Two-stage wine lees airing machine

Abstract

The application discloses a two-section type fermented grains airing machine and relates to the technical field of wine brewing equipment. The airing machine is split into two sections of modular air chambers with separate temperature control. The first section of the airing device is controlled by a control system combined with temperature sensor data to rapidly reduce the temperature of fermented grains from high temperature to 60 DEG C, inhibit the rearrangement of amylose, and then quickly pass through the 60-40 DEG C sensitive zone of starch aging to reduce the long-term crystallization window of amylopectin, shorten the residence time in the aging temperature danger zone by 60%, and reduce the aging enthalpy by 25-40%. The second section of the airing device quickly passes through the 40-30 DEG C temperature zone to prevent starch from agglomerating, and then slowly and uniformly reduces the temperature to the process target temperature. In the application, the whole equipment control system is linked with a temperature sensor, an infrared moisture meter and an air cooling device to realize automatic operation. In combination with two different temperature control modes and different stirring modes, the application realizes uniform airing of fermented grains, greatly improves the utilization rate of fermented grains and the yield of wine, and is suitable for large-scale popularization and application.

Description

Technical Field

[0001] This invention relates to the field of brewing equipment technology, specifically a two-stage fermentation mash cooling machine. Background Technology

[0002] Most existing mash cooling machines adopt a single-section integral structure and use a flat chain plate for conveying. This type of cooling machine reduces the temperature of the mash material from a high temperature of 90-100℃ to a target temperature of 15-25℃ in one go, which can easily lead to a large temperature difference between the inside and outside of the mash material, accelerate starch aging, and affect the alcohol yield.

[0003] Starch retrogradation is the process by which gelatinized starch molecules rearrange from a disordered state into an ordered crystalline structure, and it consists of two stages: Short-term aging (0-12h) causes rapid recrystallization of amylose, leading to increased hardness; Over a long period of aging (several days to several weeks), the short chains on the outer side of amylopectin slowly crystallize, which determines the final degree of deterioration in taste.

[0004] Therefore, the most severe "danger zone" for starch retrogradation exists in two aspects: temperature and moisture. The fastest retrogradation occurs at 2-10℃, followed by 60-40℃. The most prone to retrogradation occurs when the moisture content is 30%-60%. The typical moisture content of fermented mash is 55%-60%, and the cooling process is from 90-100℃ to 15-25℃, which happens to fall within the sensitive zone of starch retrogradation.

[0005] Patent CN113278480A discloses a flexible cooling method for spreading fermented mash during the hot season, which includes two processes: pre-cooling and post-cooling. Pre-cooling uses a normal temperature blower to blow at a fixed frequency to quickly reduce the moisture content of the mash until the near-surface humidity is lower than a first preset value. Temperature monitoring is performed on all mash to identify areas of uneven cooling, and the blower is controlled to perform variable frequency sweeping on these areas. Post-cooling uses a blower under refrigerant conditions to perform low-temperature variable frequency sweeping on the mash, and the mash temperature is not lower than the dew point temperature. Temperature and near-surface humidity of the mash are detected to identify areas of uneven cooling, and the blower is controlled to perform variable frequency sweeping on these areas until cooling is complete. This flexible cooling method is actually a gradient air cooling method. Variable frequency air sweeping improves the uniformity of cooling, solves the problem of high cooling temperature in hot seasons, and improves cooling efficiency. At the same time, it also solves the condensation phenomenon caused by high humidity and high ambient temperature in hot seasons and improves the level of intelligence.

[0006] Actual measurements show that the temperature of the mash entering the fermentation pit is stabilized at 25-26℃ after gradient air cooling, which is 2℃ higher than that of manual cooling. This effectively avoids the low-temperature aging zone. The fermentation power is slightly lower than that of manual cooling, but the uniformity is significantly improved, the batch difference is reduced, energy consumption is reduced by 35%, and the alcohol yield is increased by 1.8-2.4%. This proves that gradient cooling can indeed solve the problems of current mash cooling equipment to a certain extent. However, it does not improve the structure of traditional cooling machines, but only adds intelligent control to achieve gradient temperature control.

