A multi-mode, unpowered gas exchange device and method for independently movable, closed, static fermentation vessels

Abstract

The application discloses a kind of multi-mode unpowered gas exchange device and method for independently movable closed static fermentation container, belong to food fermentation equipment technical field.The device includes integrated rain-sheltering insect-proof structure, multistage progressive filter module and one-way check valve core, is installed in the top of fermentation container, completely rely on the air pressure difference generated by day and night temperature difference inside and outside container automatic work, without any power drive.When the micro negative pressure is formed in container when night temperature drops, valve core is automatically opened, external air is purified after passing through umbrella-shaped rain-sheltering insect-proof cover, stainless steel insect screen and three-stage progressive filter module and enters container;When pressure recovers when daytime temperature rises, valve core is automatically closed, prevent gas backflow.Multistage filter module is composed of 10 μm activated carbon layer, 1 μm glass fiber cotton layer and 0.22 μm polytetrafluoroethylene sterile filter membrane layer, progressively, ensure that the air reaching container reaches sterile grade.The application realizes the unity of zero energy consumption, accurate trace air supplement and high-efficiency pollution prevention, adapts closed fermentation container that can be mechanized transfer and stacking, especially suitable for high-salt dilute-state soy sauce and other fermentation food that need long-period static ripening.

Description

Technical Field

[0001] This invention relates to the field of food fermentation equipment technology, specifically to a non-powered gas exchange device for liquid or solid fermented foods such as soy sauce, sauces, vinegar, and pickles, and is particularly suitable for long-cycle static fermentation containers that require micro-oxygen supplementation. Background Technology In the long-term static maturation process of fermented foods such as high-end soy sauce, the supply of trace amounts of oxygen in the later stage of fermentation (more than 90 days) is crucial for promoting the formation of key flavor substances such as esters. In existing technologies, there are two main ways to provide oxygen: one is open fermentation, which introduces air by manually turning or stirring the mash, but this has problems such as high energy consumption, high risk of contamination by miscellaneous bacteria, and unstable batch quality; the other is to use an electrically driven air pump for forced aeration, but this has drawbacks such as high energy consumption, high equipment investment, and difficulty in accurately controlling the amount of micro-aeration. Some solutions attempt to use passive air replenishment, but these typically only include simple vents or one-way valves, lacking an effective multi-stage filtration system. This fails to effectively block external bacteria, dust, and insects, posing a risk of contamination. Furthermore, the valve opening pressure and air replenishment volume in existing solutions cannot be precisely controlled, making it difficult to meet precise process requirements. In addition, existing passive aeration solutions are mostly designed for fixed fermentation tanks or large fermentation vessels, and cannot be adapted to independent mobile fermentation containers that require mechanized transportation and stacking. The latter is a key equipment form for realizing the industrialization and standardized mass production of fermented foods. Therefore, there is an urgent need for a gas exchange device that is completely powered without electricity, can achieve precise micro-gas replenishment, has multi-stage filtration and anti-pollution capabilities, and is suitable for independently movable, sealed, static fermentation containers. Summary of the Invention I. Technical problems to be solved The present invention aims to solve the problems of insufficient filtration, uncontrollable gas supply, and inability to adapt to mechanized transfer closed fermentation containers in the prior art of passive gas supply devices. II. Technical Solution A multi-mode non-powered gas exchange device for independently movable and stackable closed static fermentation containers includes an integrated rainproof and insect-proof structure, a multi-stage progressive filtration module, and a one-way check valve core. The device is installed on top of the fermentation container and operates automatically entirely based on the pressure difference between the inside and outside of the container: when the internal temperature of the container drops and forms a slight negative pressure, the valve core opens automatically, and outside air enters the container after being filtered by the rainproof and insect-proof structure and the multi-stage filtration module; when the internal temperature of the container rises and the pressure is restored, the valve core closes automatically to prevent gas backflow and external contamination from entering. The multi-stage filtration module has a three-stage progressive structure. The first stage has a filtration accuracy of 10μm, the second stage has 1μm, and the third stage has 0.22μm, which is progressive to ensure that the air entering the container reaches the sterility level. The fermentation container is an independently movable and stackable sealed unit with an integrally molded bottom structure for mechanized transport, which distinguishes it from a fixed fermentation tank. III. Beneficial Effects Zero energy consumption: It works automatically entirely by relying on the air pressure difference generated by the temperature difference between day and night, without requiring any power input. Precise micro-air replenishment: By setting the opening and closing pressure of the valve core, the amount of air replenished each time can be precisely controlled. Highly efficient pollution prevention: The three-stage progressive filtration system, combined with a rainproof and insect-proof structure, ensures the quality of the air entering the container. Industrialization Adaptation: The container is defined as an independently movable unit, adapted to mechanized transfer and stacking, to meet the needs of large-scale production. Completely static fermentation: No stirring, no turning of the mash, and no electric ventilation throughout the entire process, preserving the natural fermentation flavor to the maximum extent. Detailed Implementation The performance data involved in the following embodiments are expected results obtained from engineering calculations and theoretical analysis of the technical solution of the present invention, rather than measured data. However, based on the well-known principles of heat transfer, microbiology, and food fermentation in the art, as well as existing experimental data of similar systems, those skilled in the art can reasonably expect that the technical effects within the range can be obtained after adopting the technical solution described in the present invention. Example 1 (Basic Example) A multi-stage filtered air intake valve, made of food-grade 316 stainless steel, is installed on top of a 500L sealed soy sauce fermentation tank. The valve core opening pressure is set to gauge pressure -0.005MPa, and the closing pressure is 0MPa. The filtering module has a three-level structure: First stage: Food-grade coconut shell activated carbon filter layer, with a filtration accuracy of 10μm, used to remove large particles of dust and odors; Second stage: Glass fiber filter cotton layer, with a filtration accuracy of 1μm, used to remove fine particles; The third stage: a sterile polytetrafluoroethylene (PTFE) filter membrane with a filtration accuracy of 0.22μm, used to intercept bacteria and microorganisms. The rain and insect protection device has an umbrella-shaped surface, with the outer edge projecting vertically to completely cover the air inlet. A stainless steel insect net is installed on the inner side, and a drainage channel is opened at the bottom. The soy sauce mash had a salinity of 18%. After 90 days of fermentation, oxygen was automatically replenished once a day using the pressure difference created by the diurnal temperature variation, with each replenishment amounting to approximately 0.7% of the container volume. The entire fermentation process involved no stirring, no turning of the mash, and no electrically driven ventilation. Upon completion of fermentation, the expected amino acid nitrogen content in the soy sauce was ≥0.92g / 100mL, and the content of ester flavor compounds was expected to increase by 35% compared to the control group without oxygen replenishment. Example 2 (Alternative to ceramic membrane filtration) A food-grade ceramic membrane was used as the third-stage filter medium, with a filtration accuracy of 0.2 μm. The remaining structure was the same as in Example 1. Based on the same mass transfer principle and driving force conditions as in Example 1, the expected gas replenishment stability was not significantly different from that in Example 1. Example 3 (Alternative to Polypropylene Meltblown Filter) A polypropylene melt-blown filter element was used as the second-stage filter medium, with a filtration accuracy of 1 μm. The remaining structure was the same as in Example 1. The test results were expected to be consistent with those of Example 1. Example 4 (Adapted for kimchi fermentation containers) Install this device on top of a 300L kimchi fermentation tank. Adjust the valve opening pressure to gauge pressure -0.003MPa. During the 20-day kimchi fermentation period, the device automatically maintains a slight negative pressure inside the container. A small amount of outside air enters after three-stage filtration. There is no stirring or turning of the fermentation mixture throughout the entire process. The expected contamination rate is ≤0.1%. Example 5 (Multi-tank linkage adaptation) Multiple units of this device are installed on top of multiple fermentation vessels, and each vessel is connected to a central multi-stage filtration manifold via quick-release aseptic connectors to achieve centralized filtration and decentralized gas supply. Each vessel retains its independent mobility and stacking capability.

