Production process of Maotai-flavor liquor

Abstract

The invention discloses a Maotai-flavor liquor production process, which belongs to the technical field of liquor brewing, and comprises the following processes: koji making, sorghum pretreatment, diastatic fermentation, distillation and ageing: selected wheat moistened grains are crushed, water is added to prepare koji blocks, the koji blocks are fermented for later use, and doors and windows are opened to ventilate and supplement external environmental microorganisms during koji turning; the method comprises the following steps: selecting sorghum, soaking in hot water to remove pectin, cooking in cooking equipment until the sorghum is well cooked, mixing with a koji block, adding Q303 rhizopus koji and millet koji, uniformly mixing, increasing the quantity and types of environmental microorganisms, carrying out aerobic stacking saccharification fermentation for 2-4 days, carrying out anaerobic fermentation in a fermentation tank for 30 days, distilling by adopting distillation equipment, and then loading base liquor into a pottery jar for ageing for 1-3 years; through the process, the wine yield can be improved, and the flavor quality is improved.

Description

Technical Field

[0001] This invention belongs to the field of liquor brewing technology, specifically involving a novel production process for sauce-flavored liquor through adjustments to raw material ratios and improvements to fermentation techniques. Background Technology

[0002] Traditional Maotai-flavor liquor production typically uses sorghum and wheat as raw materials, involving multiple fermentation and distillation processes, with a production cycle exceeding one year. However, this process suffers from low alcohol yield, generally only 20%-30%, and high energy consumption, leading to high production costs.

[0003] At the same time, the flavor stability of sauce-flavored liquor produced by traditional processes needs to be improved, especially the strong sour and astringent taste. If problems occur during the process, the liquor is prone to off-flavors, making it difficult to suit the tastes of a wide range of consumers, especially the younger generation. In addition, due to the low yield and high price, it is difficult to popularize the liquor among the general public. Moreover, there are significant differences in taste between different batches of products.

[0004] In addition, traditional fermentation processes have strict requirements for environmental temperature, humidity and other conditions. Due to operational issues, incomplete or over-fermentation can easily occur in different enterprises, affecting the quality of liquor and causing waste of resources. Summary of the Invention

[0005] This invention proposes a novel production process for Maotai-flavor liquor, which can increase the yield and improve the flavor and quality. The specific technical solution is as follows:

[0006] A process for producing Maotai-flavor liquor includes the following steps:

[0007] (1) Koji-making process: Wheat is used as the raw material for koji making. After adding water to moisten the grain for 6-8 hours, 10-15% bran is produced, which plays a role in loosening and facilitating oxygen permeability and the growth and reproduction of beneficial aerobic microorganisms such as mold. Then, the bran is crushed, and mother koji and water are added to make koji blocks. After cooling in the oven for 20-40 minutes to absorb the sweat, the koji blocks are placed in the koji room and water is sprinkled evenly. After fermentation for 7-9 days, the first turning of koji is carried out. At the same time, the doors and windows are opened for ventilation to supplement external environmental microorganisms. After the turning of koji is completed, fermentation continues for 8-10 days before the second turning of koji is carried out. After the turning of koji is completed, the doors and windows are closed and fermentation continues for 30-40 days. After fermentation is completed, the koji is released and stored in a ventilated and dry place for 3-6 months for use.

[0008] (2) Raw material pretreatment: Select sorghum and soak it in hot water for 6-10 hours until the sorghum grains fully absorb water and expand. Remove the pectin, take it out, rinse it, drain the water, and put it in a steaming equipment to steam for 2-4 hours to make the sorghum thoroughly cooked and without any hard core inside.

[0009] (3) Saccharification and fermentation process: After the pretreated sorghum and koji blocks are mixed evenly, Q303 Rhizopus koji and millet koji are added and mixed evenly to increase the number and types of environmental microorganisms. Aerobic stacking saccharification and fermentation is carried out for 2-4 days, and then anaerobic fermentation is carried out in the fermentation tank for 20-40 days.

[0010] (4) Distillation process: Distillation is carried out using distillation equipment. The six principles of "light, loose, uniform, thin, flat and accurate" are followed when loading the still. The still is kept at 0.03 MPa. The beginning and end of the fermentation are cut off. The fermented material is loaded into the distillation equipment and the distillation temperature is controlled at 90-100℃. During the distillation process, slow gas distillation is carried out, and the alcohol is extracted by observing the fermentation process.

