A method for preparing a low-fat, spicy chili sauce

Abstract

This invention relates to the field of functional food processing and intelligent manufacturing technology, specifically a method for preparing a low-fat, spicy chili sauce. The method includes the following steps: a. Raw material pretreatment and stepped fermentation: The main chili raw material is mixed with a fruit matrix and then subjected to a first-stage lactic acid fermentation, while some spices undergo a second-stage separate fermentation; b. Intelligent process control: During the fermentation stage, integrated sensors are used to monitor fermentation parameters in real time, and an AI system is used to dynamically predict and adjust process conditions such as temperature and time; c. Precise addition of functional ingredients: Heat-sensitive or easily oxidized functional ingredients are microencapsulated using fluidized bed gradient encapsulation technology and added to the product after fermentation at a low temperature. The final product has a fat content of less than 0.5g / 100g. Simultaneously, through composite gelation and stepped fermentation, the rich taste and complex flavor profile of traditional chili sauce are achieved.

Description

Technical Field

[0001] This invention belongs to the field of functional food processing and intelligent manufacturing technology, specifically relating to a method for preparing a low-fat, spicy chili sauce. This method systematically integrates technologies such as compound gel oil substitution, step-by-step fermentation, precise addition of functional ingredients, and intelligent control of the fermentation process, aiming to solve the technical problems of traditional low-fat chili sauces, including bland flavor, thin texture, short shelf life, and easy deactivation of functional ingredients. Background Technology

[0002] The development of low-fat chili sauce currently faces the following challenges: First, drastically reducing oil content leads to a loss of fat-soluble flavor compounds and a bland taste; second, heat treatment to ensure shelf life can easily destroy heat-sensitive nutrients and fresh flavor; and third, simple ingredient blending makes it difficult to achieve a layered flavor profile and effectively preserve functional components.

[0003] Existing technologies, such as "zero-oil, zero-fat rose chili sauce," use tomatoes as a base and produce flavor through high-temperature stir-frying, but the product lacks the complex and rich flavor resulting from fermentation. While "low-fat slimming chili sauce" incorporates various functional ingredients (such as konjac flour and L-carnitine), its complex composition may interfere with the main flavor, and the process fails to adequately protect these functional components. Some solutions use exogenous microbial inoculation to shorten the fermentation cycle, but lack precise dynamic control over the fermentation process, making it difficult to guarantee product consistency.

[0004] Therefore, there is an urgent need for a comprehensive technical solution that can balance low-fat health, rich flavor, functional activity, and stable production. Summary of the Invention

[0005] The purpose of this invention is to provide a method for preparing a low-fat, spicy chili sauce to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for preparing a low-fat, spicy chili sauce, the method comprising the following steps:

[0007] a. Raw material pretreatment and stepped fermentation: The main chili raw material is mixed with the fruit substrate and then subjected to the first stage of lactic acid fermentation, while some spices are subjected to the second stage of separate fermentation.

[0008] b. Intelligent process control: During the fermentation stage, integrated sensors are used to monitor fermentation parameters in real time, and an AI system is used to dynamically predict and adjust process conditions such as temperature and time.

[0009] c. Precise addition of functional ingredients: Heat-sensitive or easily oxidized functional ingredients are microencapsulated using fluidized bed gradient encapsulation technology and added to the product after fermentation and at low temperature.

[0010] d. Texture and preservation system construction: Add a complex gel system composed of konjac gum and oat β-glucan to the product, and use citric acid and sodium d-isoascorbate as natural preservatives and antioxidants in combination;

[0011] e. Mild sterilization and filling: The final product is pasteurized or concentrated at low temperature and then filled.

[0012] Preferably, in the stepped fermentation, the first stage of lactic acid fermentation uses a mixed bacterial culture of Lactobacillus plantarum and Lactococcus lactis in a volume ratio of 1:2~3, with a fermentation temperature of 25-30℃ and a fermentation time of 6-10 days; the second stage of separate fermentation is carried out on garlic slices, with a fermentation time of 15-20 days.

