Dynamic and static coupling fermentation method and system for hot peppers

Abstract

The invention discloses a dynamic and static coupling fermentation method and system for hot peppers, and belongs to the technical field of food fermentation processing. The method comprises the steps of raw material pretreatment, collaborative batching and inoculation, cyclic dynamic three-stage fermentation, cyclic termination and material transfer, static fermentation storage and final treatment. The system comprises a dynamic fermentation subsystem, a circulation control unit and a static storage subsystem. The dynamic fermentation subsystem is composed of three fermentation sections which are sequentially connected in series and have different functions, materials are circulated for multiple times in the dynamic fermentation subsystem through a circulation control unit, and rapid anaerobic starting, mild dynamic homogenizing and curing monitoring are achieved respectively; when the pH value is monitored to reach a threshold value, the discharging mode is automatically switched, and the materials are conveyed to the static storage subsystem for static after-ripening. Mass transfer and homogenization are enhanced through dynamic circulation, flavor is stabilized through static storage, the problems that traditional static fermentation is low in efficiency and poor in uniformity are solved, and high efficiency, homogenization, controllability and automation of the fermentation process are achieved.

Description

Technical Field

[0001] This invention relates to the field of food fermentation and processing technology, specifically to a fermentation method for chili pepper embryos, and particularly to a dynamic and static coupled fermentation method and system for chili peppers. Background Technology

[0002] Fermented chili products (such as pickled chilies, chili sauce, and chili flakes used as a raw material for broad bean paste) are important traditional condiments. Traditional chili fermentation often uses static fermentation methods such as pickling jars and pits, which have problems such as difficulty in controlling process parameters, limited production scale, susceptibility to contamination by miscellaneous bacteria, and poor fermentation uniformity, resulting in large quality fluctuations between batches and difficulty in ensuring consistent flavor.

[0003] Existing technologies include improved tank fermentation schemes (such as CN107279880A), which involve placing dried chili pepper embryos in a fermentation tank, adding lactic acid bacteria powder, and using inert gas for oxygen isolation protection, conducting static anaerobic fermentation under constant temperature conditions. This method improves process controllability to some extent, reduces the risk of harmful microbial contamination, and is suitable for continuous production on a certain scale. However, this technology still falls under the category of static or semi-static fermentation. The materials are essentially in a static state during fermentation, and the contact between lactic acid bacteria and materials, the diffusion of metabolites, and the formation of flavor substances mainly rely on natural penetration and diffusion. This results in slow fermentation start-up, a long cycle (usually more than 15 days), and the easy formation of temperature, acidity, and microbial distribution gradients within the tank, causing significant differences in flavor and texture between different locations within and between batches of the product (acidity variation coefficient can reach 15-20%), resulting in poor uniformity. Furthermore, the single fermentation stage and static management method make it difficult to finely control different process requirements such as rapid start-up, deep fermentation, and flavor maturation, resulting in insufficient production flexibility.

[0004] Therefore, how to further improve fermentation efficiency, enhance flavor uniformity, achieve multi-stage fine control, and adapt to larger-scale continuous production while ensuring fermentation quality and safety has become an urgent technical problem to be solved in chili fermentation technology. Summary of the Invention

[0005] To address the problems existing in the prior art, the present invention aims to provide a dynamic and static coupled fermentation method and system for chili peppers. The present invention constructs a modular and automated coupled fermentation system by combining dynamic cyclic three-stage fermentation with static maturation and storage, thereby achieving high efficiency, uniformity and controllability of the fermentation process.

[0006] The objective of this invention is achieved through the following technical solution: A method for coupled dynamic and static fermentation of chili peppers includes the following steps: S1. Raw material pretreatment: Wash fresh chili peppers, remove stems, and process them into segments or slices.

[0007] S2. Synergistic ingredient preparation and inoculation: The pepper embryos are mixed evenly with salt and a synergistic fermentation additive composed of a natural antibacterial agent and a lactic acid bacteria fermentation agent; the natural antibacterial agent is selected from at least one of plant-derived extracts and microbial-derived antimicrobial peptides.

[0008] S3. Circulating Dynamic Three-Stage Fermentation: The mixed material is placed into a dynamic fermentation subsystem consisting of a first fermentation section, a second fermentation section, and a third fermentation section connected in series. The circulation mode is activated, allowing the material to pass through the first fermentation section, the second fermentation section, and the third fermentation section in sequence for three-stage dynamic fermentation. Then, the material is returned through a reflux pipeline located between the end of the third fermentation section and the beginning of the first fermentation section, and the fermentation is repeated multiple times.

[0009] S4. Circulation Termination and Material Transfer: When the pH value of the material at the end of the third fermentation stage reaches the predetermined threshold, the circulation mode is terminated, the reflux pipeline is closed, and all the material that has completed the dynamic fermentation cycle is transferred to the static storage subsystem.

[0010] S5. Static fermentation storage and final treatment: The material is statically fermented and stored at 10-20℃ for 2-7 days to complete the final maturation, and then discharged, packaged and sterilized.

[0011] Furthermore, the three-stage dynamic fermentation includes: The first stage (dynamic anaerobic start-up and colonization): The material is injected with inert gas driven by centrifugal force at 20-35℃ in the first fermentation section to quickly establish a deep anaerobic environment and start lactic acid-dominated fermentation. The second stage (dynamic homogenization primary fermentation): The material is subjected to gentle dynamic stirring by flexible and elastic mechanical parts at 25-30℃ in the second fermentation section to promote the formation and homogenization of flavor substances. The third stage (dynamic monitoring and circulation control): The material is matured in the third fermentation section at 15-25℃, and the pH value of the material is monitored in real time at the end of this section.

[0012] The fundamental principle of this invention lies in constructing a dynamic fermentation subsystem with cyclical material flow, coupled with a final static storage subsystem, thus achieving an organic combination of "dynamic enhancement" and "static maturation" in the fermentation process. In the dynamic circulation stage, the material circulates multiple times in a three-stage series system. Each stage provides differentiated treatment based on the different physiological and biochemical requirements of fermentation (rapid anaerobic establishment, gentle homogenization and agitation, and low-temperature maturation monitoring), greatly enhancing mass and heat transfer efficiency, accelerating the fermentation process, and ensuring uniform material processing. The system automatically switches operating modes based on real-time pH monitoring, achieving seamless transition and precise control from dynamic fermentation to static storage. The static storage stage provides the necessary conditions for further flavor integration and stabilization. This method, working synergistically with the system, solves the technical problems of low efficiency, poor uniformity, and coarse control inherent in traditional static fermentation.

