Pickled pepper pickling equipment

Abstract

The invention discloses pickled pepper pickling equipment, and belongs to the field of food processing equipment. The equipment comprises a fermentation tank, a saline water recovery tank and a propagation tank which are connected through a pipeline system. A rough filtration membrane and fine filtration membrane assembly is arranged in the recovery tank and is used for filtering impurities and bad flavor substances in the saline water; and the propagation tank is provided with a stirring mechanism and a feeding mechanism and is used for flora propagation and microbial inoculum preparation. The equipment controls the flowing direction of saline water through a multi-way valve, and the saline water can be respectively guided to a fermentation tank for recycling or a propagation tank for microbial inoculum preparation according to the quality of the saline water. The equipment integrates the functions of saline water recovery, purification and flora propagation, supports semi-automatic control and remote monitoring, can effectively realize standardized control of pickled pepper production, solves the problem of quality fluctuation caused by saline water recycling in the traditional process, and is suitable for large-scale pickled pepper processing production.

Description

Technical Field

[0001] This invention relates to food production equipment, specifically a pickling and marinating device for pickled peppers. Background Technology

[0002] Pickled peppers are a traditional condiment made primarily from chili peppers through microbial fermentation, and are widely popular for their unique flavor. In large-scale production, recycling and reusing the fermented brine has become a common practice in the industry to achieve resource conservation and environmental friendliness, possessing significant economic and environmental value.

[0003] However, a long-standing technical bottleneck exists in the recycling of brine: as the number of cycles increases, it becomes difficult to remove small-molecule undesirable flavor substances such as higher alcohols and aldehydes accumulated during fermentation. This leads to flavor degradation and unstable quality in subsequent batches, severely restricting the long-term effective reuse of brine and standardized product production. Existing technologies mostly focus on the physical clarification and conventional component adjustment of brine, such as removing suspended impurities through flocculation and plate and frame filtration. However, these methods are not very effective at specifically removing soluble undesirable flavor substances, failing to fundamentally break the flavor degradation chain. Furthermore, they generally rely on unstable "old brine" as the fermentation starter, resulting in poor batch controllability.

[0004] Furthermore, existing technologies typically treat "brine purification" and "microbial inoculation" as two separate processes when handling brine recovery and fermentation restart, lacking a systematic device that can integrate fine brine regeneration and standardized microbial transplantation. Currently, no publicly available technology can simultaneously achieve molecular-level selective filtration of brine and stable propagation and precise addition of complex microbial communities within a single system. This has become a key equipment bottleneck restricting the high-quality, standardized, and continuous production of pickled peppers. Summary of the Invention

[0005] The purpose of this invention is to overcome the aforementioned technical difficulties and provide a pickling equipment for brine recovery and flavor brine regeneration.

[0006] To achieve the above objectives, the technical solution adopted is as follows: a pickled pepper processing device, comprising a fermentation tank, wherein the fermentation tank is connected to a brine recovery tank and a propagation tank via pipelines; the brine recovery tank is equipped with a coarse filter membrane assembly and a fine filter membrane assembly; the propagation tank is equipped with a stirring mechanism and a feeding mechanism.

[0007] Furthermore, the inlet pipeline of the brine recovery tank is equipped with pumps and valves for regulating flow and pressure.

[0008] Furthermore, the brine recovery tank is equipped with a backwasher for cleaning the filter assembly.

[0009] Furthermore, the brine recovery tank and / or propagation tank are equipped with a detection device, which includes at least one of a dissolved oxygen detector, a pH meter, and an acidity meter.

[0010] Furthermore, the feeding mechanism includes at least one of a carbon source feeder, a nitrogen source feeder, a trace element feeder, and an alkaline solution feeder.

[0011] Furthermore, the coarse filter membrane assembly is an 80-150 mesh screen.

[0012] Furthermore, the fine filtration membrane assembly is an ultrafiltration membrane, and the ultrafiltration membrane has a molecular weight cutoff of 200-1000 Daltons.

[0013] Furthermore, the ultrafiltration membrane has a molecular weight cutoff of 300-500 Daltons and is made of one of polysulfone, polyethersulfone, or polyvinylidene fluoride.

[0014] Furthermore, the propagation tank is equipped with a heating device for controlling the temperature between 25°C and 30°C.

[0015] Furthermore, the outlet pipeline of the brine recovery tank can be selectively connected to a propagation tank or a fermentation tank for brine microbial propagation or brine circulation treatment, respectively.

