Tea beverage production method, tea beverage production system, and tea beverage production program

Abstract

The present application relates to the technical field of matcha production preparation, and discloses a matcha filling and sterilizing device based on microcapsule embedding technology and a sterilizing method thereof, which comprises a sterilizing and color-preserving tank, one end of the sterilizing and color-preserving tank is connected with a liquid inlet pipeline for allowing matcha concentrate to enter the sterilizing and color-preserving tank, the other end is connected with a liquid outlet pipeline for outputting sterile filling matcha concentrate, and the sterilizing and color-preserving tank is connected with a mixing pipeline for conveying mixed microcapsules through airflow impact; the sterilizing and color-preserving tank is divided into a sterilizing area and a color-preserving area along the axial direction thereof, the sterilizing area is provided with a wrapping chamber connected with the liquid inlet pipeline, the wrapping chamber is connected with the mixing pipeline synchronously, and the wrapping chamber receives and mixes matcha concentrate and microcapsules, so that the microcapsules are embedded in the molecules of the matcha concentrate to protect the molecules during mixing sterilization, and the color-preserving area is provided with a cooling chamber connected with the liquid outlet pipeline, and the cooling chamber is used for low-temperature color locking of the matcha concentrate.

Description

Technical Field

[0001] This invention relates to the technical field of matcha production and preparation, specifically to a matcha filling and sterilization device and sterilization method based on microencapsulation technology. Background Technology

[0002] Matcha refers to ultra-fine powder made from shaded tea leaves through a series of processing techniques. Due to its unique processing method, it retains the original color and nutritional value of the tea leaves to the greatest extent, making it a core high-quality raw material in the tea, baking, and new beverage industries. As a key product in the deep processing of matcha, concentrated matcha liquid has become the mainstream form of large-scale application in the food industry due to its ease of use and strong adaptability.

[0003] In the current industrial production of matcha concentrate, the sterilization process is the core and critical step that restricts the quality of the matcha concentrate. Currently, the industry's conventional sterilization methods mostly adopt traditional pasteurization or ultra-high temperature heat treatment processes. The high-temperature environment easily causes thermal degradation and oxidative inactivation of chlorophyll in the matcha system, and a large amount of aromatic volatile aroma substances decompose and dissipate. At the same time, heat-sensitive functional active ingredients such as tea polyphenols and theanine are denatured and lost. Ultimately, this leads to browning and darkening of the matcha concentrate, rapid loss of fresh and refreshing flavor, and a significant decrease in the content of core nutrients, which seriously reduces the quality and application value of the matcha concentrate.

[0004] Meanwhile, in conventional production processes, heat treatment sterilization of matcha concentrate can damage the trace natural protective colloidal structure of matcha itself, causing denaturation of macromolecules and weakening of surface charge of particles, further weakening the system's self-stabilizing ability. Simply relying on physical sterilization and low-temperature storage can only inhibit microbial metabolism in the short term and cannot effectively control the microbial recovery and slow proliferation during the storage period, resulting in a significantly limited shelf life. Therefore, traditional matcha concentrate relies on chemical preservatives and artificial synthetic stabilizers for system regulation before bottling. Although this can extend the shelf life, it goes against the consumption trend of natural, additive-free, green and healthy food, poses certain food safety risks, and is difficult to adapt to the production standards of high-end food ingredients.

[0005] On the other hand, the spacing between solid particles in matcha concentrate is significantly reduced. During long-term static storage, the van der Waals forces and hydrophobic interactions between molecules are significantly enhanced, and the probability of particle collisions increases significantly. This makes it very easy for particles to agglomerate and flocculate, gradually forming large particle aggregates. Under the influence of gravity, these aggregates continue to settle, leading to problems such as turbidity, bottom sedimentation, liquid layer separation, and uneven color distribution. The quality of matcha concentrate deteriorates rapidly with prolonged storage time, severely limiting the storage period and usage scenarios of matcha concentrate.

