High-efficiency preparation process and system of fishy-smell-free instant rana japonica oil

Abstract

The invention relates to the technical field of food processing, in particular to an efficient preparation process and system of fishy-smell-free instant rana japonica oil, and the process comprises the steps of raw material pretreatment, multistage countercurrent cleaning, biological-physical combined fishy smell removal, flavor freshness locking and embedding, sterilization, packaging and the like. The system comprises a circulating water temporary culture pond, a cleaning system, an enzymolysis tank, a supercritical extraction unit, drying equipment, embedding equipment, sterilization equipment and a packaging machine, efficient deodorization, nutrition retention and long-term preservation of the rana japonica oil are achieved through process integration and parameter optimization, the content of fishy substances in the product is smaller than or equal to 10 ppm, the shelf life can reach 24 months, comprehensive energy consumption is reduced by 30%, and the product quality is improved. The method is suitable for industrial production of the rana japonica oil.

Description

Technical Field

[0001] This invention relates to the field of food processing technology, specifically to a high-efficiency preparation process and system for odorless, ready-to-eat frog oil, and particularly to an integrated production process and equipment for pretreatment, deodorization, freshness locking, and sterilization of frog oil, suitable for industrial-scale production of high-purity, odorless, ready-to-eat frog oil products. Background Technology

[0002] Frog oil (also known as snow frog oil) is a traditional tonic food with high nutritional value, rich in protein, amino acids, unsaturated fatty acids, and various trace elements. Traditional frog oil processing methods often rely on chemical reagents for deodorization or high-temperature treatment, which easily destroys nutrients and leaves noticeable fishy residue, affecting taste and flavor. Furthermore, the lack of precise control in cleaning and drying processes leads to high impurity rates, easy oxidation, and difficulty in maintaining color and shape. In addition, existing technologies such as supercritical extraction and high-temperature sterilization have low energy utilization rates and high production costs. Traditional packaging methods are also ineffective in effectively isolating oxygen and microorganisms, resulting in short shelf life and easy spoilage. To solve these problems, this invention provides an integrated, highly efficient, and energy-saving frog oil preparation process and system. Through innovative technologies such as combined biological and physical deodorization, multi-stage countercurrent cleaning, and biphasic microencapsulation for freshness locking, it achieves the production of frog oil that is fishy-free, ready-to-eat, and has a long shelf life. Summary of the Invention

[0003] The purpose of this invention is to provide a high-efficiency preparation process and system for odorless, ready-to-eat forest frog oil, in order to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: A highly efficient process for preparing odorless, ready-to-eat forest frog oil includes the following steps: Step 1, Raw material pretreatment: Live forest frogs are temporarily kept in a circulating water system with added green tea extract and vitamin C, with the water temperature controlled at 12-15℃ for 72 hours, with 50% of the water changed daily, and the ammonia nitrogen concentration ≤0.2mg / L; then they are processed through a quick-freezing tunnel and a low-temperature thawing chamber. Step 2, Multi-stage Countercurrent Cleaning: Perform three stages of cleaning sequentially, including the first stage... Solution spray cleaning, secondary tea saponin-citric acid solution ultrasonic cleaning, and tertiary β-cyclodextrin-trehalose solution rotary soaking cleaning; Step 3, combined biological-physical deodorization: including enzymatic deodorization and supercritical fluid extraction. Extraction and vacuum microwave drying; Step 4, Flavor Locking and Encapsulation: This includes biphasic microcapsule encapsulation and the formulation of natural anti-odor agents; Step 5, Sterilization and Packaging: This includes ultra-high pressure sterilization and nitrogen-filled packaging.

[0005] As a further aspect of the present invention: the temperature of the quick-freezing tunnel in step 1 is -35°C and the time is 30 min, and the temperature of the low-temperature thawing chamber is 4°C and the time is 12 h.

[0006] As a further aspect of the present invention: the specific parameters for the three-stage cleaning in step 2 are as follows: Stage 1 cleaning: 3% NaCl and Mixed solution, vortex spray, flow rate Secondary cleaning: ultrasonic cleaning with a mixed solution of 0.05% tea saponin and 0.2% citric acid at a frequency of 40kHz and a temperature of 35±1℃; Tertiary cleaning: rotary soaking with a mixed solution of 1% β-cyclodextrin and 0.5% trehalose at a pH of 6.0 and a stirring speed of 20rpm.

