Alcohol tricholoma matsutake fungus bag production process

Abstract

The invention discloses a production process of an alcohol tricholoma matsutake fungus bag, which realizes standardized production of the fungus bag by optimizing the raw material ratio (70-80 parts of sawdust, 15-25 parts of wheat bran and the like), innovating a four-stage sterilization method (preheating at the temperature of 55 DEG C, sterilizing at the temperature of 125 DEG C and cooling in a gradient manner) and a closed liquid inoculation technology. According to the process, the biotransformation rate of the fungus bags is increased to 1: 1.8, the single-stick productivity is 0.8-1.2 kg, the pollution rate is reduced to 0.3%, the technical problems of insufficient raw material standardization, high sterilization energy consumption, high pollution rate and the like in the traditional process are solved, and reliable guarantee is provided for industrial cultivation of the mellow tricholoma matsutake.

Description

Technical Field

[0001] This invention relates to the field of edible fungi cultivation technology, specifically to the production process of matsutake mushroom spawn bags containing alcohol. Background Technology

[0002] The global edible fungi market has grown at an average annual rate of 8.2% (2020-2025), but the standardization rate of mushroom bag production in my country is less than 43%, with traditional workshop-style production still dominating. The existing mushroom bag raw material ratios are chaotic (the proportion of sawdust fluctuates by ±18%), resulting in a difference of ±15% in mycelial growth rate, which seriously affects the uniformity of mushroom production. The traditional sterilization process uses a high temperature of 121℃ for 4 hours, with an energy consumption of 1.2 kW·h per mushroom bag, and there is also the problem of incomplete sterilization at cold spots.

[0003] Open inoculation leads to a contamination rate of 8%-12%, resulting in annual economic losses of over 1.5 billion yuan; the lack of pretreatment of agricultural and forestry waste results in a general impurity content of wood chips exceeding 12%, increasing the risk of contamination.

[0004] my country produces approximately 900 million tons of agricultural and forestry waste annually, but the utilization rate in the edible fungi industry is less than 35%, resulting in serious resource waste. Furthermore, the shelf life of mushroom bags is short (only 90 days with traditional processes), and the loss rate during cross-regional distribution reaches 15%-20%. Summary of the Invention

[0005] The purpose of this invention is to provide a process for producing matsutake mushroom spawn using alcohol.

[0006] To achieve the above objectives, this invention utilizes the following technical solution: A production process for matsutake mushroom spawn bags employs a specific raw material system. Wood chips are the primary carbon source (70-80 parts), supplemented with wheat bran (15-25 parts) as the nitrogen source, and further supplemented with soybean meal (1-3 parts) and corn flour (0.5-2 parts) to provide trace elements. Light calcium carbonate (0.8-1.5 parts) adjusts the pH to a slightly alkaline environment. Fermented pine wood chips are used, and gypsum powder (0.5-1.2 parts) enhances the stability of the culture medium structure. The moisture content of the raw materials is strictly controlled at 58-62% to ensure a balance between water supply and demand during mycelial growth. This formulation, through the scientific combination of agricultural and forestry waste and nutrient additives, reduces raw material costs while improving the air permeability and water retention of the spawn bags, providing a balanced nutritional supply for the matsutake mycelium.

[0007] Furthermore, 8-12 mesh broadleaf tree wood chips are selected and soaked in lime water at a 1:1 volume ratio for 24 hours before being dried. This treatment softens the wood fiber structure, improves the biodegradability of the wood chips, and the lime water effectively kills surface bacteria, reducing the pressure of subsequent sterilization. The dried wood chip particles are loose and porous, ensuring air permeability while avoiding excessive compaction, creating favorable conditions for mycelial penetration and the diffusion of metabolic waste, ultimately improving the overall conversion efficiency of the spawn bag.

[0008] Furthermore, the preparation process comprises three core steps: In the raw material mixing stage, a tank mixer is used to stir at a low speed of 25 rpm for 45 minutes to avoid high-speed shearing damaging the material structure; in the bagging stage, an automatic bagging machine achieves high-precision filling of ±50g per bag, ensuring sterilization uniformity; the four-stage sterilization method uses stepped temperature control (55℃ preheating → 125℃ sterilization → gradient cooling → ≤35℃ cooling) to thoroughly kill thermophilic bacteria while avoiding condensation residue caused by sudden cooling. This process increases the sterilization pass rate to 99.8% while saving 32% energy compared to traditional methods.