[0006] Therefore, in response to the core pain points of matcha concentrate, such as easy heat damage during sterilization, dependence on chemical additives, instability of storage system, and difficulty in long-term aroma preservation, we need to develop a matcha concentrate preparation technology that can achieve protection of heat-sensitive active ingredients, physical slow-release encapsulation, long-term system stability, and aroma sealing and locking. This technology has important practical application value for improving the quality of matcha concentrate in deep-processed matcha, aligning with the development direction of healthy food, and breaking through the technical bottlenecks in the industry. Summary of the Invention

[0007] The present invention aims to provide a matcha filling and sterilization device and sterilization method based on microcapsule encapsulation technology, which can achieve protection of heat-sensitive active ingredients, physical slow-release encapsulation, long-term system stability, and aroma sealing and retention.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: 1) A matcha filling and sterilization device based on microencapsulation technology, comprising a sterilization and color-preserving tank, one end of which is connected to an inlet pipe for entering the matcha concentrate, and the other end of which is connected to an outlet pipe for outputting aseptically filled matcha concentrate. The sterilization and color-preserving tank is connected to a mixing pipe that uses airflow to impinge and mix the microcapsules. The sterilization and color-preserving tank is divided into a sterilization zone and a color-preserving zone along its axial direction. The sterilization zone has an encapsulation chamber connected to the inlet pipe, which is simultaneously connected to the mixing pipe. The encapsulation chamber receives and mixes the matcha concentrate and microcapsules, with the microcapsules encapsulating the molecules within the matcha concentrate for protection during mixing and sterilization. The color-preserving zone has a cooling chamber connected to the outlet pipe, which is used for low-temperature color locking of the matcha concentrate.

[0009] This invention divides the sterilization and color preservation zones along the axial direction of the sterilization and color preservation tank, integrating the sterilization and color preservation processes of matcha concentrate into a single tank. This reduces the loss and contamination risks associated with transferring matcha concentrate from multiple processing devices, simplifies the overall production process, and improves the efficiency of the matcha concentrate sterilization and filling process. During this process, the invention simultaneously delivers microcapsules into the encapsulation chamber of the sterilization zone via a mixing pipe, achieving synchronous mixing of the matcha concentrate and microcapsules. Airflow impact is used to complete the mixing of microcapsules and matcha concentrate. Compared to traditional stirring, airflow impact causes the microcapsules to disperse more evenly around the matcha concentrate molecules. This airflow impact also prevents micro-agglomeration of the matcha concentrate, ensuring that each matcha molecule receives uniform encapsulation and protection, thus improving the uniformity and stability of the product quality after the overall sterilization process.

[0010] Moreover, the microcapsules are directly embedded on the outside of the active ingredient molecules in the matcha concentrate. During the sterilization and heating process, the microcapsules can form a protective barrier to prevent high-temperature sterilization from destroying heat-sensitive active substances such as chlorophyll and aroma components in the matcha. This solves the industry pain point that traditional high-temperature sterilization easily leads to discoloration and flavor loss in matcha. After sterilization and encapsulation, the matcha concentrate enters the cooling chamber of the color preservation area, where it can be rapidly cooled at low temperatures. Through low-temperature treatment, the natural green color and original flavor of the matcha are locked in. The final sterile matcha concentrate product has a stable and natural appearance and a higher degree of flavor retention. The product quality is far superior to products processed by traditional sterilization processes.

[0011] 2) The matcha filling and sterilization device based on microencapsulation technology described in 1), wherein: The sterilization and color preservation tank has a cylindrical processing barrel arranged horizontally, so that the sterilization area and the color preservation area are located in the processing barrel. There is an insulated chamber between the processing barrel and the sterilization and color preservation tank. A double-layer ring is fitted in the middle of the processing barrel and located in the insulated chamber. The outer wall of the double-layer ring along its circumferential direction is embedded in the inner wall of the sterilization and color preservation tank. The double-layer ring divides the insulated chamber into a hot air chamber and a cold air chamber. The position of the hot air chamber corresponds to the position of the sterilization area, and the position of the cold air chamber corresponds to the position of the color preservation area.