[0007] In addition, traditional cooling machines also have the problem of material loss. Traditional conveyor chains are prone to causing the mash (especially sticky materials) to leak and stick to the plates during conveying and turning, resulting in yield loss and cleaning difficulties. Summary of the Invention

[0008] To address the aforementioned technical problems, this invention provides a two-stage fermentation mash cooling machine. It features two separate temperature-adjustable air chambers for segmented, gradient cooling of the fermentation mash. Temperature sensors and moisture detection devices monitor the temperature and moisture content of the fermentation mash in real time. The control system links the two-stage cooling equipment for online regulation, achieving rapid cooling, avoiding the sensitive area of ​​starch aging in the fermentation mash, and shortening the residence time in the 60-40℃ temperature range, thus significantly delaying starch aging in the fermentation mash.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A two-stage fermentation mash cooling machine includes a first-stage cooling device, a second-stage cooling device, and a control system. The first-stage and second-stage cooling devices are functionally independent and their temperatures can be controlled separately. The first-stage cooling device is connected to a feeder to receive fermentation mash material from the feeder for conveying and cooling. The first-stage cooling device is mounted on top of the second-stage cooling device, which receives fermentation mash material that falls and spills from the first-stage cooling device. After cooling, the material is conveyed to the koji-adding machine's chain conveyor for the koji-adding process. The control system receives temperature information from temperature sensors installed inside the two-stage cooling devices and controls the first-stage cooling device to reduce the temperature of the fermentation mash material from the discharge high temperature to 40°C within 10 minutes, and the second-stage cooling device to reduce the temperature of the fermentation mash material from 40°C to the process target temperature within 10 minutes.

[0010] The cooling process of the first cooling device is divided into two stages: Energy-saving phase: Rapidly reducing temperature from high to 60℃; To prevent starch retrogradation, the temperature should be rapidly reduced from 60℃ to 40℃. The cooling process of the second cooling device is divided into two stages: To prevent clumping: rapidly reduce the temperature from 40℃ to 30℃; To prevent the core from cooling down while the surface remains cool, the temperature is slowly reduced from 30℃ to the target process temperature.

[0011] The first and second cooling devices are each set as separate modular independent air chambers, using stainless steel honeycomb panel air ducts. An electric regulating valve is installed between the two independent air chambers to achieve temperature gradient control.

[0012] Several PT temperature probes are installed at intervals in the first and second cooling devices, and dew point sensors are installed at the ends.

[0013] Infrared moisture detectors are installed at the front end of the first cooling device and the end of the second cooling device to detect the moisture content of the mash provided by the feeder. The moisture content data is used to feed back the deviation of the moisture content of the mash. When the moisture content is lower than 55%, the control system starts the water replenishment device to replenish the moisture content of the mash to the required moisture content. The moisture content accuracy is controlled within ±1%.

[0014] Both the first and second cooling devices employ centrifugal fans with asymmetrical configurations, and the volutes of all centrifugal fans face upwards with the air inlets facing downwards.

[0015] The conveyor chain plates of the first and second cooling devices are diamond-shaped perforated chain plates.

[0016] The first cooling device has a built-in spiral turner with a turning frequency of ≥30s / time and a rotation speed of 12rpm. The second cooling device has a built-in variable frequency rake loosener with a frequency range of 0.5-2Hz.

[0017] The first and second cooling devices are connected in series along the material conveying direction and fixedly mounted on the frame. A movable cleaning tank is provided at the bottom of the frame.

[0018] The first cooling device is equipped with a waste steam collection hood at the top to collect the waste steam generated during the cooling process of the high-temperature mash.