[0007] As a further aspect of the present invention: the enzyme preparations used for deodorizing by enzymatic treatment in step 3 are 0.15% lipase and 0.05% flavor protease, and the treatment conditions are 45±0.5℃ and pH 6.8-7.2.

[0008] As a further aspect of the present invention: the supercritical fluid described in step 3 The extraction conditions were: pressure 35 MPa, temperature 45 °C, entrainer 5% ethanol, and dynamic circulation time 2 hours.

[0009] As a further aspect of the present invention: the vacuum microwave drying in step 3 adopts a three-stage cooling process, gradually reducing the temperature from 45°C to 25°C, with the final water activity Aw ≤ 0.65.

[0010] As a further aspect of the present invention: the wall material used for the biphasic microcapsule encapsulation in step 4 is sodium alginate and whey protein in a mass ratio of 3:1.

[0011] As a further aspect of the present invention: the natural deodorizing agent compound in step 4 includes mogroside V (0.008%), vanilla bean extract (0.003%) and sugarcane polyphenols (0.02%).

[0012] As a further aspect of the present invention: the ultra-high pressure sterilization conditions in step 5 are 600MPa, 4℃, and 3 minutes; the nitrogen-filled packaging uses a PET / AL / CPP composite film with a residual oxygen content ≤0.8%.

[0013] A system for achieving the above-mentioned efficient preparation process of odorless, ready-to-eat frog oil includes: a circulating water holding tank, a three-stage countercurrent cleaning system, a jacketed enzymatic hydrolysis tank, and a supercritical fluid processing unit. Extraction units, vacuum microwave drying equipment, high-pressure homogenizers, spray drying towers, ultra-high pressure sterilization equipment, and nitrogen-filled packaging machines.

[0014] Compared with the prior art, the beneficial effects of the present invention are: This application is the first to combine three-stage countercurrent washing, bio-enzymatic hydrolysis, and supercritical fluid. Extraction combined with other methods achieves efficient deodorization and nutrient retention, with fishy substances (trimethylamine) ≤10ppm, hexanal removal rate ≥92%, frog oil integrity ≥95%, and thiobarbituric acid value (TBARS) ≤0.5mgMDA / kg. Through segmented vacuum microwave drying and biphasic microencapsulation technology, the oxidation and flavor loss of frog oil are solved. Under nitrogen-filled packaging, the shelf life can reach 24 months. The ethanol recovery rate of supercritical extraction is ≥85%, the overall energy consumption is reduced by 30%, and the production cost is reduced by 20%. Detailed Implementation

[0015] The technical solution of this application will be further described in detail below with reference to specific embodiments.