[0013] Furthermore, the total cycle time for cyclic fermentation is preferably 307 days. The first stage consists of a single cycle of 6-10 hours to ensure sufficient oxygen removal; the second stage lasts 8-15 hours to achieve effective homogenization; and the third stage lasts 12-20 hours to complete the main acidification. The number of cycles is typically 3-10.

[0014] Furthermore, the natural antibacterial agent may be one or more of tea polyphenol extract, rosemary extract, and natamycin (microbial source), and its addition amount accounts for 0.01%-0.1% of the weight of pepper embryo.

[0015] In addition, the present invention also provides a chili dynamic and static coupled fermentation system for implementing the above method, which includes a dynamic fermentation subsystem, a circulation control unit and a static storage subsystem; The dynamic fermentation subsystem includes a first fermentation section, a second fermentation section, and a third fermentation section connected in series. Each fermentation section consists of at least two vertical fermentation tank units connected in series. A feed chute is connected to the feed inlet at the beginning of the first fermentation section. A switching conveyor mechanism is connected to the discharge outlet at the end of the third fermentation section. The circulation control unit includes a reflux pipeline, which is a closed chute or pipe. Its inlet end is connected to the switching conveying mechanism at the end of the third fermentation section, and its outlet end is connected to the feed chute at the beginning of the first fermentation section. A reflux control valve is provided on the reflux pipeline. An online pH sensor for monitoring the pH value of the material is provided at the discharge port at the end of the third fermentation section. The static storage subsystem includes multiple finished product fermentation tanks, and the feed pipe of the finished product fermentation tank is connected to the discharge port at the end of the third fermentation section through a switching conveying mechanism; The system configuration has two operating modes: Circulation mode: When the reflux control valve is turned on, the material circulates within the dynamic fermentation subsystem under the series connection of the circulation control unit; Discharge mode: The reflux control valve is closed, and all materials are transported from the third fermentation stage to the static storage subsystem.

[0016] Furthermore, the vertical fermenter unit includes a fermenter and a central screw conveyor; the fermenter has a feed inlet on the lower side wall and a discharge outlet on the upper side wall (each fermentation tube has a pressure relief valve at the top); adjacent fermenters in each fermentation section and adjacent fermenters in adjacent fermentation sections are connected in series by series pipelines, with the upper end of the series pipeline connected to the discharge outlet of the previous fermenter and the lower end connected to the feed inlet of the next fermenter; the central screw conveyor is used to screw-transport the material from the lower part of the fermenter to the upper part.

[0017] Furthermore, the bottom of the switching conveyor mechanism has at least three discharge ports, one of which is connected to the inlet end of the return pipeline, and the other discharge ports are respectively equipped with discharge mechanisms for docking with the finished product fermentation tank. The discharge mechanism includes a discharge pipe, a telescopic pipe, a docking sleeve, and an automatic telescopic rod. The discharge pipe is fixed to the bottom of the switching conveyor mechanism and communicates with the inside of the switching conveyor mechanism, and a discharge valve is provided on the discharge pipe. The telescopic pipe is connected to the bottom of the discharge pipe and can extend and retract vertically. The docking sleeve is connected to the bottom of the telescopic pipe and can dock with the feed pipe of the finished product fermentation tank. The automatic telescopic rod is fixed to the bottom of the switching conveyor mechanism, and its telescopic end is connected to the docking sleeve and can drive the docking sleeve to move up and down (causing the telescopic pipe to extend and retract vertically).

[0018] Furthermore, the switching conveying mechanism is a screw conveyor, which is controlled by the signal of the online pH sensor. When the pH reaches the threshold, the controller automatically controls the reflux control valve to close and the discharge valve to open, automatically switching from guiding the material to the reflux pipeline to guiding the static storage subsystem.

[0019] Furthermore, the chili dynamic and static coupled fermentation system also includes a fermentation broth collection and distribution subsystem; the fermentation broth collection and distribution subsystem includes a fermentation broth storage tank, a fermentation broth collection tank integrally fixed to the bottom of each fermentation tank, a fermentation broth collection pipe integrally fixed to the bottom of each series pipeline and connected to the series pipelines through multiple through holes, a reflux broth collection pipe integrally fixed to the bottom of the reflux pipeline and connected to the reflux pipelines through multiple through holes, a water pump for extracting fermentation broth from the fermentation broth collection tank, a main outlet pipe, and several branches. The fermentation broth storage tank and each fermentation broth collection tank are connected by a guide pipe; the lower end of the fermentation broth collection pipe is connected to the fermentation broth collection tank at the bottom of the fermentation tank connected to the lower end of the series pipe at the top of the fermentation broth collection pipe; the lower end of the reflux broth collection pipe is connected to the fermentation broth collection tank at the bottom of the fermentation tank at the beginning of the first fermentation section; one end of the main outlet pipe is connected to the outlet end of the water pump, and the other end is connected to the inlet end of each branch pipe; the outlet end of each branch pipe is connected to the outlet pipe of a discharge mechanism, and an electric valve is installed on each branch pipe.

[0020] Furthermore, the spiral blades of the central spiral conveyor in the first fermentation section have a cavity structure. The cavity of the spiral blade is connected to an inert gas source through a channel preset in the rotating shaft of the central spiral conveyor, and multiple exhaust holes are opened on the outer edge surface of the spiral blade to dynamically establish and maintain an anaerobic environment through centrifugal force in the first stage.

[0021] Furthermore, several sets of extended flexible stirring rods are fixed on the spiral blades of the central spiral conveyor in the second fermentation section, which are used to dynamically and with low damage turbulence and mixing of the material in the second stage.

[0022] Furthermore, the finished product fermentation tank is equipped with a sealed tank lid, and the upper space inside the tank can be connected to a food-grade inert gas for pressure maintenance; the feed conduit is integrally fixed to the tank lid and connected to the finished product fermentation tank.