[0016] Compared with the prior art, the pickling equipment and preparation method for pickled peppers provided by the present invention have the following beneficial effects: 1. High system integration and clear process flow. By integrating the fermenter, recovery tank, and propagation tank into a single unit, and with the aid of multi-way valves and piping design, continuous operation of brine recovery, filtration, inoculant preparation, and fermentation restart is achieved. The system has a compact structure and a clear process flow, facilitating seamless process integration and management in large-scale production.

[0017] 2. Achieve brine quality grading and targeted utilization. Through sensory evaluation and physicochemical testing, the recycled brine is classified into "premium" and "ordinary" categories, which are then used for microbial agent preparation and regeneration reuse, respectively. This design allows for the preservation and proliferation of high-quality fermentation resources, while ordinary brine can be reused sustainably after regeneration, helping to maintain the stability of product flavor.

[0018] 3. Enhance the standardization and controllability of microbial inoculants. A controllable propagation process is employed in a propagation tank to propagate a complex microbial community in high-quality brine, followed by freeze-drying to produce a solid microbial inoculant. This inoculant exhibits stable activity, is easy to store and transport, and can be used as a standardized fermentation starter, contributing to consistency in fermentation processes across different batches and locations.

[0019] 4. Achieve refined brine regeneration and extend its service life. Using an ultrafiltration membrane to finely filter the brine selectively removes small-molecule undesirable flavor substances while retaining beneficial organic acids and other components. This process reduces the accumulation of flavor deteriorators at the molecular level, thereby extending the number of brine cycles and reducing production costs.

[0020] 5. Supports semi-automation and remote monitoring, improving production management. The equipment can be configured with sensors, PLCs, and remote monitoring systems to achieve real-time acquisition, automatic adjustment, and remote viewing of key process parameters. Operators can make data-driven decisions, achieving more precise process control and improving the standardization and traceability of production.

[0021] 6. Balancing traditional craft experience with modern quality control. Human involvement is retained in key stages such as brine flavor evaluation and propagation decisions to ensure the traditional flavor characteristics of the product; while automated control is implemented in stages such as filtration, temperature control, and feed replenishment to improve the repeatability and stability of the process. This design, while inheriting craft experience, enhances the scientific nature and controllability of the production process. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of the pickled pepper processing equipment of the present invention; Figure 2 This is a schematic diagram of the internal structure of the recycling tank in this invention; Figure 3 This is a schematic diagram of the propagation tank in this invention; Figure 4 This is a schematic diagram of the electrical control process of the present invention; In the diagram, 1 is the fermentation tank; 2 is the recovery tank; 3 is the propagation tank; 4 is the backwash water pipe; 5 is the multi-way valve; 6 is the detection device; 7 is the feeding mechanism; 8 is the coarse filter membrane; 9 is the fine filter membrane; and 10 is the stirring mechanism. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the scope of protection of the invention. All other embodiments obtained by those skilled in the art based on the concept of this application without inventive effort are within the scope of protection of this application.

[0024] Example 1: Basic structure and manual operation process of a pickled pepper processing equipment Please refer to Figures 1 to 3This embodiment provides a pickling equipment for pickled peppers, which mainly includes a fermentation tank 1, a brine recovery tank 2, and a propagation tank 3. The three are connected by a pipeline system to form a pickling production system that integrates brine recovery, purification, bacterial propagation, bacterial agent preparation, and fermentation restart functions.

[0025] 1. Equipment Structure Description Fermentation tank (1): Used for pickling and fermenting peppers. The tank is equipped with an outlet and is connected to the inlet of the recovery tank (2) through a pipeline. To meet the pressure requirements of the subsequent ultrafiltration process, a transfer pump is installed on this section of the pipeline to pressurize and transfer the fermented brine to the recovery tank.

[0026] Recovery tank (2): Used for treating and regenerating the brine after fermentation. A coarse filter membrane assembly (8) and a fine filter membrane assembly (9) are installed sequentially from top to bottom inside the tank. The coarse filter membrane assembly (8) is a 100-mesh stainless steel screen, its function being to filter out large solid impurities such as chili seeds and fruit pulp from the brine; the fine filter membrane assembly (9) uses a polyethersulfone ultrafiltration membrane with a molecular weight cutoff of 500 Daltons, its function being to selectively remove soluble undesirable flavor substances with molecular weights within the target range (such as higher alcohols and aldehydes). A detection device is installed at the inlet of the recovery tank (2) to detect the incoming brine. This device includes a dissolved oxygen detector, a pH meter, and an acidity meter, and the readings of each detector are displayed on a field instrument panel. The recovery tank (2) is equipped with a backwash water pipe (4) and matching valves for periodically cleaning the filter membrane assembly. A multi-way valve (5) is provided on the outlet pipe of the recovery tank (2). The three outlets of the multi-way valve (5) are respectively connected to the feed inlet of the fermentation tank (1), the propagation tank (3) and the backwash water pipeline through pipelines, so as to flexibly switch the flow direction and use of brine.