[0013] Preferably, in the intelligent process control, the AI ​​system used predicts the key control points until the end of fermentation based on the monitoring data of the first 20 hours of the fermentation process, and automatically generates temperature and ventilation control schemes, thereby reducing the production fluctuation rate by more than 30%.

[0014] Preferably, in the precise addition of the functional components, the microcapsules formed by the fluidized bed gradient encapsulation technology have a three-layer structure of core material, wall material, and enteric layer, with the enteric layer being a pH-responsive release material.

[0015] Preferably, in the composite gel system, the mass ratio of konjac gum to oat β-glucan is (1.5~2.5):(1~1.5).

[0016] Preferably, the fruit matrix is ​​tomato or apple, and the amount added is 5%-15% of the total raw materials.

[0017] A method for preparing low-fat spicy chili sauce.

[0018] Preferably, the fat content is less than 0.5g / 100g, and it contains functional ingredients such as encapsulated compound vitamins or plant extracts, with a retention rate of more than 90% in the product.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] Extremely low fat content combined with rich flavor: The final product has a fat content of less than 0.5g / 100g, while achieving the rich taste and complex flavor layers of traditional chili sauce through compound gelation and step fermentation.

[0021] High retention rate of functional ingredients: Through precise encapsulation technology and post-addition strategy, the processing retention rate of functional ingredients can reach more than 90%, and the bioavailability is significantly improved.

[0022] Intelligent production and stable quality: The AI ​​system enables precise control of the fermentation process, reducing product quality volatility by about 30% and significantly improving product consistency and production efficiency.

[0023] Clean label trend: Maximizing the use of natural raw materials (fruits, spices) and preservatives produced by bio-fermentation reduces reliance on chemical preservatives and is more in line with modern health consumption concepts. Attached Figure Description

[0024] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0025] Figure 1 This is a process flow diagram of the present invention. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only 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.

[0027] Please see Figure 1 The present invention aims to overcome the shortcomings of the prior art and provide a systematic solution. Its core objective is:

[0028] It creates a full-bodied texture and rich flavor layers without relying on large amounts of oil.

[0029] Ensure that added heat-sensitive functional ingredients (such as vitamins and prebiotics) remain highly active during processing and storage.

[0030] By using intelligent methods to precisely control the fermentation process, the consistency and stability of product quality can be improved.

[0031] Under low-oil and low-salt conditions, natural methods and process optimization are used to ensure the microbial safety and shelf life of the product.

[0032] This approach establishes the flavor base through a stepped fermentation process, ensures fermentation quality using an intelligent control system, precisely adds protected functional components in the later integration stage, and finally completes product manufacturing through a gentle process.

[0033] Module 1: Compound Formulations and Stepped Fermentation (Building the Foundation of Flavor)

[0034] This module aims to establish a low-fat and flavorful base for the product through ingredient blending and staged fermentation.

[0035] Main ingredient blend: Use fresh red chili peppers (60-75%, it is recommended to blend Erjingtiao and millet peppers in a specific ratio to balance the aroma and spiciness) as the main ingredient. Introduce apples (5-10%) or tomatoes (10-15%) as a natural zero-oil base. The natural fructose and organic acids they contain can enrich the flavor and help prevent spoilage.

[0036] Step fermentation process:

[0037] The first stage (dominated by lactic acid bacteria): A pulp made from chili peppers and tomatoes (or apples) is inoculated with a selected, unique compound lactic acid bacteria strain (such as a specific combination of Lactobacillus plantarum and Lactococcus lactis) and fermented at 25-30℃ for 6-10 days. This stage mainly produces organic acids such as lactic acid and acetic acid, forming a mellow, sour, and fragrant base flavor, and lowering the pH value to inhibit unwanted bacteria.

[0038] The second stage (flavor enhancement): A portion of the single-clove garlic slices (5-8%) are fermented separately in another container for a short period (e.g., 15-20 days). This process produces a mild, non-irritating fermented garlic aroma, enriching the flavor profile. Some minced garlic can also be briefly sautéed in a little oil (total amount <0.5%) or hot air and added later to provide an initial aroma.