[0023] The beneficial effects of this invention are as follows: (1) This invention greatly enhances the contact efficiency between lactic acid bacteria and materials through dynamic cyclic three-stage fermentation, and accelerates the fermentation start-up and process. Compared with traditional static tank fermentation, the total fermentation cycle can be shortened by about 30%.

[0024] (2) The circulation and segmented differential gentle stirring realize the homogenization of the material fermentation, solve the problem of uneven distribution of flavor substances commonly found in static fermentation, and improve the flavor consistency within and between batches of the product (in terms of acidity variation coefficient) to below 5%, which is significantly better than traditional processes (15-20%).

[0025] (3) The system achieves fully automatic switching from dynamic fermentation to static storage based on online pH monitoring, which greatly reduces manual intervention, improves the continuity and stability of production, and is suitable for large-scale industrial application.

[0026] (4) The closed system design, the dynamically established deep anaerobic environment, and the fermentation liquid collection and redistribution mechanism together constitute multiple hygiene barriers, effectively inhibiting the growth of harmful microorganisms such as Escherichia coli and mold, and making the product safer.

[0027] (5) This system and method have strong adaptability and scalability. It can process fresh chili peppers or dried chili pepper embryos. By adjusting parameters such as the number of cycles, temperature of each stage, and static storage time, different flavored chili pepper fermentation products can be flexibly produced. Attached Figure Description

[0028] Figure 1 This is a layout diagram of the dynamic and static coupled fermentation system for chili peppers according to the present invention.

[0029] Figure 2 This is a top view of the overall structure of the dynamic and static coupled fermentation system for chili peppers of the present invention.

[0030] Figure 3 for Figure 2 A cross-sectional view along the AA direction.

[0031] Figure 4 This is a schematic diagram of the structure of the vertical fermenter unit in the first fermentation section.

[0032] Figure 5 This is a schematic diagram of the structure of the vertical fermenter unit in the second fermentation section.

[0033] Figure 6 This is a schematic diagram of the return pipeline.

[0034] Figure 7 This is a schematic diagram of the structure for switching between the conveying mechanism and the discharge mechanism.

[0035] The diagram shows: 1-Dynamic fermentation subsystem; 101-First fermentation section; 102-Second fermentation section; 103-Third fermentation section; 2-Circulation control unit; 201-Recirculation pipeline; 202-Recirculation control valve; 3-Static storage subsystem; 301-Finished product fermentation tank; 302-Tank lid; 303-Feed conduit; 4-Feed chute; 5-Switching conveyor mechanism; 6-Online pH sensor; 7-Discharge mechanism; 701-Discharge pipe; 702-Telescopic pipe; 703-Connecting sleeve; 704-Automatic telescopic rod; 705-Discharge valve; 8-Fermentation broth collection and... Distribution subsystem; 801-Fermentation broth storage tank; 802-Fermentation broth collection tank; 803-Fermentation broth collection pipe; 804-Reflux broth collection pipe; 805-Water pump; 806-Main outlet pipe; 807-Branch pipe; 808-Guide pipe; 809-Electric valve; 9-Feed hopper; 10-Vertical fermenter unit; 11-Fermenter; 12-Inlet; 13-Outlet; 14-Pressure relief valve; 15-Series pipeline; 16-Central screw conveyor; 17-Screw blade; 18-Rotating shaft; 19-Exhaust port; 20-Flexible stirring rod; 21-Support frame. Detailed Implementation

[0036] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The described embodiments are merely some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1

[0037] This embodiment provides a dynamic and static coupled fermentation system for chili peppers, the overall structure of which is as follows: Figure 1 As shown, it mainly consists of a dynamic fermentation subsystem 1, a circulation control unit 2, a static storage subsystem 3, and a fermentation broth collection and distribution subsystem 8.

[0038] The dynamic fermentation subsystem 1 includes a first fermentation section 101, a second fermentation section 102, and a third fermentation section 103 connected in series via a series pipeline 15. The first fermentation section 101 and the third fermentation section 103 are formed by two vertical fermentation tank units 10 connected in series, and the second fermentation section 102 is formed by three vertical fermentation tank units 10 connected in series. The feed inlet 12 at the beginning of the first fermentation section 101 is connected to a feed chute 4, and the upper end of the feed chute 4 is connected to a feed hopper 9. The bottom of the feed hopper 9 is equipped with a gate valve. The discharge outlet 13 at the end of the third fermentation section 103 is connected to a switching conveyor mechanism 5. Each vertical fermentation tank unit 10 includes a fermentation tank 11 and a central spiral conveyor 16 vertically arranged inside the fermentation tank 11. The fermentation tank 11 is a vertical hollow cylindrical body used to provide a closed fermentation space. The lower part of the side wall of the fermentation tank 11 is provided with a feed inlet 12, and the upper part of the side wall of the fermentation tank 11 is provided with a discharge outlet 13, forming a flow path of material from bottom to top. Each fermenter 11 is equipped with a pressure relief valve 14 at the top to ensure system safety and prevent excessive pressure caused by abnormal fermentation and gas production. Adjacent fermenters 11 in each fermentation section and adjacent fermenters 11 in adjacent fermentation sections are connected in series via series pipes 15. The upper end of the series pipe 15 is connected (welded to) the discharge port 13 of the previous fermenter, and the lower end of the series pipe 15 is connected (welded to) the inlet 12 of the next fermenter. The central screw conveyor 16 is a screw conveyor, whose primary function is to vertically lift the material and drive it to move (convey) spirally upward from the lower inlet 12 of the fermenter 11 to the upper outlet 13. It is the power source for continuous material flow, and its rotation also plays a certain role in mixing the material. Each fermenter 11 is equipped with a geared motor at the top or bottom, which is connected to the rotating shaft 18 of the central screw conveyor 16 via a coupling. The speed of the motor is controlled by a frequency converter.