[0012] This invention utilizes an insulated chamber between the processing tank and the sterilization and color preservation tank to isolate heat exchange between the inside of the processing tank and the outside of the sterilization and color preservation tank. This reduces heat loss during the sterilization and color preservation stages, lowers temperature control energy consumption, and prevents external temperature interference with the processing temperature stability of the sterilization and color preservation areas. Furthermore, by integrating the sterilization and color preservation areas into the same horizontal cylindrical processing tank, the transfer structure of matcha concentrate between different functional areas is eliminated, shortening the sterilization and color preservation process path. This avoids temperature loss and quality fluctuations during matcha concentrate transfer, improving processing continuity and stability.

[0013] Furthermore, this invention uses a double-layered ring embedded in the inner wall of the sterilization and color preservation tank to separate the heat preservation chambers, precisely forming a hot air chamber and a cold air chamber corresponding to the sterilization area and the color preservation area respectively. This achieves independent temperature control for the two processing areas within the same tank structure: the hot air chamber continuously maintains suitable high-temperature sterilization conditions for the sterilization area, while the cold air chamber quickly provides the required low-temperature cooling and color preservation environment for the color preservation area. This ensures that the temperatures of the sterilization area and the color preservation area do not interfere with each other, guaranteeing the temperature control accuracy of both sterilization and color preservation processes, and improving the sterilization, storage, and processing quality of the matcha concentrate.

[0014] 3) The matcha filling and sterilization device based on microencapsulation technology described in 2), wherein: The processing barrel is fitted with a heating ring at the end of the sterilization area, the position of which corresponds to the position of the double-layer ring. The double-layer ring has a steam ring facing the heating ring, and there is a certain distance between the heating ring and the steam ring. The length of the distance is used to define the length of the wrapping chamber. The processing barrel has several heating tubes wrapped around the periphery of the wrapping chamber, and the two ends of the heating tubes are respectively connected to the heating ring and the steam ring.

[0015] This invention places a heating ring at the end of the sterilization area of ​​the processing barrel, corresponding to the double-layer ring on the barrel. The steam ring of the double-layer ring faces the heating ring. A pre-defined distance between the heating ring and the steam ring defines the length of the encapsulation chamber. Simultaneously, multiple heating pipes are arranged around the periphery of the encapsulation chamber on the processing barrel, with each end connected to the heating ring and the steam ring respectively. This precisely defines the effective range of steam sterilization heating, ensuring the heating length of the sterilization area matches processing requirements. It also constructs a complete steam heating loop connecting the heating ring, heating pipes, and steam ring, enabling uniform steam distribution around the encapsulation chamber. This provides a uniform and stable heating effect to the sterilization area of ​​the processing barrel. The short heating path reduces heat loss and improves the efficiency and stability of sterilization heating.

[0016] 4) The matcha filling and sterilization device based on microencapsulation technology described in 3), wherein: The processing barrel is connected to the liquid inlet pipe at the end of the sterilization zone through the first cover of the sterilization and color preservation tank, so that the liquid inlet pipe is connected to the internal space of the processing barrel. The side of the first cover facing the internal space of the processing barrel is welded to the heating ring. Several air inlets are evenly distributed along the circumferential direction on the side of the first cover away from the internal space of the processing barrel. All air inlets are connected to the heating ring separately and together. One air inlet is connected to the steam delivery pipe. The remaining air inlets are equipped with graphite wound gaskets with inner rings. Nuts for pressing the graphite wound gaskets with inner rings pass through the air inlets. The steam ring is connected to the exhaust pipe that passes through the sterilization and color preservation tank.

[0017] This invention achieves stable delivery of matcha concentrate to the interior of the processing tank by connecting a first cap, which is inserted through the end of the processing tank into the sterilization and color-preserving vessel and then connected to the inlet pipe. Simultaneously, the welded connection between the first cap and the heating ring ensures a tight and stable seal, preventing steam leakage during heating. Multiple air inlets are evenly distributed circumferentially on the side of the first cap away from the processing tank. All air inlets are connected to the heating ring, with only one inlet connected to the steam delivery pipe. The remaining inlets are fitted with graphite-wound gaskets with inner rings and secured with nuts. This circumferentially distributed air inlet design allows steam to enter the heating ring more evenly, enabling the heating ring to deliver steam to the heating pipe and evenly sterilize the matcha concentrate within the encapsulated chamber of the processing tank, resulting in better temperature stability during the sterilization process.