[0016] The embodiments of this application are described in detail below. Examples of these embodiments are shown, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0017] In one embodiment of the present invention, a highly efficient process for preparing odorless, ready-to-eat forest frog oil includes the following steps: Step 1, Raw Material Pretreatment: Fresh forest frogs are placed in a recirculating water holding tank, with the water temperature controlled at 12-15℃. Green tea extract and vitamin C are added, and the frogs are held for 72 hours, with 50% of the water changed daily, and the ammonia nitrogen concentration controlled at ≤0.2mg / L. Subsequently, the frogs are treated in a quick-freezing tunnel (-35℃, 30min) and a low-temperature thawing chamber (4℃, 12h) to ensure that the oviduct integrity is ≥95% and the impurity rate is ≤0.3%. Step 2, Multi-stage Countercurrent Cleaning: Perform three stages of cleaning sequentially: Primary cleaning: A vortex spray cleaning process is performed using a mixed solution of 3% NaCl and 0.1% NaHCO3, with a flow rate of... ; Secondary cleaning: Ultrasonic cleaning is performed using a mixed solution of 0.05% tea saponin and 0.2% citric acid at a frequency of 40kHz and a temperature of 35±1℃. Three-stage cleaning: Rotary soaking cleaning was performed using a mixed solution of 1% β-cyclodextrin and 0.5% trehalose at pH 6.0 and a stirring speed of 20 rpm. The water used for cleaning is Reverse osmosis water, conductivity After washing, the residue is ≤0.5g / kg; Step 3, combined biological and physical deodorization: includes: Enzymatic deodorization: Lipase (0.15%) and flavor protease (0.05%) were used, along with a compound antioxidant, and the mixture was treated with intermittent stirring at 45±0.5℃ and pH 6.8-7.2. Supercritical CO2 extraction: Extracted under pressure of 35 MPa and temperature of 45 °C with 5% ethanol in a dynamic circulation for 2 hours; Vacuum microwave drying: A three-stage cooling process is adopted, gradually reducing the temperature from 45℃ to 25℃, so that the water activity Aw of the final product is ≤0.65; Step 4, Flavor Locking and Encapsulation: Includes: Biphasic microcapsule encapsulation: Sodium alginate and whey protein at a mass ratio of 3:1 were used as wall materials to encapsulate forest frog oil extract. After high-pressure homogenization (50MPa, 2 times), it was spray-dried with an inlet air temperature of 160℃. Natural deodorizing agent compound: with added mogroside V (0.008%), vanilla bean extract (0.003%) and sugarcane polyphenols (0.02%). Step 5, Sterilization and Packaging: Includes: High-pressure sterilization (HPP): Treat at 600MPa and 4℃ for 3 minutes; Nitrogen-filled packaging: Nitrogen-filled packaging is carried out using PET / AL / CPP composite film, and the residual oxygen content is controlled to be ≤0.8%.

[0018] A system for achieving the above-mentioned efficient preparation process of odorless, ready-to-eat frog oil includes: a circulating water holding tank equipped with an ozone aeration system and a temperature control device; a three-stage countercurrent cleaning system, including a vortex spray device, an ultrasonic cleaning tank, and a rotating soaking tank; a jacketed enzymatic hydrolysis tank equipped with a temperature control and stirring device; and a supercritical fluid dynamics system. The extraction unit is equipped with an ethanol recovery device; a vacuum microwave drying device; a high-pressure homogenizer and a spray drying tower; an ultra-high-pressure sterilization device; and a nitrogen-filled packaging machine. Example 1

[0019] Take 500 kg of fresh forest frogs and process them according to the following steps: Temporarily incubate in a circulating water tank for 72 hours at a water temperature of 13℃, add 0.1% green tea extract (EGCG content 55%) and 0.05% vitamin C, change 50% of the water daily, and control the ammonia nitrogen concentration at 0.15mg / L; After being treated in a quick-freezing tunnel (-35℃, 30 min) and a low-temperature thawing chamber (4℃, 12 h), the integrity of the fallopian tubes reached 96%, and the impurity rate was 0.28%. The process involved three stages of countercurrent washing, resulting in a residue level of 0.45 g / kg after washing. Enzymatic deodorization is carried out in a jacketed enzymatic hydrolysis tank, followed by supercritical fluid extraction. Extraction yielded a hexanal removal rate of 93.5%. The water activity Aw of the product after vacuum microwave drying is 0.62; It adopts biphasic microcapsule encapsulation with an encapsulation rate of 91.2%, and is formulated with added natural deodorizing agents; After ultra-high pressure sterilization (600MPa, 4℃, 3min), the total bacterial count is ≤80CFU / g; Nitrogen-filled packaging, residual oxygen content 0.7%.

[0020] This efficient process and system for preparing odorless, ready-to-eat frog oil thoroughly removes the fishy smell, with fishy substances (trimethylamine) ≤10ppm and hexanal removal rate ≥92%; it retains nutrients well, with frog oil integrity ≥95% and thiobarbituric acid value (TBARS) ≤0.5mgMDA / kg; it has a long shelf life, up to 24 months under nitrogen-filled packaging; it is energy-saving and environmentally friendly, with ethanol recovery rate ≥85%, overall energy consumption reduced by 30%, and production costs reduced by 20%.