[0019] The beneficial effects of this invention are as follows: 1) The cooling machine is divided into two modular air chambers with independent temperature control. The control system, combined with temperature sensor data, controls the first cooling device to quickly reduce the temperature of the mash from high temperature to 60℃, inhibiting amylose rearrangement. Then, it quickly passes through the starch aging sensitive zone of 60-40℃, reducing the long-term crystallization window of amylopectin, shortening the residence time in the dangerous aging temperature zone by 60%, and reducing the aging enthalpy by 25-40%. The second cooling device quickly passes through the temperature zone of 40-30℃ to prevent starch agglomeration, and then slowly and evenly cools down to the target process temperature. The control system sets the control program to link the centrifugal fans of the two cooling devices. Combined with the temperature information from the temperature sensor, the fan speed or air temperature is adjusted to achieve precise preset control of the two temperatures. 2) Infrared moisture meters are installed at the front end of the first cooling device and the end of the second cooling device to detect the moisture content of the incoming material in real time. When the moisture content of the mash material is lower than 55%, the water replenishment device is activated to replenish moisture in time, ensuring that the moisture content of the mash material is within the required process moisture content and avoiding the starch aging moisture sensitive area. 3) The segmented modular air-cooling structure combined with the gradient temperature control system avoids the starch aging sensitive zone of 40-60℃ and shortens the residence time of starch agglomeration in the 40-30℃ range, realizing uniform segmented cooling of mash materials, significantly delaying starch aging of mash and effectively improving alcohol yield. 4) The conveyor chain plate was improved by adopting a diamond-shaped chain plate, which reduced the occurrence of material leakage and sticking, and improved the utilization rate of mash materials; 5) A movable cleaning tank is installed at the bottom of the frame, which makes cleaning convenient and saves labor. 6) The entire equipment control system is linked with temperature sensors, infrared moisture meters and air-cooling equipment to achieve automatic operation. With two different temperature control modes and different material turning methods, the mash material is cooled evenly, which greatly improves the utilization rate of mash material and the output of alcohol, making it suitable for large-scale promotion and application. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the main structure of the present invention; Figure 2 This is a top view of the main structure of the present invention; Figure 3 for Figure 2 A partial enlarged view of the first cooling device in the middle section; Figure 4 This is a schematic diagram of the spiral material turner in this invention; Figure 5 for Figure 2 A partial enlarged view of the second cooling device in the middle section; Figure 6 This is a schematic diagram of the structure of the variable frequency rake-type loosener in this invention; Figure 7This is a schematic diagram of the diamond-shaped chain plate in this invention; Figure 8 This is a schematic diagram of the movable cleaning tank in this invention. Detailed Implementation

[0021] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments: like Figure 1-2 As shown, the two-stage fermented mash cooling machine includes a first-stage cooling device 1, a second-stage cooling device 2, and a control system. The first-stage cooling device 1 and the second-stage cooling device 2 are configured as independent cooling devices with separately adjustable temperatures. The first-stage cooling device 1 is connected to the feeder 3 and receives fermented mash from the feeder 3 for conveying and cooling. The first-stage cooling device 1 is mounted on the second-stage cooling device 2. The second-stage cooling device 2 receives the fermented mash that falls and spills from the first-stage cooling device 1, and after cooling, it is conveyed to the koji-adding machine chain conveyor 4 for the koji-adding process. The control system receives temperature information from temperature sensors installed inside the two-stage cooling devices and controls the first-stage cooling device 1 to reduce the temperature of the fermented mash from the discharge high temperature to 40°C within 10 minutes, and the second-stage cooling device 2 to reduce the temperature of the fermented mash from 40°C to the process target temperature within 10 minutes.

[0022] As a preferred embodiment, in this case, the cooling process of the first cooling device 1 is divided into two stages: Energy-saving stage: The temperature is rapidly reduced from high temperature to 60℃. Since the discharge temperature of the mash material provided by feeder 1 is generally 90-100℃ and there is no starch aging problem, rapid cooling can save energy. To prevent starch retrogradation, the temperature should be rapidly reduced from 60℃ to 40℃. The 40-60℃ range is a sensitive zone for starch retrogradation, so this range should be quickly skipped to minimize starch retrogradation. The cooling process of the second cooling device 2 is divided into two stages: Preventing clumping stage: Rapidly reduce the temperature from 40℃ to 30℃. This temperature range is where starch is prone to clumping, so quickly skip this stage to prevent starch clumping. To prevent the surface from cooling while the core remains cool: the temperature is slowly reduced from 30℃ to the target temperature of the process. The target temperature varies slightly depending on the process, but is generally within the range of 15-25℃. During this process, the temperature is reduced slowly and steadily so that the mash material cools down evenly inside and out at the same time, preventing the surface from cooling while the core remains cool, which would affect the distillation process.

[0023] As a preferred embodiment, the first cooling device 1 and the second cooling device 2 are respectively set as separate modular independent air chambers 12, each with a length of 5 meters, using stainless steel honeycomb panel air ducts, and an electric regulating valve is installed between the two independent air chambers 12 to achieve temperature gradient control.

