fed back to the industrial control tablet. Since the model prediction error was within the allowable range, no model update was triggered this time. Production data was completely archived.

[0150] Through the above specific application examples, it is illustrated that this system realizes the full-process automation, informatization and intelligent production from raw materials to finished products. Through two rolling optimizations and feedforward compensation of the central processing unit, key processes such as texture control and non-thermal sterilization are dynamically coordinated. Under the premise of fully ensuring microbial safety, the original flavor, color and ideal texture of braised pig trotters are preserved to the greatest extent, and the goal of efficient "freshness locking" is achieved.

[0151] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for the production of fresh-keeping pork trotter by synergistic non-thermal sterilization and texture control, characterized in that, Includes the following steps: S1. Thaw, remove hair, clean, and chop fresh pig trotters into predetermined sizes; S2. Transfer the pretreated pig trotters to the texture control equipment. At the same time, use the industrial control tablet computer to call the initial process formula and set the initial parameters according to the target product type. S3. The industrial control tablet computer performs the first rolling strategy optimization, determines the pressure, temperature and time parameters of vacuum tumbling and sends them to the texture control equipment, and controls the texture control equipment to use vacuum low-temperature tumbling to allow the brine to penetrate the pig's trotters; The first rolling strategy optimization includes the following steps: L1. The industrial control panel PC establishes a dynamic mathematical model of the vacuum tumbling process based on the target product type and initial process formula; L2. The MPC model predictive control algorithm is adopted to optimize the multi-objective rolling strategy within a finite time domain, with brine penetration uniformity and textural properties as optimization objectives. L3. Optimize variables, including vacuum pressure, tumbling temperature, and tumbling time; L4. Real-time monitoring of pressure and temperature inside the tumbling chamber, and dynamic adjustment of tumbling speed and interval ratio based on sensor feedback; S4. Transfer the texture-controlled pig trotters to the braising equipment for braising. At the same time, receive real-time data from the sensors of the braising equipment through the industrial control tablet. If a significant deviation is detected, trigger the optimization and recalculation of the subsequent pre-cooling, drying or sterilization process for feedforward compensation. S5. Quickly transfer the braised pig's trotters to the pre-cooling equipment. Cool the braised pig's trotters using the pre-cooling equipment according to the latest pre-cooling parameters. After cooling, use the drying equipment according to the latest cold air drying parameters to control the surface water activity Aw of the cooled braised pig's trotters to below 0.

85. S6. The industrial control tablet computer performs a second rolling strategy optimization, collaboratively solving for the optimal ultra-high pressure processing parameters and modified atmosphere packaging parameters, and then sends the ultra-high pressure processing parameters and modified atmosphere packaging parameters determined by the second rolling strategy optimization to the non-thermal sterilization equipment and the modified atmosphere packaging equipment, respectively. The second rolling strategy optimization includes the following steps: N1. Establish a synergistic optimization model for ultra-high pressure treatment and modified atmosphere packaging, with microbial inactivation rate, color retention and shelf life as multiple objective functions; N2. Optimization variables include ultra-high pressure, holding time, holding temperature, and the proportion of gas components in modified atmosphere packaging; N3. A multi-objective genetic algorithm is used to solve for the Pareto optimal solution set, and the optimal parameter combination is selected according to actual needs; S7. Pack the dried braised pig's trotters into flexible packaging bags and place them in a non-thermal sterilization device. The dried braised pig's trotters are then sterilized using the non-thermal sterilization device according to the latest ultra-high pressure processing parameters. S8. Immediately after non-thermal sterilization, braised pig trotters are modified atmosphere packaged in an aseptic environment using modified atmosphere packaging equipment according to the latest modified atmosphere packaging parameters. S9. Store the packaged braised pig's trotters at 0 to 4°C. S10. After refrigeration for 24 hours, sample the packaged braised pig's trotters and test them. The measured quality data is then fed back to the industrial control tablet computer for model parameter calibration and learning.

2. The fresh-keeping production method of halogen pig trotter non-thermal sterilization and texture control synergy according to claim 1, characterized in that, The feedforward compensation in step S4 includes the following steps: M1. During the braising process, the temperature, pressure, and pH of the brine are monitored in real time; M2. When the temperature deviation of the brine exceeds ±2℃ or the pH value deviation exceeds ±0.3, it is determined to be a significant deviation, triggering the compensation algorithm to recalculate the precooling time, cold air drying time or ultra-high pressure treatment intensity based on the degree and direction of the deviation. The M3 compensation algorithm considers the deviation propagation model and inter-process coupling effects to ensure the consistency of final product quality.

3. The method for preserving freshness of braised pig's trotters through synergistic non-thermal sterilization and texture regulation as described in claim 1, characterized in that... The model parameter correction learning in step S10 includes the following steps: Q1. Collect quality data on total microbial count, Aw value, textural properties, and color parameters from the samples tested; Q2. Compare the prediction error and model confidence with the output value of the prediction model; Q3. When the confidence level is lower than the preset threshold, the incremental learning algorithm in machine learning is used to update the model parameters; Q4. The updated model parameters are used for optimization calculations in the next batch of production, enabling adaptive improvement of the model.