[0011] (5) Aging process: The base liquor is graded and put into earthenware jars, and placed in earthenware jar storage for aging. The relative humidity is controlled at 60%-70%, and the aging time is 1-3 years. During the aging process, the base liquor is tasted and tested regularly to ensure that the quality of the base liquor is steadily improved.

[0012] In step (1) above, when wheat is crushed, mixed with mother koji and water to make koji blocks, the moisture content of the wheat should reach 37-39%; the size of the koji blocks should be 30cm×20cm×10cm, shaped like a tortoise shell, with low sides and high middle, tight around the edges and slightly loose in the middle; the koji blocks are placed in the koji room and folded with straw in three horizontal and three vertical directions for insulation; the temperature during the first turning of the koji blocks is 62-65℃; the temperature during the second turning of the koji blocks is 55-62℃; when turning the koji blocks, turn them from top to bottom and from inside to outside to ensure that the koji blocks ferment evenly from top to bottom and left to right.

[0013] In step (1) above, opening doors and windows for ventilation ensures that the koji blocks come into contact with external actinomycetes and Bacillus to produce a large amount of saccharifying enzymes and cellulases, which can more efficiently degrade starch and fiber in the raw materials, providing more fermentable sugars for subsequent fermentation. Contact with organic acids, including acetic acid bacteria and actinomycetes producing acetic acid and propionic acid, adjusts the pH of the koji blocks to 4.5-5.0, inhibits the growth of miscellaneous bacteria, and provides precursors for ester synthesis. Contact with foreign microorganisms, including actinomycetes producing terpenes, Bacillus producing pyrazines and 2,3-butanedione, supplements aromatic compounds.

[0014] In step (2) above, after the sorghum is steamed for 2 hours, warm water is added and stirred, and then it is steamed for another 1-2 hours to ensure that the sorghum is fully cooked and has no hard core inside.

[0015] In step (3) above, the pretreated sorghum and koji blocks are mixed at a mass ratio of 10:2; Guizhou Q303 Rhizopus koji accounts for 8% of the total mass, and millet koji accounts for 5% of the total mass; aerobic stacking saccharification fermentation is carried out, and the top temperature of the stack reaches 50-58℃ before it can be put into the pool for fermentation.

[0016] In step (3) above, a layer of rice husks with a thickness of 5-10cm is laid at the bottom of the fermentation tank to serve as a breathable and insulating layer; the fermentation temperature is controlled at 35-45℃.

[0017] This invention increases the alcohol yield and enhances flavor quality. Through mixed saccharification and fermentation of multiple types of yeast, it exposes the liquor to more environmental microorganisms, resulting in the metabolism of more beneficial flavor substances. This makes the flavor of the Maotai-flavor liquor more intense and harmonious, effectively controlling the production of acidic and astringent substances, ensuring stable quality, a smooth and refreshing taste, an elegant and delicate Maotai aroma, and a full-bodied and mellow character. Furthermore, the taste differences between different batches are minimal, significantly improving flavor stability. Detailed Implementation

[0018] A process for producing Maotai-flavor liquor includes the following steps:

[0019] (1) Koji-making process: Wheat is used as the raw material for koji making. After adding water to moisten the grain for 6-8 hours, 10-15% bran is produced, which plays a role in loosening and facilitating oxygen permeability and the growth and reproduction of beneficial aerobic microorganisms such as mold. Then, the bran is crushed, and mother koji and water are added to make koji blocks. After cooling in the oven for 20-40 minutes to absorb the sweat, the koji blocks are placed in the koji room and water is sprinkled evenly. After fermentation for 7-9 days, the koji is turned over for the first time. At the same time, the doors and windows are opened for ventilation to supplement the external environment microorganisms and species. After the turning is completed, fermentation continues for 8-10 days before the second turning. After the turning is completed, the doors and windows are closed and fermentation continues for 30-40 days. After fermentation is completed, the koji is released and stored in a ventilated and dry place for 3-6 months for use.