[0039] The first fermentation section 101 is designed to rapidly establish a deep anaerobic environment and initiate fermentation. The feed inlet of the initial fermentation tank 11 of the first fermentation section 101 is connected to the feed chute 4. The spiral blades 17 of each central screw conveyor 16 in this fermentation section have a hollow structure (i.e., designed as a hollow structure). The cavities of the spiral blades 17 are connected to an inert gas source through channels pre-installed in the rotating shaft 18 of the central screw conveyor. Multiple micron-sized exhaust holes 19 are uniformly opened on the outer surface of the spiral blades 17. The rotating shaft 18 is a hollow shaft, and its top end is connected to a fixed inert gas source pipeline through a rotating vent connector. The inner cavity of the rotating shaft 18 is connected to the cavity of the spiral blades 17 through radial holes. During system operation, inert gas is released from the exhaust holes 19 under centrifugal force, dynamically and efficiently establishing and maintaining the anaerobic environment of the material inside the tank. When the central screw conveyor 16 rotates, the centrifugal force throws the inert gas introduced into the cavity of the screw blades 17 out of the exhaust port 19 at high speed, directly acting on the lifted material clumps. This dynamic injection method, compared with the traditional static replacement method of filling the fermenter with gas from the top, can more quickly and thoroughly dissipate the oxygen in the gaps between materials, creating and maintaining an excellent anaerobic start-up environment for lactic acid bacteria, significantly inhibiting aerobic bacteria, and improving fermentation purity and start-up speed.

[0040] The function of the second fermentation section 102 is to promote the generation of flavor substances and achieve material homogenization. Several sets of extended flexible stirring rods 20 are fixedly installed on the spiral blades 17 of the central spiral conveyor 16 of the second fermentation section 102. These flexible stirring rods 20 are made of a stainless steel core coated with food-grade silicone, possessing good elasticity and corrosion resistance. They are used to gently and with low damage agitate the materials during transport, promoting mixing and mass transfer. The flexible stirring rods 20 are welded to the material-facing surface of the spiral blades 17 through their internal stainless steel cores. Each set consists of 305 rods evenly distributed along the spiral direction, with a length approximately 1 / 3 of the spiral blade radius. The stainless steel core is divided into upper and lower sections, connected by a spring. The lower section of the stainless steel core is welded to the material-facing surface of the spiral blades 17. When the spiral blades 17 rotate, the flexible stirring rods 20 swing accordingly, gently "stirring" and "turbulenting" the surrounding chili embryo material. This achieves two purposes: first, it avoids excessive damage to the chili tissue that may be caused by rigid stirring blades; second, through gentle and continuous stirring, it greatly promotes the uniform distribution of lactic acid bacteria, metabolites, salts, etc. in the material, breaking the temperature and concentration stratification commonly found in static fermentation, which is the key to achieving a highly uniform product flavor.

[0041] The function of the third fermentation stage 103 is to mature and monitor the material online. This stage mainly provides a relatively gentle low-temperature environment to allow flavor substances to further blend and mature. The discharge port 13 of the last fermentation tank 11 at the end of the third fermentation stage 103 is connected to the switching conveyor mechanism 5, which is supported by a support frame 21. The switching conveyor mechanism 5 is a screw conveyor with three outlets at its bottom. One outlet is connected to the inlet of the return pipeline 201, forming a circulation loop; the other two outlets are each connected to a discharge mechanism 7 for discharging materials into the static storage subsystem 3. The switching conveyor mechanism 5 is controlled by the signal from the online pH sensor 6. When the pH reaches the threshold, the controller automatically controls the return control valve 202 to close and the discharge valve 705 to open, automatically switching the material from the return pipeline 201 to the static storage subsystem 3.

[0042] The structure of the discharge mechanism 7 is as follows: Figure 3 As shown, it includes a discharge pipe 701, a telescopic pipe 702, a docking sleeve 703, and an automatic telescopic rod 704; the discharge pipe 701 is fixed to the bottom of the switching conveyor 5 and communicates with the inside of the switching conveyor 5, and a pneumatic discharge valve 705 is provided on the discharge pipe 701; the telescopic pipe 702 is connected to the bottom of the discharge pipe 701 and can extend and retract vertically, and adopts a telescopic corrugated pipe body; the docking sleeve 703 is flared and is connected to the bottom of the telescopic pipe 702. It can also connect to the feed pipe 303 of the finished product fermentation tank 301; the automatic telescopic rod 704 is fixed at the bottom of the switching conveying mechanism 5, and its telescopic end (push rod) is connected to the docking sleeve 703 and can drive the docking sleeve 703 to move up and down. The automatic telescopic rod 704 is an electric telescopic rod driven by a servo motor. There are two sets of them, which are evenly arranged on both sides of the discharge pipe 701. They are used to control the lifting and lowering of the docking sleeve 703 to realize the automatic docking and disconnection with the feed pipe 303 of the finished product fermentation tank 301.

[0043] The function of the circulation control unit 2 is to construct and control the closed-loop flow path of the material. The circulation control unit 2 has a return pipeline 201, which is a closed chute or pipe. Its inlet end is connected to the switching conveying mechanism 5 at the end of the third fermentation section 103, and its outlet end is connected to the feed chute 4 at the beginning of the first fermentation section 101. A return control valve 202 is provided on the return pipeline 201. An online pH sensor 6 for monitoring the pH value of the material is provided at the discharge port 13 at the end of the third fermentation section 103. The signal of the online pH sensor 6 is connected to the programmable logic controller (PLC). When the pH value is continuously detected to be ≤4.2 for more than 30 seconds, the PLC determines that the dynamic fermentation is complete and executes the following in sequence: a. Close the return control valve 202; b. Delay for 10 seconds (to ensure that the material in the return pipeline 201 is completely discharged); c. Open the designated discharge valve 705 and start the corresponding discharge mechanism 7 for docking.