Claims

1. A multi-mode, non-powered gas exchange device for independently movable, stackable, closed static fermentation containers, characterized in that, include: The device integrates a rainproof and insect-proof structure; a multi-stage progressive filtration module; and a one-way check valve. Installed on top of the fermentation container, it operates automatically solely based on the pressure difference between the inside and outside of the container, requiring no electrical drive. When the internal pressure of the container is lower than the external atmospheric pressure, the valve automatically opens, allowing outside air to enter the container after being filtered by the rainproof and insect-proof structure and the multi-stage filtration module. When the internal pressure returns to equilibrium with the outside pressure, the valve automatically closes. The filtration accuracy of the multi-stage filtration module increases progressively, with the final stage having a filtration accuracy ≤0.22μm, effectively trapping bacteria and microorganisms. The fermentation container is an independently movable, stackable, sealed unit with an integrally molded bottom structure for mechanized transport and stacking.

2. The apparatus according to claim 1, characterized in that, The multi-stage filtration module has a three-stage structure: the first stage is an activated carbon filter layer with a filtration accuracy of 10μm; the second stage is a glass fiber filter cotton layer with a filtration accuracy of 1μm; and the third stage is a polytetrafluoroethylene (PTFE) sterile filter membrane layer with a filtration accuracy of 0.22μm.

3. The apparatus according to claim 2, characterized in that, The third-stage filter medium can be replaced with a food-grade ceramic membrane with a filtration accuracy of 0.2μm.

4. The apparatus according to claim 2, characterized in that, The second-stage filter medium can be replaced with a polypropylene meltblown filter element with a filtration accuracy of 1μm.

5. The apparatus according to claim 1, characterized in that, The opening pressure of the one-way check valve core is gauge pressure -0.005MPa, and the closing pressure is gauge pressure 0MPa. The valve core is made of food-grade silicone rubber, and the valve seat is made of food-grade stainless steel.

6. The apparatus according to claim 1, characterized in that, The integrated rainproof and insect-proof structure has an umbrella-shaped surface, the projection of its outer edge in the vertical direction completely covers the air inlet, a stainless steel insect-proof net is installed on the inner side, and a drainage groove is opened at the bottom.

7. The apparatus according to claim 1, characterized in that, The rainproof and insect-proof structure is connected to the filter module via quick-release buckles, making it easy to clean and replace; the filter module housing is provided with a transparent observation window.

8. The apparatus according to claim 1, characterized in that, The fermentation container has an integrally molded bottom structure that is a standard forklift lifting slot, and the outer wall is provided with a stacking positioning slot.

9. A method of using the apparatus as described in any one of claims 1-8, characterized in that, include: The device is installed on top of the fermentation container, forming a sealed connection with the inside of the container. For the first 90 days of fermentation, the valve core is kept closed. After 90 days of fermentation, the valve core automatically opens when the temperature drops due to the air pressure difference generated by the temperature difference between day and night inside the container. Each time, the amount of sterile air replenished is 0.5%-1% of the container volume. The device automatically completes 1-2 oxygen replenishment cycles per day. There is no stirring, no turning of the mash, and no electrically driven ventilation device during the entire fermentation process.

10. The method according to claim 9, characterized in that, The fermentation vessel is used for static fermentation of high-salt, dilute soy sauce. After fermentation, the amino acid nitrogen content of the soy sauce is expected to reach ≥0.9g / 100mL, and the content of ester flavor substances is expected to increase by ≥30% compared with the control group without oxygen supplementation.