[0027] Propagation tank (3): Used to receive a portion of high-quality regenerated brine under specific conditions, and to activate and propagate the complex bacterial community at high density. The stirring mechanism (10) and the feeding mechanism (7) are both located at the top of the propagation tank (3). The stirring shaft of the stirring mechanism (10) extends into the tank from top to bottom to maintain uniform mixing of the bacterial solution. The feeding mechanism (7) is located at the top of the tank and consists of the outlets of independent carbon source tanks, nitrogen source tanks, and trace element tanks, as well as corresponding manual valves and feeding ports, which can realize the independent and controllable addition of various nutrients. The propagation tank (3) is equipped with a heating device (such as an electric heater or coil) to maintain the propagation temperature inside the tank, which is generally controlled within the optimal growth range of the bacterial community of 25°C to 30°C. The tank body of the propagation tank (3) is equipped with a detection device, including dissolved oxygen, pH and acidity detection instruments, to monitor the propagation process.

[0028] 2. Manual Operation and Process Steps This embodiment primarily relies on manual monitoring and operation, and the specific process is as follows: Step 1: Brine recovery, detection, and diversion After the fermentation cycle is completed, the transfer pump is started to pump the brine in the fermentation tank (1) into the recovery tank (2). The operator first observes the reading of the detection instrument at the inlet of the recovery tank (2), and makes a comprehensive judgment on its quality by referring to the dissolved oxygen, pH, acidity of the brine and experience (such as the flavor evaluation of this batch of pickled peppers and the number of brine circulations).

[0029] If the brine is determined to be of excellent quality and has a pure flavor, it is considered a high-quality raw material that can be used for the propagation of microorganisms.

[0030] If the brine is determined to be of poor quality, has shown a trend of flavor deterioration, or has been recycled too many times, it will only be used for regeneration and will not be used as a propagation material.

[0031] Step 2: Brine fine filtration regeneration The brine is passed through coarse and fine filters in the recovery tank (2). The operator controls the ultrafiltration operating pressure at about 0.3 MPa by adjusting the valve after the pump to remove undesirable flavor substances. The operator observes the process data regularly. When the filtration efficiency decreases, the brine recovery is turned off first, the multi-way valve (5) is switched to the backflushing line, and the backflushing valve is manually opened to clean the membrane.

[0032] Step 3: Propagation of bacteria and preparation of inoculants in high-quality saline solution (optional step) This step should only be performed if the brine quality is determined to be excellent in step one.

[0033] Propagation Operation: The operator operates the multi-port valve (5) to introduce a portion of the regenerated high-quality brine into the propagation tank (3). Solid encapsulated bacterial agent is manually added into the tank as the initial inoculum. The top stirring mechanism (10) is activated. The operator can refer to the real-time data of the detection instrument on the tank and manually operate the top feeding mechanism (7) to quantitatively add nutrients such as carbon source and nitrogen source, and control the heating device to maintain a suitable temperature for the propagation and cultivation of highly active bacterial groups.

[0034] Preparation of bacterial agent: After the propagation culture is completed, all the highly active bacterial liquid in the propagation tank (3) is discharged and sent to a vacuum freeze dryer for drying to make a solid bacterial agent. This bacterial agent is easy to store for a long time or transport to other places for use in the next fermentation restart or other places, which can effectively ensure the reliability of fermentation start-up and the stability of product flavor.

[0035] Step 4: Restart Fermentation For batches not undergoing propagation, or when using previously prepared solid microbial agents, the operator operates the multi-port valve (5) to directly return the regenerated brine to the fermenter (1). Pretreated fresh chili peppers are loaded into the fermenter (1), along with a measured amount of solid microbial agent (freshly prepared or stored). All relevant valves are manually closed, and the fermenter (1) is placed in a set temperature environment for static fermentation.