[0044] The static storage subsystem 3 includes two finished product fermentation tanks 301. The feed conduit 303 (cylindrical) of each finished product fermentation tank 301 is connected to the discharge port 13 at the end of the third fermentation section 103 via a switching conveying mechanism 5. Each finished product fermentation tank 301 is equipped with a tank cover 302 with a locking device. The tank cover 302 is equipped with an air inlet valve, a safety valve, and a feed conduit 303, which can be connected to inert gas for pressure storage. The two finished product fermentation tanks 301 are fed alternately. When the first finished product fermentation tank 301 is being filled, the discharge valve 705 of the discharge mechanism 7 above the second finished product fermentation tank 301 is activated, but the connecting sleeve 703 of the discharge mechanism 7 is inserted downward into the feed conduit 303 of the finished product fermentation tank 301 under the action of the automatic telescopic rod 704, and inert gas is injected into the finished product fermentation tank 301 for later use. After the first finished product fermentation tank 301 is filled, the discharge valve 705 above the finished product fermentation tank 301 is closed. At the same time, the connecting sleeve 703 is disengaged from the feed pipe 303 of the finished product fermentation tank 301 by the action of the automatic telescopic rod 704. The finished product fermentation tank 301 is then moved away, and a sealing cap is placed on the feed pipe 303. Inert gas is then injected into the finished product fermentation tank 301 through the air inlet valve. The tank is then moved to the finished product storage area. After that, the discharge valve 705 of the second finished product fermentation tank 301 is opened for filling. At the same time, a new finished product fermentation tank 301 is moved to the position of the first finished product fermentation tank 301. After the second finished product fermentation tank 301 is filled, the material is stored. This process is repeated continuously.

[0045] The fermentation broth collection and distribution subsystem 8 includes a fermentation broth storage tank 801, a fermentation broth collection tank 802 integrally fixed to the bottom of each fermentation tank 11, a fermentation broth collection pipe 803 integrally fixed to the bottom of each series pipeline 15 and connected to the series pipeline 15 through multiple through holes, a reflux broth collection pipe 804 integrally fixed to the bottom of the reflux pipeline 201 and connected to the reflux pipeline 201 through multiple through holes, a water pump 805 for extracting fermentation broth from the fermentation broth collection tank 802, a main outlet pipe 806, and several branch pipes 807; the fermentation broth storage tank 801 and each fermentation broth collection tank 802 are respectively connected by a guide pipe 808. The lower end of the fermentation broth collection pipe 803 is connected to the fermentation broth collection tank 802 at the bottom of the fermentation tank 11, which is connected to the lower end of the top series pipe 15; the lower end of the reflux broth collection pipe 804 is connected to the fermentation broth collection tank 802 at the bottom of the fermentation tank 11 at the beginning of the first fermentation section 101; one end of the main outlet pipe 806 is connected to the outlet end of the water pump 805 (the inlet end of the water pump 805 is connected to a pipe extending below the liquid surface of the fermentation broth storage tank 801), and the other end is connected to the inlet end of each branch pipe 807; the outlet end of each branch pipe 807 is connected to the outlet pipe 701 of a discharge mechanism 7, and an electric valve 809 is installed on each branch pipe 807.

[0046] Each fermenter 11, the series pipeline 15, and the return pipeline 201 are equipped with a collection device (fermentation broth collection tank 802, fermentation broth collection pipe 803, and return broth collection pipe 804) to collect the seeping fermentation broth, which is then collected in the fermentation broth storage tank 801. The collected fermentation broth can be pumped back into the discharge pipe 701 during discharge via a water pump 805, main discharge pipe 806, branch pipe 807, and guide pipe 808, where it mixes with the solid material before entering the finished product fermenter 301. That is, while the solid material is being transported by the switching conveyor mechanism 5, the electric valve 809 of the branch pipe 807 connected to the discharge pipe 701 above the finished product fermenter 301 is simultaneously opened, mixing with the solid material in the discharge pipe 701 before entering the finished product fermenter 301 until it is full.

[0047] The system configuration has two operating modes: Circulation mode: Open the reflux control valve 202, switch the conveying mechanism 5 to guide the material to the reflux pipeline 201, and the material circulates in a closed loop in the dynamic fermentation subsystem 1 under the series connection of the circulation control unit 2, repeatedly undergoing the above three-stage treatment.

[0048] Discharge Mode: When the online pH sensor 6 detects that the pH value of the material has reached a preset threshold (e.g., 4.2) and stabilized, it sends a signal to the system controller (e.g., PLC). The controller then executes the following: ① closing the reflux control valve 202; ② controlling the switching conveyor 5 to switch the material flow path to the static storage subsystem 3; ③ starting the corresponding discharge mechanism 7 to connect with the feed pipe 303 of the finished product fermentation tank 301. The material is thus completely transported out of the dynamic fermentation subsystem from the third fermentation section 103. Example 2

[0049] This embodiment provides a method for the coupled dynamic and static fermentation of chili peppers, using the system described in Embodiment 1, and includes the following steps: S1. Raw material pretreatment: Select fresh red chili peppers, wash and remove the stems from the fresh chili peppers, and process them into pepper embryos with a length of 1.5-2.0 cm.

[0050] S2. Co-mixing and inoculation: Mix pepper embryos with 8% by weight of edible salt, 0.5% of freeze-dried Lactobacillus plantarum powder and 0.05% of tea polyphenol extract in a mixing tank until homogeneous.

[0051] S3. Circulating Dynamic Three-Stage Fermentation: The mixed material is placed into a dynamic fermentation subsystem 1 consisting of a first fermentation section 101, a second fermentation section 102, and a third fermentation section 103 connected in series. The circulation mode is started, the controller opens the reflux control valve 202 and closes the discharge valve 705, so that the material passes through the first fermentation section 101, the second fermentation section 102, and the third fermentation section 103 in sequence for three-stage dynamic fermentation, and then returns through the reflux pipeline 201 set between the end of the third fermentation section and the beginning of the first fermentation section for multiple cycles of fermentation. The three-stage dynamic fermentation includes: First stage (first fermentation section 101): The material temperature is controlled at 30℃. In the first fermentation section 101, the material is driven by the centrifugal force of the central screw conveyor 16 rotating at 10 rpm, while nitrogen is injected through the hollow screw blades 17 to quickly establish a deep anaerobic environment and initiate lactic acid-dominant fermentation. Each cycle, the first fermentation section 101 runs for 8 hours to ensure sufficient oxygen removal. This stage utilizes the dynamic inert gas injection through the hollow screw blades 17 to quickly establish and maintain a deep anaerobic environment. Each time the material flows through this section, it receives enhanced anaerobic treatment.