[0018] On the other hand, the design of reserving extra air inlets and using a sealed and tightened solution with an inner ring graphite spiral wound gasket not only facilitates the expansion of steam delivery pipe access methods according to processing needs, but also fully utilizes the excellent sealing performance, temperature resistance, and pressure resistance of the inner ring graphite spiral wound gasket. With the tightening nut, a reliable seal can be achieved to prevent steam leakage. At the same time, maintenance and disassembly are more convenient, improving the adaptability and maintenance efficiency of the sterilization and color preservation tank.

[0019] 5) The matcha filling and sterilization device based on microencapsulation technology described in 2), wherein: The processing barrel is fitted with a cooling ring at the end of the color-preserving area. The position of the cooling ring corresponds to the position of the double-layer ring. The double-layer ring has a cooling air ring facing the cooling ring. There is a certain distance between the cooling ring and the cooling air ring. The length of the distance is used to define the length of the cooling chamber. The processing barrel has several cooling air pipes wrapped around the periphery of the cooling chamber. The two ends of the cooling air pipes are respectively connected to the cooling ring and the cooling air ring. The number of cooling air pipes is three times the number of heating pipes.

[0020] This invention establishes a cooling ring at the end of the color-preserving area, corresponding to the position of the double-layer ring, and a cooling air ring on the double-layer ring facing the cooling ring. The distance between the two rings defines the length of the cooling chamber. Simultaneously, cooling air pipes are arranged around the cooling chamber on the processing barrel, with their ends connected to the cooling ring and the cooling air ring respectively. The number of cooling air pipes is set to three times the number of heating pipes. This forms a uniform cooling path around the color-preserving area of ​​the processing barrel, which can precisely define the cooling range. After the color-preserving process, this area of ​​the processing barrel is cooled quickly and evenly. This avoids the cooling range being too large and affecting the processing temperature of other areas of the processing barrel. The sufficient number of cooling air pipes can improve the cooling efficiency and uniformity, helping the matcha concentrate to quickly stabilize its color and improving the quality of the finished matcha concentrate.

[0021] 6) The matcha filling and sterilization device based on microencapsulation technology described in 5), wherein: The processing barrel located at the end of the color-preserving area passes through the second cover of the sterilization and color-preserving tank and is connected to the liquid outlet pipe, so that the liquid outlet pipe is connected to the internal space of the processing barrel. The side of the second cover facing the internal space of the processing barrel is welded to the cooling ring. Several cold air ports are evenly distributed along the circumferential direction on the side of the second cover away from the internal space of the processing barrel. All cold air ports are connected to the cooling ring separately and together. One cold air port is connected to the cold air delivery pipe. The remaining cold air ports are equipped with graphite wound gaskets with inner rings. Nuts for pressing the graphite wound gaskets with inner rings pass through the cold air ports. An exhaust pipe passing through the sterilization and color-preserving tank is connected to the cold air ring.

[0022] This invention features a structure where evenly distributed cold air vents are connected to the cooling ring on the second cap. Only one cold air vent is connected to the cold air delivery pipe, while the remaining vents are fitted with graphite-wound gaskets with inner rings and tightened with nuts. This structure ensures stable cooling from the cooling ring, providing a uniform and controllable low-temperature color-preserving environment for the processing tank, thus guaranteeing a uniform and stable color-preserving effect for the matcha concentrate. The graphite-wound gaskets with inner rings also improve the sealing of the cold air vents, preventing cold air leakage, ensuring stable cooling pressure, and guaranteeing color-preserving stability during rapid cooling of the matcha concentrate.

[0023] Meanwhile, this invention utilizes the fact that the liquid outlet pipe is located outside the second cap and connects to the inside of the processing tank, which meets the discharge requirements of matcha concentrate without interfering with the cold supply structure layout inside the sterilization and color preservation tank; the connection method of directly welding the cold supply ring to the second cap improves the overall stability of the sterilization and color preservation tank; the cooling ring, several cold air pipes and exhaust pipes work together to form a cooling flow to the cooling chamber, ensuring the continuous and smooth operation of the cooling process.