[0039] Module Two: Precise Addition Process of Functional Ingredients (Active Protection and Targeted Release)

[0040] This module is a core innovation addressing the problem of functional ingredients being easily deactivated, employing advanced encapsulation technology to ensure its efficacy.

[0041] Fluidized bed gradient encapsulation technology: For heat-sensitive, photosensitive, or easily oxidized functional ingredients (such as B vitamins, vitamin C, tea extract, etc.), a three-layer encapsulation protection is used.

[0042] Core material: functional factors (such as vitamin C and B vitamins in a specific ratio).

[0043] Wall material: A compound of gum arabic and maltodextrin is selected as the main wall material and encapsulated using fluidized bed equipment.

[0044] Enteric coating: The outermost layer is further coated with enteric materials such as hydroxypropyl methylcellulose (HPMC) to form a pH-responsive release mechanism, which enables the functional components to be released into the intestines, significantly improving bioavailability.

[0045] Timing of addition: The encapsulated functional ingredient particles should be added during the flavoring stage after fermentation (when the system pH has stabilized and the temperature is low) to minimize losses during processing.

[0046] Module 3: Flavoring and Preservation Technology (Alternative Oils and Natural Preservatives)

[0047] Complex gel system: To mimic the smooth texture of fats, konjac gum (1.5-2.5%) and oat beta-glucan (1-1.5%) are combined as fat substitutes. This system not only provides a thick and smooth texture similar to fats, but also enhances the product's health attributes as a soluble dietary fiber. The gel network also encapsulates flavor molecules, slowing their dissipation.

[0048] Natural preservative system: Lemon vinegar (2-3%) provides a refreshing sour taste, and works synergistically with sodium d-isoascorbate (0.1%) to provide antioxidant and preservative effects, reducing reliance on high-temperature sterilization and better preserving fresh flavor.

[0049] Module Four: Intelligent Control System for Fermentation Process (Precision Manufacturing)

[0050] This module is key to achieving high-quality, standardized production of products.

[0051] Multi-sensor data acquisition: Raman spectrometer, mass spectrometer, pH and temperature sensors are integrated into the fermenter to monitor the dynamic changes of microbial metabolites (such as lactic acid and acetic acid), flavor substances (such as esters and alcohols), and physical parameters such as pH and temperature in the fermentation broth in real time.

[0052] AI-powered dynamic prediction and control: Based on intelligent control systems such as ManuDrive, a dynamic model of the fermentation process is established using collected data. This system can predict key control points (such as peak lactic acid bacteria activity and inflection points in flavor compound formation) in the early stages of fermentation (e.g., the first 20 hours) and generate optimized control schemes in advance, dynamically adjusting parameters such as temperature and aeration. For example, it can achieve a precise temperature control curve of "higher temperature in the early stage to promote cell proliferation → suitable temperature in the middle stage to produce flavor → lower temperature in the later stage to inhibit excessive acid production."

[0053] Digital Twin and Optimization Iteration: Construct a digital twin model of the fermentation process, continuously train and optimize the AI ​​model using historical data to form a closed-loop control, and continuously improve the stability and efficiency of the fermentation process.

[0054] Example 1: Low-fat, fresh and spicy fermented chili sauce

[0055] Formula: 70 parts fresh Erjingtiao chili flakes, 10 parts apple pulp, 8 parts single-clove garlic (5 parts for fermentation and 3 parts for stir-frying), 4 parts edible salt, a complex gel system (2 parts konjac gum and 1.2 parts oat β-glucan), 2.5 parts lemon vinegar, 0.1 parts sodium d-isoascorbate, 0.5 parts microencapsulated complex vitamins, and 1 part double-petaled red rose petals.

[0056] preparation:

[0057] Pretreatment and fermentation: Mix chopped Erjingtiao chili peppers with apple pulp, inoculate with compound lactic acid bacteria (Lactobacillus plantarum: Lactococcus lactis = 1:2), and ferment at 28℃ for 8 days. At the same time, add a small amount of salt to 5 portions of garlic slices and ferment separately at room temperature for 18 days.