4. A freshness-locking production system for braised pig trotters that combines non-thermal sterilization and texture regulation, comprising the method described in any one of claims 1-3; characterized in that: This includes raw material pretreatment equipment, texture control equipment, brining equipment, precooling equipment, drying equipment, non-thermal sterilization equipment, modified atmosphere packaging equipment, and industrial control tablet PCs; The raw material pretreatment equipment is used for the thawing, hair removal, cleaning and chopping processes in the production and processing of braised pig trotters; The texture control equipment is connected to the raw material pretreatment equipment via a production line and is used to perform texture control treatment on the pretreated pig trotters. The braising equipment is connected to the texture control equipment via a production line and is used to braise the texture-controlled pig trotters. The precooling equipment is connected to the braising equipment via a production line and is used to cool down the braised pig's trotters. The drying equipment is connected to the precooling equipment via a production line and is used to dry the cooled braised pig trotters with cold air. The non-thermal sterilization equipment is connected to the drying equipment via a production line and is used to perform non-thermal physical field sterilization on the braised pig trotters after cold air drying. The modified atmosphere packaging equipment is connected to the non-thermal sterilization equipment via a production line and is used to package sterilized braised pig trotters in a sterile or semi-sterile environment. The industrial control tablet computer is connected to the texture control equipment, brining equipment, precooling equipment, drying equipment, non-thermal sterilization equipment, and modified atmosphere packaging equipment via RS485 port using the Modbus protocol. It is used to coordinate the control of texture control parameters, brining parameters, precooling parameters, cold air drying parameters, non-thermal sterilization parameters, and packaging environment parameters to achieve synergistic optimization of sterilization and texture and freshness preservation control.

5. The non-thermal sterilization and texture regulation synergistic freshness-locking production system for braised pig trotters as described in claim 4, characterized in that: The texture control equipment is a vacuum tumbler, which has a built-in pressure sensor, temperature sensor and PLC controller, used to control the vacuum tumbling and penetration of pig trotters soaked in brine for 10 to 60 minutes under the conditions of processing pressure of -0.06 to -0.08 MPa and processing temperature of 4 to 15℃. The braising equipment is a fully automatic hoisted honeycomb braising pot, which is equipped with a temperature sensor, pressure sensor, weighing sensor, liquid level sensor, pH sensor and PLC controller. It is used to collect data on temperature, pressure, weight of pig trotters, liquid level of braising liquid and pH value during the braising process, and control the pig trotters to be braised at 90 to 100℃ for 60 to 120 minutes to fully absorb the flavor. The precooling equipment is a vacuum precooling machine, which has a built-in temperature sensor and PLC controller to control the cooling of pig trotters with a temperature of 85 to 98°C after braising to a core temperature of 10 to 25°C within 3 to 10 minutes. The drying equipment is a vertical cold air drying cabinet, which is equipped with a temperature sensor, humidity sensor, wind speed sensor and PLC controller. It is used to control the temperature of the pre-cooled braised pig trotters at 18±2℃ and the humidity at ≤40% RH for 2 to 3 hours to achieve rapid dehydration of the pig trotter surface, inhibit oil seepage and microbial growth.

6. The non-thermal sterilization and texture regulation synergistic freshness-locking production system for braised pig trotters as described in claim 4, characterized in that: The non-thermal sterilization equipment is an ultra-high pressure sterilizer, which has a built-in pressure sensor, temperature sensor and PLC controller. It is used to control the holding time of the braised pig trotters after cold air drying to be 3 to 15 minutes under the conditions of processing pressure of 300 to 600 MPa and processing temperature of 20 to 45℃ to complete the sterilization process. The modified atmosphere packaging equipment is a modified atmosphere packaging machine, which has built-in pressure sensors, temperature sensors, nitrogen sensors, carbon dioxide sensors, oxygen sensors and PLC controllers. It is used to control the filling of 70% to 80% nitrogen and 20% to 30% carbon dioxide into the box after sterilization and vacuuming, and then sealing it.

7. The non-thermal sterilization and texture regulation synergistic freshness-locking production system for braised pig trotters as described in claim 4, characterized in that: The industrial control tablet PC is pre-set with multiple sets of collaborative process recipes. Each recipe is associated with at least one set of pressure-temperature-time parameters for texture regulation, one set of brining temperature-time parameters, one set of precooling temperature-time parameters, one set of cold air drying temperature-humidity-wind speed-time parameters, and one set of non-thermal sterilization pressure-time parameters. The industrial control tablet PC is used to send instructions to each device according to the selected recipe and receive sensor data from each device in real time, and use a rolling strategy optimization algorithm for closed-loop feedback control.

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