[0024] 7) The matcha filling and sterilization device based on microencapsulation technology described in 1), wherein: The mixing pipeline includes a mixing tube that passes through the sterilization and color preservation tank and extends toward the encapsulation chamber. The bottom of the mixing tube is welded to a communication port opened in the processing barrel, so that the mixing tube communicates with the encapsulation chamber inside the processing barrel. The top of the mixing tube is connected to a microcapsule delivery pipeline through a flange, which leads to the addition of microcapsules into the mixing tube. A connecting pipe extending outward is welded to the side of the microcapsule delivery pipeline. The connecting pipe is connected to the microcapsule delivery pipeline through a flange, which is a pneumatic delivery pipeline that delivers mixed microcapsules into the microcapsule delivery pipeline by airflow impact.

[0025] This invention utilizes a connecting layout that extends from the sterilization and color-preserving tank to the encapsulation chamber, allowing microcapsules to be directly delivered into the encapsulation chamber of the processing tank, ensuring precise delivery of microcapsules. Simultaneously, the connection scheme, with the bottom of the mixing tube welded to the processing tank's connecting port and the top flange connecting to the microcapsule delivery pipeline, ensures the airtightness of the connection between the mixing tube and the processing tank, preventing leakage of matcha concentrate during processing. It also facilitates subsequent disassembly and maintenance of the mixing tube and delivery pipeline, making it easy to clean residual microcapsules and matcha concentrate from the pipeline. Furthermore, it eliminates the need for extensive disassembly when replacing components, reducing maintenance difficulty and cost.

[0026] An additional connecting pipe is installed on the side of the microcapsule delivery pipeline to connect to the airflow delivery pipeline, forming an airflow impact delivery. The airflow disturbance can mix the microcapsules in the microcapsule delivery pipeline, which can not only prevent the microcapsules from accumulating and clogging the pipeline, ensuring a smooth and stable microcapsule delivery process, but also allow the microcapsules to be evenly dispersed under the action of airflow before entering the mixing tube, improving the uniformity of the subsequent mixing and encapsulation of microcapsules with matcha concentrate in the encapsulation chamber, and ultimately improving the processing quality of matcha concentrate.

[0027] 8) The matcha filling and sterilization device based on microencapsulation technology described in 7), wherein: The microcapsules are sodium carboxymethyl cellulose-pectin composite microcapsules, which are composed of sodium carboxymethyl cellulose and pectin in a mass ratio of 3:2-5:1, and form a matrix with a three-dimensional network structure through solution blending-ionic crosslinking.

[0028] In this invention, sodium carboxymethyl cellulose (CMC)-pectin composite microcapsules combine the excellent water solubility of CMC with the gel stability of pectin. During transport, these microcapsules are delivered via airflow into the encapsulation chamber within the processing tank of a sterilization and color-preserving vessel. Simultaneously, an inlet pipe delivers matcha concentrate into the encapsulation chamber. Before the matcha concentrate enters the encapsulation chamber, a heating element maintains the temperature within the chamber at 100-120°C. Simultaneously, as the matcha concentrate enters the chamber, airflow propels the CMC-pectin composite microcapsules into the concentrate. The sodium carboxymethyl cellulose (CMC)-pectin composite microcapsules adhere to the surface of matcha concentrate molecules using the adhesive properties of CMC. Multiple CMC-pectin composite microcapsules are attached to the periphery of the matcha concentrate molecules, encapsulating them. The pectin enhances the heat resistance of the matcha concentrate molecules, thus achieving sterilization while reducing the thermal degradation and oxidative inactivation of chlorophyll in the matcha concentrate molecules. This preserves the content of aromatic volatile substances and core nutrients in the matcha concentrate, maintaining its quality and application value.

[0029] Meanwhile, since the sodium carboxymethyl cellulose-pectin composite microcapsules are composed of sodium carboxymethyl cellulose and pectin, a matrix with a three-dimensional network structure is formed through solution blending-ionic crosslinking. The two molecules form a hydrogen bond crosslinking network structure. When the sodium carboxymethyl cellulose-pectin composite microcapsules are attached to the surface of the matcha concentrate molecules, the mechanical strength and thermal stability of the matcha concentrate molecular wall material are enhanced. This prevents the sodium carboxymethyl cellulose-pectin composite microcapsules from breaking when they are mixed with the matcha concentrate molecules. At the same time, it also prevents the sodium carboxymethyl cellulose-pectin composite microcapsules from agglomerating during the airflow mixing process, ensuring that a uniform and stable mixing system is formed with the matcha concentrate.