[0024] As a preferred embodiment, in this embodiment, several PT temperature probes are spaced apart in the first cooling device 1 and the second cooling device 2, and a dew point sensor is installed at the end. In this embodiment, a PT temperature probe is installed every 2 meters.

[0025] As a preferred embodiment, infrared moisture detectors are respectively installed at the front end of the first cooling device 1 and the end of the second cooling device 2 to detect the moisture content of the mash provided by the feeder 3. The moisture content data is used to feed back the deviation of the moisture content of the mash. When the moisture content is lower than 55%, the control system starts the water replenishment device to replenish the moisture content of the mash to the required moisture content (generally within the range of 65-70%). The moisture content accuracy is controlled within ±1% to prevent surface crusting from affecting heat transfer and to inhibit the aging of the mash.

[0026] As a preferred embodiment, both the first cooling device 1 and the second cooling device 2 adopt centrifugal fans 13 with an asymmetrical structure. This design ensures uniform airflow from the cooling fan and guarantees the cooling effect. Furthermore, the volutes of all centrifugal fans 13 are on top and the air inlets are facing downwards, preventing moisture in the air chamber from entering the motor through the fan inlets and causing damage to the motor.

[0027] As a preferred embodiment, in this case, the conveyor chain plates of the first cooling device 1 and the second cooling device 2 are diamond-shaped perforated chain plates. While ensuring ventilation, the unit area is slightly larger than that of traditional chain plates, increasing the unit ventilation area by 14%. The diamond-shaped teeth of adjacent chain plates interlock during operation, forming a continuous, seamless conveying surface. This effectively supports the finely broken mash, preventing it from falling through the gaps in the chain plates into the ventilation chamber, reducing material loss and cleaning issues during transport. The specific structure of the diamond-shaped chain plate is clearly described in our patent No. 2023231374918, entitled "A Diamond-Shaped Perforated Screen Plate for a Cooling Machine," as shown in the following figure. Figure 7 As shown, no further details will be provided here.

[0028] like Figure 3-6 As shown, in this preferred embodiment, the first cooling device 1 has a built-in spiral turner 11 with a turning frequency ≥30s / time and a rotation speed of 12rpm, and the second cooling device 2 has a built-in variable frequency rake loosener 21 with a frequency range of 0.5-2Hz.

[0029] As a preferred embodiment, in this case, the first cooling device 1 and the second cooling device 2 are connected end-to-end and fixedly mounted on the frame 3 along the material conveying direction. A movable cleaning trough is provided at the bottom of the frame 3 for easy manual removal and cleaning. The structure of the movable cleaning trough adopts the design of our company's patent number 2023229574140, entitled "A Movable Cleaning Device," and its specific structure is as follows: Figure 8 As shown, due to space limitations, further details will not be elaborated here.

[0030] As a preferred embodiment, in this embodiment, a waste steam collection hood 5 is provided on the upper part of the first cooling device 1 to collect the waste steam generated during the cooling process of the high-temperature mash material. The waste steam collection hood 5 is set as a cover covering the first cooling device 1, and the cover is then connected to a waste steam treatment device. This will not be described in detail here. This design is because the temperature of the mash material being cooled in the first cooling device 1 is relatively high, and a large amount of waste steam is easily generated during the cooling process. By the time it reaches the second cooling device 2, the temperature of the mash has dropped below 40°C, so there is no need to add a waste steam treatment device.

[0031] In summary, the two-stage cooling device achieves rapid cooling of the starch in the mash during the cooling process through four temperature-controlled cooling stages with different purposes. This allows the starch to quickly pass through the aging-sensitive zone of 60-40℃, then rapidly pass through the 40-30℃ temperature range to prevent clumping, and finally slowly and evenly cool to the target temperature. The entire cooling process is controlled within 20 minutes. If the weather is hot, an auxiliary cooling device can be added at the end of the second-stage cooling device 2 to ensure that the final cooling time is within 10 minutes, significantly delaying starch aging, improving taste, and increasing alcohol yield.

[0032] In this invention, the design of the control system, including the design of the control system and control program according to the temperature control steps and methods, is a basic skill for those skilled in the art and will not be described in detail here. The control system receives data signals from temperature sensors and moisture detectors, and coordinates the wind speed of the air-cooled equipment in the first cooling device 1 and the second cooling device 2, as well as the actions of the turning device, water replenishment device, and auxiliary cooling device, to keep the overall cooling time within 20 minutes. This allows for rapid passage through the temperature-sensitive aging zone and ensures the temperature is at the target temperature before discharge, maximizing the inhibition of starch aging. The final cooling stage requires careful control to achieve precise temperature control of the fermentation mash during the cooling process.