[0009] Furthermore, the sterilization process takes place in a sealed tunnel-type sterilization cabinet, maintaining a pressure environment of 0.12-0.15 MPa inside. This high-pressure environment raises the boiling point of water to above 121°C, enhancing sterilization penetration, especially targeting sterilization dead zones in deep materials. The heat recovery system recycles the high-temperature steam condensate after sterilization, achieving tiered heat utilization in conjunction with pressure regulation. Compared to traditional sterilization equipment, this saves over 40% of water and reduces unit energy consumption by 35%.

[0010] Furthermore, the inoculation device integrates a sterile inoculation chamber, a liquid culture storage tank, and a quantitative inoculation pump. The sterile chamber is equipped with a high-efficiency air filtration system (HEPA filter with a 0.3μm filter and a 99.97% interception rate), combined with positive pressure maintenance technology, to ensure an environmental cleanliness level of 10,000. The liquid culture storage tank uses a constant temperature control system (25±0.5℃) to maintain the activity of the culture; the quantitative pump achieves precise inoculation volume control of 0.5-1.0mL / bag, improving inoculation efficiency by 4 times compared to traditional solid culture inoculation, with a single batch inoculation error rate of <1%.

[0011] Furthermore, the inoculation chamber is equipped with a UV-C ultraviolet lamp group with a wavelength of 253.7nm and an irradiation intensity of ≥90μW / cm². 2 The UV-C light wave lasts for 30 seconds. It can destroy the DNA structure of microorganisms and inactivate both airborne bacteria and spores on object surfaces. Combined with the in-cabin laminar flow purification system (wind speed 0.35m / s), it can achieve dynamic disinfection of the inoculation area, reducing the contamination rate of the inoculation bags from 8-12% in traditional processes to below 0.3%, significantly improving the finished product qualification rate.

[0012] Furthermore, during the fermentation stage, the temperature is controlled at 22-25℃, humidity at 85-90%, and CO2 concentration at 0.1-0.15%, maintaining a weakly anaerobic environment. This combination of parameters inhibits the proliferation of aerobic bacteria while promoting the formation of the *Matsutake* mycelial network. The CO2 concentration gradient stimulates primordia differentiation, resulting in shorter fruiting body stalks and thicker caps, thus improving the commercial grade. In the later stages of fermentation, intermittent ventilation (15 minutes per hour, wind speed 0.3-0.5 m / s) is used to balance oxygen supply and humidity, preventing excessive CO2 accumulation that could lead to deformed mushrooms.

[0013] Furthermore, the ventilation strategy in the later stages of fermentation is achieved through timed start-stop fan operation: each ventilation session lasts 15 minutes at a wind speed of 0.3-0.5 m / s. This design removes excess CO2 while maintaining a humidity drop of less than 5%, preventing the surface of the culture bags from hardening due to dehydration. The alternating ventilation and sealing cycles create a dynamic microenvironment, allowing mycelial respiration and material transformation to achieve optimal coupling, ultimately shortening the fermentation cycle to 150 days, a 25% reduction compared to conventional processes.

[0014] Furthermore, the fully automated production line integrates four functional units: raw material processing, sterilization, inoculation, and fermentation. These units are seamlessly connected via stainless steel conveyor belts. The raw material processing unit is equipped with an AI visual recognition system to automatically remove foreign objects; the sterilization unit features a double-door design, enabling continuous production while maintaining batch isolation; and the inoculation unit uses a six-axis robotic arm to precisely position multi-sized spawn bags. The entire line has a daily capacity of ≥50,000 bags, representing a 15-fold increase in efficiency compared to traditional manual production lines, an 80% reduction in labor costs, and a significant improvement in product consistency.

[0015] Furthermore, in factory-scale cultivation, a reasonable density of 80-100 bags per square meter of cultivation area is achieved, maximizing space utilization through a three-dimensional cultivation rack. At this density, the competitive pressure between the bags is moderate, the CO2 concentration gradient promotes stipe thickening, and the uniform light distribution ensures consistent fruiting body color. Coupled with a micro-sprinkler irrigation system (atomized particle size 50-80μm) and intelligent temperature and humidity control, the biological efficiency of matsutake mushrooms reaches 85-95% (dry matter conversion rate), more than 30% higher than traditional ground cultivation methods, resulting in a significant increase in yield per unit area.

[0016] This invention provides a process for producing matsutake mushroom spawn bags using alcohol, which has the following beneficial effects:

[0017] (1) Using the golden ratio of "wood chips: wheat bran: auxiliary materials = 70:20:10", the wood chips are pretreated with 1:1 lime water, which increases the lignin degradation rate by 42% and the cellulose utilization rate by 35%. Adding 0.8-1.5% light calcium carbonate to adjust the pH to a slightly alkaline environment inhibits bacterial growth and extends the shelf life of the inoculum to 180 days (the traditional process is only 90 days).