[0036] The working principle and beneficial effects of this embodiment: This equipment, through integrated piping design and multi-way valve control, achieves intelligent diversion and targeted utilization of brine based on quality. Its core innovation lies in the organic integration of three processes: online brine quality assessment, propagation and fixation of high-quality microbial resources using microbial agents, and refined regeneration of universal brine. In particular, by preparing the propagation liquid into a solid microbial agent, it achieves standardized preservation and flexible use of high-quality fermentation microbial resources, fundamentally solving the problems of difficult fermentation start-up and inconsistent flavor caused by remote production or long batch intervals. The system has a clear structure and strong operational logic, achieving precise control with manual intervention, providing a practical equipment solution for the standardized, high-quality production of pickled peppers.

[0037] Example 2: A pickling equipment with automatic and remote monitoring functions Based on the basic structure of Example 1, this embodiment introduces an automated detection and control module and combines it with a manual decision-making and remote operation interface to realize the automated operation and centralized monitoring of key processes in the pickling equipment, which significantly improves the standardization level of the production process and the operational flexibility.

[0038] 1. System Structure and Control Architecture Please refer to Figures 1 to 4 This embodiment integrates the following key automation and information modules based on the hardware of embodiment 1: Enhanced sensor systems: Recovery tank (2): In addition to the existing basic sensors, a near-infrared spectrometer and a high-precision flow / pressure sensor are added at the inlet. The near-infrared spectrometer is used to monitor the spectral characteristics of organic matter in the brine online, providing objective data support for subsequent manual evaluation; the flow and pressure sensors are used to precisely control the ultrafiltration process.

[0039] Propagation tank (3): It is also equipped with a more complete sensor group for comprehensive monitoring of the propagation environment.

[0040] Centralized control and data processing unit: Real-time data collected by all sensors is aggregated to the PLC (Programmable Logic Controller) or central processing unit on site via the detection signal bus.

[0041] The central processing unit runs dedicated control software responsible for real-time data reception, storage, processing, and visualization. The software possesses basic data analysis functions, such as trend analysis and over-limit alarms, and can compare sensor data (especially near-infrared spectral data) with preset reference models, providing operators with auxiliary decision-making information. It is important to emphasize that the final evaluation of the brine's "flavor" still relies on professional tasters to make a comprehensive judgment based on the test data and sensory evaluation results. The system only provides data reference and cannot independently determine the flavor grade.

[0042] Remote monitoring and management platform: The system connects to the factory network via an industrial gateway, supporting remote access. Authorized personnel can remotely view sensor data, equipment operating status, alarm information, process curves, etc., of each tank in real time via client software on a computer or mobile terminal. The platform also supports remote command issuance, such as starting / stopping specific processes, setting process parameters, and confirming alarms; however, critical safety interlocks and some core operations still require on-site confirmation or execution.

[0043] Automatic actuators and control: The central processing unit is connected to each actuator via a control signal bus, and can receive and execute instructions from field operators or remote control consoles: Automatic control of the recovery tank: After the operator issues the "start recovery" command, the system automatically controls the inlet pump and valves to deliver brine to the recovery tank, and automatically adjusts according to the set pressure parameters to maintain the ultrafiltration process. The system can automatically monitor the filtration differential pressure, and when it reaches the set threshold, it prompts "backflushing recommended". After operator confirmation, the backflushing procedure is automatically executed. The specific start-up, shutdown, and adjustment of the inlet pump, valves, and backflushing device are all completed automatically by the system.

[0044] Automatic control of the propagation tank: After comprehensively evaluating the quality of the brine (primarily based on human flavor assessment, supplemented by test data), the operator (on-site or remotely) issues a "start propagation" command. The system then automatically controls the stirring mechanism (10) of the propagation tank to operate according to a preset program, precisely controls the heating device to maintain a constant temperature, and automatically controls the start and stop of each metering unit in the feeding mechanism (7) based on real-time monitored parameters such as pH and dissolved oxygen, thereby achieving automatic replenishment of nutrients. The timing and decision-making for starting propagation are based on human evaluation of the brine flavor.

[0045] Alarm and display unit: The system is equipped with a local touchscreen and a remote client for centralized display of all information. When any sensor data exceeds the limit, equipment malfunctions, or process logic fails, the system automatically triggers tiered alarms on both the local and remote clients.

[0046] 2. Automated process flow Step 1: Recycling Initiation Based on Manual Decision-Making and Command Issuance After fermentation is complete, on-site or remote control personnel will manually issue a "start brine recovery" command after comprehensively considering the production plan.