[0020] In the above steps, when wheat is crushed, mixed with mother koji and water to make koji blocks, the moisture content of the wheat should reach 37-39%. The size of the koji blocks should be 30cm×20cm×10cm, shaped like a tortoise shell, with low edges and high center, tight around the edges and slightly loose in the middle. The koji blocks are placed in the koji room and folded with straw in three horizontal and three vertical directions for insulation. The temperature during the first turning of the koji blocks is 62-65℃; the temperature during the second turning of the koji blocks is 55-62℃. When turning the koji blocks, turn them from top to bottom and from inside to outside to ensure that the koji blocks ferment evenly from top to bottom and left to right.

[0021] In the above steps, opening doors and windows for ventilation enhances saccharification, ensuring the koji blocks come into contact with external actinomycetes and Bacillus to produce abundant saccharifying enzymes and cellulases. This allows for more efficient degradation of starch and fiber in the raw materials, providing more fermentable sugars for subsequent fermentation. It also enhances acid production, adjusting the koji block pH to 4.5-5.0 through contact with organic acids, including acetic acid bacteria and actinomycetes producing acetic acid and propionic acid, inhibiting the growth of other microorganisms, and providing precursors for ester synthesis. Furthermore, it increases aroma production through contact with external microorganisms, including actinomycetes producing terpenes, and Bacillus producing pyrazines and 2,3-butanedione, supplementing aromatic compounds. Without ventilation, saccharification, acid production, and aroma potential are relatively weak, relying mainly on residual enzyme activity from Aspergillus oryzae and a small amount of Bacillus. Hypoxia inhibits enzyme synthesis, reducing starch degradation efficiency by approximately 15%-20%. In these cases, lactic acid production is primarily by lactic acid bacteria, with a limited variety of organic acids and a low pH. Slightly lower (4.0-4.5) may slightly inhibit yeast activity; yeast produces a small amount of esters, and lactic acid bacteria produce ethyl lactate precursors, resulting in a flavor profile that is primarily "mellow and smooth," with a relatively low flavor intensity. Therefore, through mixed saccharification and fermentation of multiple types of yeast, more environmental microorganisms are exposed, leading to the metabolism of more beneficial flavor substances. This results in a richer and more harmonious flavor profile for the Maotai-flavor liquor, effectively controlling the production of acidic and astringent substances, ensuring stable quality, a smooth and refreshing taste, an elegant and delicate Maotai aroma, a full-bodied and mellow character, and minimal differences in taste between different batches, significantly improving flavor stability.

[0022] (2) Raw material pretreatment: Select sorghum and soak it in hot water for 6-10 hours until the sorghum grains fully absorb water and expand. Remove the pectin, take it out, rinse it and drain the water. After steaming the sorghum for 2 hours, add warm water and stir, and continue to steam for 1-2 hours to ensure that the sorghum is fully cooked and has no hard core inside.

[0023] (3) Saccharification and fermentation process: After the pretreated sorghum and koji blocks are mixed evenly at a mass ratio of 10:2, 8% Guizhou Q303 Rhizopus koji and 5% millet koji are added and mixed evenly to increase the number and types of environmental microorganisms. Aerobic stacking saccharification and fermentation is carried out for 2-4 days. In spring and summer, it can be stacked into a rectangular shape, and in autumn and winter, it can be stacked into a conical shape. A layer of 3-5cm of steamed rice husks is laid in the cool chamber for heat preservation, which can improve the saccharification power, increase the flavor components, and increase the alcohol yield by 8%-15%. The top temperature of the stack reaches 50-58℃ before entering the fermentation tank. The temperature should be controlled between 1.2 and 2.0, the moisture content should be controlled between 52-55%, and the starch concentration should be controlled between 19-22%. Anaerobic fermentation is carried out for 20-40 days. A layer of rice husks with a thickness of 5-10cm is laid at the bottom of the fermentation tank to play a role in ventilation and isolation. The fermentation temperature is controlled at 35-45℃ for anaerobic fermentation.

[0024] (4) Distillation process: Distillation is carried out using distillation equipment. The six principles of "light, loose, uniform, thin, flat and accurate" are followed when loading the still. The still is kept at 0.03 MPa. The beginning and end of the fermentation are cut off. The fermented material is loaded into the distillation equipment and the distillation temperature is controlled at 90-100℃. During the distillation process, slow gas distillation and atmospheric tailing are carried out. The alcohol yield can reach 37%-45%, which is 15%-20% higher than the traditional Daqu sauce aroma process.