[0018] (2) The four-stage temperature-controlled sterilization method saves 32% more energy than the traditional process, and the energy consumption per unit of bacteria bag is reduced to 0.81 kW·h; the heat recovery system of the tunnel sterilizer enables the cooling water to be recycled at a rate of 89%, saving 1,200 tons of water per million bags per year.

[0019] (3) The closed liquid inoculation system enables precise control of bacterial age (18-22 hours spore stage), increasing inoculation efficiency by 4 times and contamination rate <0.3%; the Class 10,000 cleanroom is combined with UV-C ultraviolet disinfection (irradiation intensity ≥90μW / cm²). 2 Airborne particles <3500 / m 3.

[0020] (4) Each ton of mushroom bag consumes 1.2 tons of agricultural and forestry waste. The production line with an annual processing capacity of 30,000 tons can consume 36,000 mu of farmland straw. The organic matter content of the mushroom residue is >35%, and the total nitrogen, phosphorus and potassium nutrients are ≥6%. It can be directly used as organic fertilizer to improve the soil structure.

[0021] (5) A production line with a daily capacity of 50,000 bags can drive 500 surrounding farmers to participate in raw material collection and create 200 seasonal jobs; standardized mushroom bags can increase the success rate of mushroom production for farmers to 92% (compared to only 65% ​​in the traditional model), with an average annual income increase of more than 28,000 yuan per household. Detailed Implementation

[0022] Example 1

[0023] When preparing matsutake mushroom spawn bags, select broadleaf wood chips with a diameter of 8-12 mesh, and mix them at a ratio of 60% with 25% wheat bran, 2% soybean meal, 1% corn flour, 10% fermented pine wood chips, 1% light calcium carbonate, and 1% gypsum powder. The wood chips are pre-soaked in lime water (volume ratio 1:1) for 24 hours, drained, and then added to a trough mixer along with the other auxiliary materials. The mixture is stirred at 25 rpm for 45 minutes to precisely control the moisture content to 60%. The mixture is then filled into polypropylene corner bags using an automatic bagging machine, with a single bag weight deviation not exceeding ±50 grams. After bagging, the spawn bags undergo a four-stage temperature control process in a tunnel sterilizer: first, preheating to 55℃ for 30 minutes, then raising the temperature to 125℃ and maintaining it for 90 minutes, followed by a gradual cooling at a rate of 80℃ per hour, and finally cooling to below 35℃. The entire sterilization process is carried out under a pressure of 0.12-0.15 MPa to ensure complete inactivation of contaminating microorganisms. After sterilization, the spawn bags are transferred to a Class 10,000 cleanroom, where 0.5 ml of liquid inoculum (18-22 hours old) is injected using a closed inoculation device. The inoculated spawn bags are then placed in a fermentation chamber and cultured for 18 days at a temperature of 22-25℃, humidity of 85-90%, and carbon dioxide concentration of 0.1-0.15%. During the later stages of fermentation, ventilation is maintained for 15 minutes per hour at a speed of 0.3 m / s, ultimately yielding high-quality spawn bags with a bioconversion rate of 1:1.8.

[0024] Example 2

[0025] In the production of matsutake mushroom spawn bags, a combination of 45% sawdust, 20% wheat bran, 30% fermented pine sawdust, 2% soybean meal, 1.5% corn flour, 1.2% light calcium carbonate, and 0.8% gypsum powder is used. The sawdust is soaked in a 1:1 lime water solution for 24 hours, then dried and mixed with other raw materials. The mixture is stirred at 25 rpm for 45 minutes, and the moisture content is adjusted to 58%. During bagging, an automated machine is used to dispense the mixture into polypropylene corner bags, with the weight error of each bag controlled within ±50 grams. The sterilization stage uses a tunnel sterilizer, sequentially executing a preheating process at 55℃ for 30 minutes, a high-temperature sterilization at 125℃ for 90 minutes, a gradient cooling process at 80℃ / hour, and a cooling process at ≤35℃, while maintaining the pressure inside the sterilizer at 0.13-0.14 MPa. After sterilization, the spawn bags are injected with 1.0 ml of liquid inoculum (18-22 hours old) in a sterile environment using a quantitative inoculation pump. During the fermentation stage, maintain a temperature of 23-24℃, humidity of 88%, and carbon dioxide concentration of 0.12% for 20 days before transitioning to mushroom production management. During cultivation, place 80 mushroom bags per square meter, controlling the temperature at 12-15℃ and humidity at 80-85%, ultimately achieving a fruiting body yield of 0.9 kg / bag and a bioconversion rate of 1:1.85.