[0021] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present invention, and these should also be considered within the scope of protection of the present invention. These will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. A high-efficiency preparation process for odorless, ready-to-eat forest frog oil, characterized in that, Includes the following steps: Step 1, Raw material pretreatment: Live forest frogs are temporarily kept in a circulating water system with added green tea extract and vitamin C, with the water temperature controlled at 12-15℃ for 72 hours, with 50% of the water changed daily, and the ammonia nitrogen concentration ≤0.2mg / L; then they are processed through a quick-freezing tunnel and a low-temperature thawing chamber. Step 2, Multi-stage Countercurrent Cleaning: Perform three stages of cleaning sequentially, including the first stage... Solution spray cleaning, secondary tea saponin-citric acid solution ultrasonic cleaning, and tertiary β-cyclodextrin-trehalose solution rotary soaking cleaning; Step 3, combined biological-physical deodorization: including enzymatic deodorization and supercritical fluid extraction. Extraction and vacuum microwave drying; Step 4, Flavor Locking and Encapsulation: This includes biphasic microcapsule encapsulation and the formulation of natural anti-odor agents; Step 5, Sterilization and Packaging: This includes ultra-high pressure sterilization and nitrogen-filled packaging.

2. The efficient preparation process of odorless, ready-to-eat frog oil according to claim 1, characterized in that, The quick-freezing tunnel in step 1 is set at -35°C for 30 minutes, and the low-temperature thawing chamber is set at 4°C for 12 hours.

3. The efficient preparation process of odorless, ready-to-eat frog oil according to claim 1, characterized in that, The specific parameters for the three-stage cleaning described in step 2 are as follows: Stage 1 cleaning: 3% NaCl and Mixed solution, vortex spray, flow rate Secondary cleaning: ultrasonic cleaning with a mixed solution of 0.05% tea saponin and 0.2% citric acid at a frequency of 40kHz and a temperature of 35±1℃; Tertiary cleaning: rotary soaking with a mixed solution of 1% β-cyclodextrin and 0.5% trehalose at a pH of 6.0 and a stirring speed of 20rpm.

4. The efficient preparation process of odorless, ready-to-eat frog oil according to claim 1, characterized in that, The enzyme preparations used for deodorizing in step 3 are 0.15% lipase and 0.05% flavor protease, and the treatment conditions are 45±0.5℃ and pH 6.8-7.

2.

5. The efficient preparation process of odorless, ready-to-eat forest frog oil according to claim 1, characterized in that, The supercritical state described in step 3 The extraction conditions were: pressure 35 MPa, temperature 45 °C, entrainer 5% ethanol, and dynamic circulation time 2 hours.

6. The efficient preparation process of odorless, ready-to-eat forest frog oil according to claim 1, characterized in that, The vacuum microwave drying process described in step 3 employs a three-stage cooling process, gradually reducing the temperature from 45°C to 25°C, with the final water activity Aw ≤ 0.

65.

7. The efficient preparation process of odorless, ready-to-eat frog oil according to claim 1, characterized in that, The wall material used for the biphasic microcapsule encapsulation in step 4 is sodium alginate and whey protein in a mass ratio of 3:

1.

8. The efficient preparation process of odorless, ready-to-eat forest frog oil according to claim 1, characterized in that, The natural deodorizing agent compound mentioned in step 4 includes mogroside V (0.008%), vanilla bean extract (0.003%), and sugarcane polyphenols (0.02%).

9. The efficient preparation process of odorless, ready-to-eat forest frog oil according to claim 1, characterized in that, The ultra-high pressure sterilization conditions in step 5 are 600 MPa, 4°C, and 3 minutes; the nitrogen-filled packaging uses a PET / AL / CPP composite film with a residual oxygen content ≤0.8%.

10. A system for implementing the efficient preparation process of odorless, ready-to-eat frog oil according to any one of claims 1-9, characterized in that, include: Circulating water holding tank, three-stage countercurrent cleaning system, jacketed enzymatic hydrolysis tank, supercritical water Extraction units, vacuum microwave drying equipment, high-pressure homogenizers, spray drying towers, ultra-high pressure sterilization equipment, and nitrogen-filled packaging machines.