[0033] The temperature sensor, moisture detector, spiral return feeder, rake loosener, water replenishment device, and auxiliary cooling device described in this invention are all conventional mechanical equipment, commonly used finished equipment by those skilled in the art. Therefore, the specific structure is not disclosed in detail in the specification. There are various finished products available, and you can choose according to your needs without any restrictions.

[0034] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A two-stage fermented mash cooling machine, characterized in that, The device includes a first cooling device (1), a second cooling device (2), and a control system. The first cooling device (1) and the second cooling device (2) are set as cooling devices with independent functions and independently adjustable temperatures. The first cooling device (1) is connected to the feeder (3) and receives fermented mash from the feeder (3) for conveying and cooling. The first cooling device (1) is attached to the second cooling device (2). The second cooling device (2) receives the fermented mash that falls and spills from the first cooling device (1), and after cooling, it is conveyed to the chain conveyor (4) of the koji-adding machine for the koji-adding process. The control system receives temperature information from the temperature sensors installed inside the two cooling devices and controls the first cooling device (1) to reduce the temperature of the fermented mash from the discharge high temperature to 40°C within 10 minutes, and the second cooling device (2) to reduce the temperature of the fermented mash from 40°C to the process target temperature within 10 minutes.

2. The two-stage fermented mash cooling machine according to claim 1, characterized in that, The cooling process of the first cooling device (1) is divided into two stages: Energy-saving phase: Rapidly reducing temperature from high to 60℃; To prevent starch retrogradation, the temperature should be rapidly reduced from 60℃ to 40℃. The cooling process of the second cooling device (2) is divided into two stages: To prevent clumping: rapidly reduce the temperature from 40℃ to 30℃; To prevent the core from cooling down while the surface remains cool, the temperature is slowly reduced from 30℃ to the target process temperature.

3. The two-stage fermented mash cooling machine according to claim 1, characterized in that, The first cooling device (1) and the second cooling device (2) are respectively set as separate modular independent air chambers (12), using stainless steel honeycomb air ducts. An electric regulating valve is set between the two independent air chambers (12) to achieve temperature gradient control.

4. A two-stage fermented mash cooling machine according to claim 1, characterized in that, Several PT temperature probes are spaced apart in the first cooling device (1) and the second cooling device (2), and a dew point sensor is installed at the end.

5. A two-stage fermented mash cooling machine according to claim 1, characterized in that, Infrared moisture detectors are installed at the front end of the first cooling device (1) and the end of the second cooling device (2) to detect the moisture content of the mash material provided by the feeder (3). The deviation of the moisture content of the mash material is fed back through the moisture content data. When the moisture content is lower than 55%, the control system starts the water replenishment device to replenish the moisture content of the mash material to the required moisture content of the process. The moisture content accuracy is controlled within ±1%.

6. A two-stage fermented mash cooling machine according to claim 1, characterized in that, Both the first cooling device (1) and the second cooling device (2) adopt centrifugal fans (13) with asymmetrical structures, and the volutes of all centrifugal fans (13) are on top and the air inlets are facing down.

7. A two-stage fermented mash cooling machine according to claim 1, characterized in that, The conveyor chain plates of the first cooling device (1) and the second cooling device (2) are diamond-shaped hole chain plates.

8. A two-stage fermented mash cooling machine according to claim 1, characterized in that, The first cooling device (1) has a built-in spiral turner (11) with a turning frequency of ≥30s / time and a rotation speed of 12rpm. The second cooling device (2) has a built-in variable frequency rake loosener (21) with a frequency range of 0.5-2Hz.

9. A two-stage fermented mash cooling machine according to claim 1, characterized in that, The first cooling device (1) and the second cooling device (2) are connected in series along the material conveying direction and fixedly mounted on the frame (3). A movable cleaning tank is provided at the bottom of the frame (3).

10. A two-stage fermented mash cooling machine according to claim 1, characterized in that, The first cooling device (1) is equipped with a waste steam collection hood (5) at the top to collect the waste steam generated during the cooling process of the high-temperature mash material.

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