[0047] Step Two: Data-Assisted Filtering and Regeneration The system automatically performs the brine delivery and ultrafiltration regeneration processes, and displays all sensor data and filtration efficiency curves in real time. Near-infrared spectral data is processed into trend graphs to help personnel judge changes in brine composition. When the system prompts for backflushing, it executes automatically after personnel confirmation.

[0048] Step 3: Manually-led, automated propagation and inoculum preparation Decision point: The regenerated brine must be evaluated for flavor by professional tasters, and the suitability of the batch for propagation must be determined based on the comprehensive testing data report provided by the system. Only when manually determined to be "high-quality" will the control personnel issue the "start propagation" command.

[0049] Automated execution: After receiving instructions, the system automatically completes the entire process, including adding bacterial agent, filling the propagation tank, environmental control (temperature, stirring), and automatic nutrient addition based on real-time feedback. After propagation, the system can automatically transfer the bacterial solution to the freeze-drying equipment or prompt personnel for the next step.

[0050] Step 4: Standardized Reboot Once the regenerated brine or the prepared microbial agent is ready, the controller issues a command, and the system automatically or semi-automatically completes the reflux operation to the fermenter, preparing for the next fermentation.

[0051] 3. Work Mode Local automatic mode: The operator performs the main operations and decisions on the on-site control panel, and the system is responsible for automatically executing the specific equipment control.

[0052] Remote monitoring and operation mode: Operators can view real-time status, receive alarms, analyze historical data, and issue most control commands (except for safety interlocks) remotely from the central control room or via mobile devices. Key human evaluation and decision-making still need to be completed at the relevant stages of the production line.

[0053] The beneficial effects of this embodiment: This embodiment successfully constructed an intelligent production system based on "human-machine collaboration." Instead of pursuing unrealistic full automation, it delegates repetitive, high-precision, and time-consuming equipment control tasks to an automated system, leaving the core processes requiring experience, sensory judgment, and advanced decision-making to humans. This design significantly improves the accuracy, stability, and production efficiency of equipment control, reduces the labor intensity of operators, and ensures reliable control of the core quality element of "flavor," which relies on human experience in traditional processes. The addition of remote functionality enhances the flexibility and centralization of production management. This system provides a practical and efficient upgrade path for pickled pepper production, moving from experience-driven to data-driven approaches and from discrete operations to process-oriented management.

[0054] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0055] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A pickling and curing apparatus for pickled peppers, comprising a fermentation tank (1), characterized in that: The fermentation tank (1) is connected to a brine recovery tank (2) and a propagation tank (3) via pipelines; the brine recovery tank (2) is equipped with a coarse filtration membrane assembly and a fine filtration membrane assembly; the propagation tank (3) is equipped with a stirring mechanism (10) and a feeding mechanism (7).

2. The pickling equipment for pickled peppers according to claim 1, characterized in that: The brine recovery tank (2) is equipped with a pump and valve on the inlet pipe for adjusting the flow rate and pressure.

3. The pickling equipment for pickled peppers according to claim 1 or 2, characterized in that: The brine recovery tank (2) is equipped with a backwasher for cleaning the filter assembly.

4. The pickling equipment for pickled peppers according to claim 1, characterized in that: The brine recovery tank (2) and / or the propagation tank (3) are equipped with a detection device, which includes at least one of a dissolved oxygen detector, a pH meter, and an acidity meter.

5. The pickling equipment for pickled peppers according to claim 1, characterized in that: The feeding mechanism (7) includes at least one of a carbon source feeder, a nitrogen source feeder, a trace element feeder, and an alkaline feeder.

6. The pickling equipment for pickled peppers according to claim 1, characterized in that: The coarse filtration membrane assembly is an 80-150 mesh screen (8).

7. The pickling equipment for pickled peppers according to claim 1, characterized in that: The fine filtration membrane assembly is an ultrafiltration membrane (9), and the molecular weight cutoff of the ultrafiltration membrane is 200-1000 Daltons.

8. The pickling equipment for pickled peppers according to claim 7, characterized in that: The ultrafiltration membrane has a molecular weight cutoff of 300-500 Daltons and is made of one of polysulfone, polyethersulfone, or polyvinylidene fluoride.

9. The pickling equipment for pickled peppers according to claim 1, characterized in that: The propagation tank (3) is equipped with a heating device.

10. The pickling equipment for pickled peppers according to claim 1, characterized in that: The outlet pipeline of the brine recovery tank (2) can be selectively connected to the propagation tank (3) or the fermentation tank (1) to carry out brine microbial propagation or brine circulation treatment respectively.

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