[0058] To enhance aroma: Sauté 3 parts minced garlic in an electric frying pan with a very small amount of oil (<0.3%) or hot air at 90°C until fragrant.

[0059] Mixing and Adding: Combine the fermented chili sauce base, sautéed minced garlic, fermented garlic slices and juice, compound gel system (pre-hydrated), rose petals, and other seasonings, and chop thoroughly. Finally, add the microencapsulated complex vitamins at a temperature below 40°C and stir well.

[0060] Sterilization and filling: Pasteurize at 85℃ for 20 minutes, and then cool rapidly after filling.

[0061] Example 2: Zero-fat instant spicy sauce

[0062] Recipe: 85 parts tomato paste, 7 parts fresh chopped chili peppers, 5 parts garlic, 2.5 parts salt, 0.4 parts compound spices, 2 parts lemon, 0.1 parts sodium d-isoascorbate.

[0063] preparation:

[0064] Using an electric frying pan, first cook the tomato puree at 95℃ until it thickens and bubbles.

[0065] Add minced garlic and chopped chili, and stir-fry for 25 minutes.

[0066] Cool to 85°C, add lemon juice and other spices, and stir-fry for 15 minutes.

[0067] Stop heating, add sodium d-isoascorbate, mix well, fill into containers, and sterilize at 102°C for 20 minutes.

[0068] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for preparing a low-fat, spicy chili sauce, characterized in that, The method includes the following steps: a. Raw material pretreatment and stepped fermentation: The main chili raw material is mixed with the fruit substrate and then subjected to the first stage of lactic acid fermentation, while some spices are subjected to the second stage of separate fermentation. b. Intelligent process control: During the fermentation stage, integrated sensors are used to monitor fermentation parameters in real time, and an AI system is used to dynamically predict and adjust process conditions such as temperature and time. c. Precise addition of functional ingredients: Heat-sensitive or easily oxidized functional ingredients are microencapsulated using fluidized bed gradient encapsulation technology and added to the product after fermentation and at low temperature. d. Texture and preservation system construction: Add a complex gel system composed of konjac gum and oat β-glucan to the product, and use citric acid and sodium d-isoascorbate as natural preservatives and antioxidants in combination; e. Mild sterilization and filling: The final product is pasteurized or concentrated at low temperature and then filled.

2. The method for preparing a low-fat, spicy chili sauce according to claim 1, characterized in that: In the stepped fermentation process, the first stage of lactic acid fermentation uses a mixed bacterial culture of Lactobacillus plantarum and Lactococcus lactis in a volume ratio of 1:2~3, with a fermentation temperature of 25-30℃ and a fermentation time of 6-10 days; the second stage of separate fermentation is carried out on garlic slices, with a fermentation time of 15-20 days.

3. The method for preparing a low-fat, spicy chili sauce according to claim 1, characterized in that: In the intelligent process control, the AI ​​system used predicts key control points from the first 20 hours of fermentation until the end of fermentation based on monitoring data, and automatically generates temperature and ventilation control schemes, reducing production fluctuation rate by more than 30%.

4. The method for preparing a low-fat, spicy chili sauce according to claim 1, characterized in that: In the precise addition of the functional components, the microcapsules formed by the fluidized bed gradient encapsulation technology have a three-layer structure of core material, wall material, and enteric layer, with the enteric layer being a pH-responsive release material.

5. The method for preparing a low-fat, spicy chili sauce according to claim 1, characterized in that: In the composite gel system, the mass ratio of konjac gum to oat β-glucan is (1.5~2.5):(1~1.5).

6. The method for preparing a low-fat, spicy chili sauce according to claim 1, characterized in that: The fruit substrate is tomato or apple, and the amount added is 5%-15% of the total raw materials.

7. A low-fat spicy chili sauce prepared by the method of any one of claims 1-6.

8. The low-fat, spicy chili sauce according to claim 7, characterized in that, Its fat content is less than 0.5g / 100g, and it contains functional ingredients such as encapsulated complex vitamins or plant extracts, with a retention rate of more than 90% in the product.

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