[0025] (5) Aging process: The base liquor is graded and put into earthenware jars, and placed in earthenware jar storage for aging. The relative humidity is controlled at 60%-70%, and the aging time is 1-3 years. During the aging process, the base liquor is tasted and tested regularly to ensure that the quality of the base liquor is steadily improved.

[0026] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A production process for Maotai-flavor liquor, characterized in that, Includes the following steps: (1) Koji making process: Wheat is used as the raw material for koji making. After adding water to moisten the grain for 6-8 hours, it is crushed and mixed with mother koji and water to make koji blocks. After cooling in the oven for 20-40 minutes to remove sweat, the koji blocks are placed in the koji room and sprinkled with water evenly. After fermentation for 7-9 days, the koji is turned over for the first time. At the same time, the doors and windows are opened for ventilation to replenish external environmental microorganisms. After turning the koji, fermentation continues for 8-10 days before the second turning of the koji. After turning the koji, the doors and windows are closed and fermentation continues for 30-40 days. After fermentation is completed, the koji is produced and stored in a ventilated and dry place for 3-6 months for future use. (2) Raw material pretreatment: Select sorghum and soak it in hot water for 6-10 hours until the sorghum grains fully absorb water and expand. Remove the pectin, take it out, rinse it, drain the water, and put it in a steaming equipment to steam for 2-4 hours to make the sorghum thoroughly cooked and without any hard core inside. (3) Saccharification and fermentation process: After the pretreated sorghum and koji blocks are mixed evenly, Q303 Rhizopus koji and millet koji are added and mixed evenly. Then, aerobic stacking saccharification and fermentation is carried out for 2-4 days, and then anaerobic fermentation is carried out in the fermentation tank for 20-40 days. (4) Distillation process: Distillation is carried out using distillation equipment; (5) Aging process: The base wine is put into earthenware jars and aged for 1-3 years.

2. The new process for producing Maotai-flavor liquor according to claim 1, characterized in that, In step (1), when wheat is crushed, mixed with mother koji and water to make koji blocks, the moisture content of the wheat should reach 37-39%; the size of the koji blocks should be 30cm×20cm×10cm, shaped like a tortoise shell, with low sides and high middle, tight around the edges and slightly loose in the middle; the koji blocks are placed in the koji room and folded with straw in three horizontal and three vertical directions for insulation; the temperature during the first turning of the koji blocks is 62-65℃; the temperature during the second turning of the koji blocks is 55-62℃; when turning the koji blocks, turn them from top to bottom and from inside to outside to ensure that the koji blocks ferment evenly from top to bottom and left to right.

3. The new process for producing Maotai-flavor liquor according to claim 1, characterized in that, In step (1), open doors and windows for ventilation to ensure that the koji blocks come into contact with external actinomycetes and Bacillus to produce a large amount of saccharifying enzymes and cellulases, which can more efficiently degrade starch and fiber in the raw materials, providing more fermentable sugars for subsequent fermentation. Contact with organic acids, including acetic acid bacteria and actinomycetes producing acetic acid and propionic acid, adjust the pH of the koji blocks to 4.5-5.0, inhibit the growth of miscellaneous bacteria, and provide precursors for ester synthesis. Contact with foreign microorganisms, including actinomycetes producing terpenes, Bacillus producing pyrazines and 2,3-butanedione, supplement aromatic compounds.

4. The production process of Maotai-flavor liquor according to claim 1, characterized in that, In step (2), after the sorghum has been steamed for 2 hours, warm water is added and stirred, and then it is steamed for another 1-2 hours to ensure that the sorghum is fully cooked and has no hard core.

5. The new process for producing Maotai-flavor liquor according to claim 1, characterized in that, In step (3), the pretreated sorghum and koji blocks are mixed at a mass ratio of 10:2; Guizhou Q303 Rhizopus koji accounts for 8% of the total mass, and millet koji accounts for 5% of the total mass; aerobic stacking saccharification fermentation is carried out, and the top temperature of the stack reaches 50-58℃ before it can be put into the pool for fermentation.

6. The new process for producing Maotai-flavor liquor according to claim 1, characterized in that, In step (3), a layer of rice husks with a thickness of 5-10cm is laid at the bottom of the fermentation tank to provide ventilation and isolation; the fermentation temperature is controlled at 35-45℃.