[0052] The second stage (second fermentation section 102): The material temperature is controlled at 28℃. In the second fermentation section 102, the material is driven by the centrifugal force of a central screw conveyor 16 rotating at 12 rpm. The central screw conveyor 16 drives a flexible stirring rod 20 (a flexible and elastic mechanical component) to gently and dynamically agitate the material, promoting the formation and homogenization of flavor compounds. Each cycle, the second fermentation section 102 runs for 12 hours to achieve effective homogenization. The gentle and dynamic agitation of the flexible stirring rod 20 strongly promotes the homogenization of the material, ensuring that lactic acid bacteria, nutrients, metabolites, and flavor precursors are fully contacted and evenly distributed throughout the batch. In the circulation mode, the material flows through this section multiple times, achieving deep homogenization through repeated gentle agitation.

[0053] The third stage (third fermentation section 103): The material temperature is controlled at 20℃. In the third fermentation section 103, the material is driven by centrifugal force from a central screw conveyor 16 rotating at 6 rpm. Maturation occurs at this fermentation stage, and the pH value of the material is monitored in real time at the end of this stage. Each cycle, the third fermentation section 103 runs for 16 hours to complete the main acidification.

[0054] The material circulates in three fermentation stages, with a total circulation time of 5 days.

[0055] The multiple cycles of materials throughout the system mean that each component undergoes differentiated treatment in the three stages described above. In this embodiment, the total cycle time is set at 5 days. During this period, the materials continuously undergo a cycle of "short-term deep anaerobic treatment → short-term homogenization and agitation → low-temperature maturation monitoring." This setup allows for more complete and thorough fermentation and flavor transformation. Furthermore, because the processing time for each stage can be flexibly optimized based on the number of cycles, the overall efficiency is far higher than that of traditional static fermentation.

[0056] S4. Cycle Termination and Material Transfer: When the online pH sensor 6 detects that the pH value of the material at the end of the third fermentation stage 103 reaches a predetermined threshold (e.g., 4.2, indicating that lactic acid fermentation is basically complete and the acidity is suitable), the system automatically determines that the dynamic fermentation stage has ended, terminates the cycle mode, and the controller immediately closes the reflux control valve 202 of the reflux pipeline 201, opens the designated discharge valve 705, and controls the automatic telescopic rod 704 to descend so that the docking sleeve 703 connects with the empty finished product fermentation tank 301, transferring all the material that has completed the cycle of dynamic fermentation to the static storage subsystem 3. When the discharge valve 705 is opened, the PLC simultaneously opens the electric valve 809 on the corresponding branch pipe 807 and starts the water pump 805, so that the fermentation liquid and solid material are mixed in a preset ratio (e.g., 1:5) and enter the finished product fermentation tank 301. When the finished product tank is full (as indicated by the feedback signal from the weighing sensor), the discharge valve 705 and the corresponding electric valve 809 are closed.

[0057] S5. Static Fermentation Storage and Final Processing: Seal the filled fermentation tank 301, pressurize it with nitrogen (anaerobic fermentation), and transfer it to a 15℃ constant temperature warehouse for static storage for 3 days to complete final maturation. After that, discharge the material, pasteurize it at 85℃ for 15 minutes, and then vacuum package it.

[0058] Example 3: Comparative Experiment Verification To verify the effectiveness of the present invention, a comparative experiment was conducted.

[0059] Comparative Example 1: The static tank fermentation method described in CN107279880A in the background art was adopted.

[0060] The specific implementation path is as follows: 1. Raw materials and ingredients: Fresh red chilies from the same batch as those used in the experimental group (Example 2 of this invention) were used, and pepper embryos of the same specifications were obtained after the same pretreatment. The ingredients were prepared and inoculated according to the same proportion (8% edible salt, 0.5% freeze-dried Lactobacillus plantarum powder, and 0.05% tea polyphenol extract by weight of pepper embryos), and mixed evenly in a mixing tank.

[0061] 2. Fermentation apparatus and loading: The uniformly mixed materials are loaded into a large vertical static fermenter (the volume of which is equivalent to the total effective volume of the dynamic fermentation subsystem of this invention). The fermenter is equipped with a pressure relief valve, a temperature control system, and a top inert gas (nitrogen) charging port.

[0062] 3. Fermentation Process: After the materials are filled, nitrogen gas is immediately introduced from the top of the fermenter to replace the air in the top space of the tank, and then the tank is sealed. The entire fermenter is placed in a constant-temperature fermentation room and statically fermented at 28°C for one stage. During the fermentation process, the materials remain essentially still, without any mechanical stirring or circulation.

[0063] 4. Monitoring and endpoint: Samples are taken periodically from different locations within the tank to monitor pH and total acid content. Instead of automated endpoint pH determination, a total fermentation time of 15 days is set as a control endpoint based on experience or preliminary experiments.

[0064] 5. Discharge and post-processing: After 15 days of fermentation, open the fermentation tank and remove the material. Subsequent processing, including static storage (3 days at 15℃), discharge, pasteurization (85℃, 15 minutes), and vacuum packaging, is the same as the experimental group.

[0065] Comparative Example 2: The same three-stage series system as the present invention is used, but the backflow is turned off, and the material passes through only once in one direction.

[0066] The specific implementation path is as follows: 1. System modification: The hardware of the chili dynamic and static coupled fermentation system with the same structure as that of Example 1 (and the experimental group) was used, including the dynamic fermentation subsystem (1), the circulation control unit (2), the static storage subsystem (3) and the fermentation liquid collection and distribution subsystem (8).

[0067] 2. Mode setting: The reflux control valve (202) on the reflux pipeline (201) is closed in advance and throughout the process, so that the system only works in "discharge mode". The material can only flow in one direction once in the dynamic fermentation subsystem (1) and cannot be circulated.

[0068] 3. Raw materials and ingredients: The same raw materials and ingredients were used as in Comparative Example 1 and the experimental group.

[0069] 4. Fermentation process: The material is fed into the system through the feed chute (4).