[0026] Example 3

[0027] The raw material composition for preparing matsutake mushroom spawn bags is as follows: 60% sawdust, 20% fermented pine sawdust, 15% wheat bran, 3% soybean meal, 0.5% corn flour, 0.8% light calcium carbonate, and 0.7% gypsum powder. The sawdust is soaked in a 1:1 lime water solution for 24 hours, dried, and then mixed with other auxiliary materials and stirred at 25 rpm for 45 minutes, with the moisture content accurate to 62%. Polypropylene corner-fold bags are used for packaging, with the weight deviation of a single bag controlled within ±50 grams. The sterilization process is carried out in stages in a tunnel sterilizer: preheating at 55℃ for 30 minutes, sterilization at 125℃ for 90 minutes, and a gradient cooling at 80℃ / hour, finally cooling to below 35℃, with the pressure inside the sterilizer maintained at 0.14-0.15 MPa. After sterilization, the spawn bags are injected with 0.8 ml of liquid inoculum (18-22 hours old) using a quantitative inoculation device in a sterile workshop. During the fermentation stage, the temperature was maintained at 24-25℃, humidity at 90%, and carbon dioxide concentration at 0.15% for 22 days. In the later stages of fermentation, intermittent ventilation was used, ventilating for 15 minutes per hour at a wind speed of 0.5 m / s. During cultivation, 100 mushroom bags were placed per square meter, with the temperature controlled at 12-15℃ and humidity at 80-85%. The final fruiting body yield reached 1.2 kg / bag, with a bioconversion rate of 1:1.9, and the mushroom bags had a shelf life of up to 180 days.

[0028] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A process for the production of alcohol truffle capsules, characterized in that: It is made from the following raw materials in parts by weight: 70-80 parts sawdust, 15-25 parts wheat bran, 1-3 parts soybean meal, 20-50 parts fermented pine sawdust, 0.5-2 parts corn flour, 0.8-1.5 parts light calcium carbonate, and 0.5-1.2 parts gypsum powder. The moisture content of the raw materials is controlled at 58-62%.

2. The alcohol truffle bar production process according to claim 1, wherein: The wood chips are broad-leaved tree chips with a diameter of 8-12 mesh, which are soaked in lime water at a 1:1 volume ratio for 24 hours and then dried before use.

3. The alcohol truffle bar production process of claim 1, wherein Includes the following steps: a) Raw material mixing: Add each component into a tank mixer according to the proportion and stir at 25 rpm for 45 minutes; b) Bagging process: Use an automatic bagging machine to fill polypropylene corner bags, with a filling deviation of ≤±50g; c) Four-stage sterilization: sequentially preheating at 55℃ for 30 min → sterilizing at 125℃ for 90 min → gradient cooling at 80℃ / h → cooling at ≤35℃.

4. The alcohol truffle bar production process of claim 3, wherein: The sterilization process is carried out in a tunnel-type sterilizer, with the pressure inside the cabinet maintained at 0.12-0.15 MPa.

5. The inoculation device for alcohol truffle mushroom bag production process according to claim 1, characterized in that: It includes a sterile inoculation chamber, a liquid culture storage tank, and a quantitative inoculation pump, with the inoculation volume controlled at 0.5-1.0 mL / bag.

6. The apparatus for alcohol truffle production process according to claim 5, wherein: The inoculation cabin is provided with a UV-C ultraviolet lamp group, and the irradiation intensity is ≥90 μW / cm 2 , and the irradiation time is 30 seconds.

7. The alcohol truffle bar production process of claim 1, wherein: The fermentation chamber temperature is maintained at 22-25℃, humidity at 85-90%, CO2 concentration at 0.1-0.15%, and the culture period is 150 days.

8. The process for producing matsutake mushroom spawn according to claim 7, characterized in that: During the later stages of fermentation, intermittent ventilation is used, with ventilation for 15 minutes per hour at a wind speed of 0.3-0.5 m / s.

9. The mushroom bag production line for the production process of matsutake mushroom bags according to claims 1-8, characterized in that: It includes a raw material processing unit, a sterilization unit, an inoculation unit, and a fermentation unit. Each unit is connected by an automated conveyor belt, with a daily production capacity of ≥50,000 bags.

10. The process for producing matsutake mushroom spawn according to claim 1, characterized in that: When applied to the industrialized cultivation of matsutake mushrooms, 80-100 mushroom bags can be placed per square meter of cultivation area, with a biological efficiency of 85-95%.