[0070] First fermentation stage (101) treatment: The material flows in the stage under the same conditions as the first stage of the experimental group (30°C, central screw conveyor speed 10 rpm, dynamic nitrogen injection). By controlling the feed rate and the number of tanks connected in series, the total residence time of the material in this stage is ensured to be 3 times the single cycle time (8 hours) of the experimental group, i.e., 24 hours, to compensate for the cumulative treatment time reduced due to the lack of circulation.

[0071] Second fermentation stage (102): The material was flowed within the stage under the same conditions as the second stage of the experimental group (28°C, central screw conveyor speed of 12 rpm, with flexible rod stirring). The total residence time was set to three times the single cycle time of the experimental group (12 hours), i.e., 36 hours.

[0072] The third fermentation stage (103) was treated as follows: the material flowed within the stage under the same conditions as the third stage of the experimental group (20°C, 6 rpm for the central screw conveyor). The total residence time was set to be three times the single cycle time of the experimental group (16 hours), i.e., 48 hours.

[0073] Total one-way processing time: The total time for materials to go from entering the first stage to leaving the third stage is 108 hours (approximately 4.5 days). During this period, the materials undergo three-stage processing only once, without recycling.

[0074] 5. Monitoring and Transfer: When the material flows to the end of the third fermentation section (103), its pH value is monitored by an online pH sensor (6). When the pH value drops to 4.2, the system automatically performs a discharge operation, mixing the material with the collected fermentation liquid and then transferring it all to a finished product fermentation tank (301).

[0075] 6. Post-processing: The finished product tanks were sealed and pressurized with nitrogen in the same manner as the experimental group, and then transferred to a 15℃ constant temperature warehouse for static storage for 7.5 days (to compare the total processing time with the experimental group's "5 days of dynamic cycle + 3 days of static storage = 8 days" and the set total research cycle of 12 days). After that, the same discharge, sterilization and packaging were carried out.

[0076] Experimental group: The method of Example 2 of this invention was used (the steps are the same as in Example 2).

[0077] Using the same batch of raw materials and the same formulation, the total processing study period from material input to finished product packaging was set at 12 days. Key results are compared in the table below: Table 1: Comparison of Key Indicators of Fermentation Process and Final Product Results analysis:

[0078] Experimental data show that the dynamic circulation and static storage coupling system and method of the present invention are significantly superior to existing static tank fermentation and non-circulating tandem fermentation processes in terms of fermentation efficiency, product uniformity, flavor quality and production cycle.

[0079] Compared to Comparative Example 1, the experimental group of this invention exhibited a lower pH and higher total acidity by day 6, demonstrating the significant advantage of dynamic cyclic three-stage fermentation over static single-stage fermentation in accelerating the fermentation process. The significant improvement in the uniformity of the final product (CV%) directly reflects the effectiveness of dynamic gentle agitation and cyclic mixing in solving the fundamental problem of uneven distribution of flavor compounds.

[0080] Compared to Comparative Example 2: Both used the same hardware and single-stage processing intensity, but the experimental group subjected the material to three-stage processing multiple times (approximately 5-6 times in this embodiment) over 5 days using a cyclical mode, while Comparative Example 2 only underwent a single pass. The superior fermentation indicators of the experimental group on day 6 (pH 4.0 vs 4.2, total acid 1.08 vs 0.92) demonstrate that the cumulative effect of dynamic circulation and multiple homogenization processes are far more efficient than simply extending the single processing time. This highlights the core role of "dynamic circulation" in this invention for enhancing mass transfer and improving overall fermentation kinetic efficiency.

[0081] Other aspects of this invention that are not detailed herein are all conventional techniques known to those skilled in the art.

[0082] It should be noted that the terms “comprising,” “including,” or any other variations are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0083] The scope of protection of this invention is not limited to the technical solutions disclosed in the specific embodiments. Any modifications, equivalent substitutions, improvements, etc., made to the above embodiments based on the technical essence of this invention shall fall within the scope of protection of this invention.

Claims

1. A dynamic and static coupling fermentation method of chili, characterized in that, Includes the following steps: S1. Raw material pretreatment: Wash and remove the stems from fresh chilies, and process them into segments or slices of chili embryos; S2. Synergistic ingredient preparation and inoculation: The pepper embryos are mixed evenly with salt and a synergistic fermentation additive composed of a natural antibacterial agent and a lactic acid bacteria starter; the natural antibacterial agent is selected from at least one of plant-derived extracts and microbial-derived antimicrobial peptides. S3. Circulating dynamic three-stage fermentation: The mixed material is placed into a dynamic fermentation subsystem (1) consisting of a first fermentation section (101), a second fermentation section (102), and a third fermentation section (103) connected in series. The circulation mode is started so that the material passes through the first fermentation section (101), the second fermentation section (102), and the third fermentation section (103) in sequence for three-stage dynamic fermentation. Then, it returns through the reflux pipeline (201) set between the end of the third fermentation section and the beginning of the first fermentation section for multiple cyclic fermentation. S4. Cycle termination and material transfer: When the pH value of the material at the end of the third fermentation stage (103) reaches the predetermined threshold, the cycle mode is terminated, the reflux pipeline (201) is closed, and all the material that has completed the cycle dynamic fermentation is transported to the static storage subsystem (3). S5. Static fermentation storage and final treatment: The material is statically fermented and stored at 10-20℃ for 2-7 days to complete the final maturation, and then discharged, packaged and sterilized.

2. The dynamic and static coupling fermentation method of chili according to claim 1, characterized in that, The three-stage dynamic fermentation includes: First stage: The material is injected with inert gas driven by centrifugal force in the first fermentation section (101) at 20-35℃, which quickly establishes a deep anaerobic environment and starts lactic acid-dominated fermentation. Second stage: The material is subjected to gentle dynamic stirring by flexible and elastic mechanical parts in the second fermentation section (102) at 25-30℃ to promote the formation and homogenization of flavor substances; The third stage: The material is matured in the third fermentation section (103) at 15-25℃, and the pH value of the material is monitored in real time at the end of this section.

3. A dynamic and static coupling fermentation system of chili, characterized in that: It includes a dynamic fermentation subsystem (1), a circulation control unit (2), and a static storage subsystem (3). The dynamic fermentation subsystem (1) includes a first fermentation section (101), a second fermentation section (102), and a third fermentation section (103) connected in series. Each fermentation section is composed of at least two vertical fermentation tank units (10) connected in series. The feed inlet (12) at the beginning of the first fermentation section (101) is connected to a feed chute (4). The discharge outlet (13) at the end of the third fermentation section (103) is connected to a switching conveyor mechanism (5). The circulation control unit (2) includes a return pipeline (201), which is a closed chute or pipe. Its inlet end is connected to the switching conveying mechanism (5) at the end of the third fermentation section (103), and its outlet end is connected to the feed chute (4) at the beginning of the first fermentation section (101). A return control valve (202) is provided on the return pipeline (201). An online pH sensor (6) for monitoring the pH value of the material is provided at the outlet (13) at the end of the third fermentation section (103). The static storage subsystem (3) includes multiple finished product fermentation tanks (301), and the feed pipe (303) of the finished product fermentation tank (301) is connected to the discharge port (13) at the end of the third fermentation section (103) through a switching conveying mechanism (5); The system configuration has two operating modes: Circulation mode: When the reflux control valve (202) is turned on, the material circulates in the dynamic fermentation subsystem (1) under the series connection of the circulation control unit (2); Discharge mode: Close the reflux control valve (202), and all materials are transported from the third fermentation section (103) to the static storage subsystem (3).

4. The dynamic and static coupling fermentation system of chili according to claim 3, characterized in that: The vertical fermenter unit (10) includes a fermenter (11) and a central screw conveyor (16); the fermenter (11) has a feed inlet (12) on the lower side wall and a discharge outlet (13) on the upper side wall; each fermenter (11) has a pressure relief valve (14) at the top; adjacent fermenters (11) in each fermentation section and adjacent fermenters (11) in adjacent fermentation sections are connected in series by a series pipeline (15), the upper end of the series pipeline (15) is connected to the discharge outlet (13) of the previous fermenter, and the lower end of the series pipeline (15) is connected to the feed inlet (12) of the next fermenter; the central screw conveyor (16) is used to screw convey the material from the lower part of the fermenter (11) to the upper part.

5. The dynamic and static coupling fermentation system of chili according to claim 4, characterized in that: The switching conveying mechanism (5) has at least three discharge ports at its bottom. One discharge port is connected to the inlet end of the return pipeline (201), and the other discharge ports are respectively equipped with discharge mechanisms (7) for connecting to the finished product fermentation tank (301). The discharge mechanism (7) includes a discharge pipe (701), a telescopic pipe (702), a connecting sleeve (703), and an automatic telescopic rod (704). The discharge pipe (701) is fixed to the bottom of the switching conveying mechanism (5) and connected to the switching conveying mechanism (5). The internal connection is provided, and a discharge valve (705) is provided on the discharge pipe (701); the telescopic pipe (702) is connected to the bottom of the discharge pipe (701) and can extend and retract up and down; the docking sleeve (703) is connected to the bottom of the telescopic pipe (702) and can dock with the feed pipe (303) of the finished product fermentation tank (301); the automatic telescopic rod (704) is fixed at the bottom of the switching conveying mechanism (5), and its telescopic end is connected to the docking sleeve (703) and can drive the docking sleeve (703) to move up and down.

6. The chili pepper dynamic and static coupled fermentation system according to claim 3 or 4, characterized in that: The switching conveying mechanism (5) is a screw conveyor, which is controlled by the signal of the online pH sensor (6). When the pH reaches the threshold, the controller automatically controls the reflux control valve (202) to close and the discharge valve (705) to open, automatically switching the material from the reflux pipeline (201) to the guided static storage subsystem (3).

7. The dynamic and static coupled fermentation system of chili according to claim 5, characterized in that: It also includes a fermentation broth collection and distribution subsystem (8); the fermentation broth collection and distribution subsystem (8) includes a fermentation broth storage tank (801), a fermentation broth collection tank (802) integrally fixed to the bottom of each fermentation tank (11), a fermentation broth collection pipe (803) integrally fixed to the bottom of each series pipeline (15) and connected to the series pipelines (15) through multiple through holes, a reflux liquid collection pipe (804) integrally fixed to the bottom of the reflux pipeline (201) and connected to the reflux pipelines (201) through multiple through holes, a water pump (805) for extracting fermentation broth from the fermentation broth collection tank (802), a main outlet pipe (806), and several branch pipes (807); the fermentation broth storage tank (801) and each fermentation broth The collection tanks (802) are connected to each other by a guide pipe (808); the lower end of the fermentation liquid collection pipe (803) is connected to the fermentation liquid collection tank (802) at the bottom of the fermentation tank (11) connected to the lower end of the series pipe (15) at the top; the lower end of the reflux liquid collection pipe (804) is connected to the fermentation liquid collection tank (802) at the bottom of the fermentation tank (11) at the beginning of the first fermentation section (101); one end of the main outlet pipe (806) is connected to the outlet end of the water pump (805), and the other end is connected to the inlet end of each branch pipe (807); the outlet end of each branch pipe (807) is connected to the outlet pipe (701) of a discharge mechanism (7), and an electric valve (809) is installed on each branch pipe (807).

8. The dynamic and static coupled fermentation system of chili according to claim 4, characterized in that: The spiral blades (17) of the central spiral conveyor (16) in the first fermentation section (101) have a cavity structure. The cavity of the spiral blades (17) is connected to an inert gas source through a channel preset in the rotating shaft (18) of the central spiral conveyor (16). Multiple exhaust holes (19) are opened on the outer edge surface of the spiral blades (17) to dynamically establish and maintain an anaerobic environment through centrifugal force.

9. The dynamic and static coupled fermentation system of chili according to claim 4, characterized in that: On the spiral blades (17) of the central spiral conveyor (16) in the second fermentation section (102), there are several sets of extended flexible stirring rods (20) for dynamic, low-damage turbulence and mixing of materials.

10. The dynamic and static coupled fermentation system of chili according to claim 4, characterized in that: The finished product fermentation tank (301) is equipped with a sealed tank lid (302), and the upper space inside the tank can be connected to a food-grade inert gas for pressure maintenance; the feed pipe (303) is integrally fixed on the tank lid (302) and connected to the finished product fermentation tank (301).

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