[0030] 9) A sterilization method for a matcha filling and sterilization device based on microencapsulation technology, applied to the matcha filling and sterilization device based on microencapsulation technology described in 1)-8) above, comprising the following steps: Step 1: The matcha concentrate to be sterilized is transported to the sterilization area of ​​the sterilization and color preservation tank through the inlet pipe. The encapsulated chamber in the sterilization area is heated and sterilized by the surrounding heating tubes to maintain the temperature at 100-120℃. Step 2: During the sterilization process in Step 1, microcapsules are transported by airflow through the mixing pipe toward the encapsulation chamber in the sterilization area and impact the matcha concentrate in the encapsulation chamber. This causes the microcapsules to be evenly mixed with the molecules in the matcha concentrate, and several microcapsules adhere to the periphery of the molecules in the matcha concentrate and encapsulate the molecules in the concentrated tea concentrate. Step 3: The sterilization time in Step 2 is 7-10 seconds for instantaneous sterilization. The matcha concentrate is then introduced into the color preservation area of ​​the sterilization and color preservation tank with fluidity. In the color preservation area, a surrounding cold air pipe cools the temperature of the sterilized matcha concentrate to 8-12℃ at a rate of 4-5℃ / min in the cooling chamber of the color preservation area, thus locking in the color of the chlorophyll molecules in the matcha concentrate and the flavor of the concentrated tea.

[0031] 10) The sterilization method of the matcha filling and sterilization device based on microencapsulation technology described in 9), wherein: The bottom of the sterilization and color preservation tank is equipped with a pressure sensor and a temperature probe. The pressure sensor is used to monitor the pressure in the wrapping chamber and the cooling chamber in real time, which is 0.12-0.15MPa. The temperature probe is used to monitor the sterilization temperature in the wrapping chamber and the cooling temperature in the cooling chamber in real time, and feeds the monitoring data back to the PLC control system to adjust the steam temperature, the cold air temperature, the steam flow rate in the steam delivery pipe, and the cold air flow rate in the cold air delivery pipe.

[0032] In this invention, the pressure sensor can monitor the internal pressure of the packaging chamber and the cooling chamber in real time, and can accurately and stably control the internal pressure within the target range of 0.12-0.15MPa. This ensures that the sterilization and cooling operations are always carried out under the set standard pressure environment, avoiding abnormal pressure from affecting the sterilization effect or color retention quality of the matcha concentrate. The temperature probe can collect the sterilization temperature of the packaging chamber and the cooling temperature of the cooling chamber in real time, respectively, and can accurately obtain the core temperature data of the operation, providing an accurate basis for process control.

[0033] The pressure sensor and temperature probe can feed back the collected pressure and temperature monitoring data to the PLC control system in real time. The PLC control system automatically adjusts the steam temperature and cold air temperature accordingly, and at the same time automatically adjusts the steam delivery flow rate of the steam delivery pipe and the cold air delivery flow rate of the cold air delivery pipe, forming a complete closed-loop control of operating parameters. This ensures that the sterilization temperature, cooling temperature and operating pressure always meet the process requirements, stabilize the sterilization effect and maintain the sterilization efficiency, and also stabilize the color of the product after the matcha concentrate is processed, avoiding the deterioration of the color retention effect caused by parameter fluctuations.

[0034] Compared with the prior art, the present invention also has the following technical effects: 1. Integrated sterilization and color preservation processes: Through axial partitioning design, sterilization and color preservation can be completed in the same tank, reducing the transfer loss and contamination risk of matcha concentrate, simplifying the production process and improving efficiency.

[0035] 2. Uniform microcapsule encapsulation: The airflow impact mixing technology is used to uniformly disperse the microcapsules around the matcha concentrate molecules, avoiding micro-agglomeration and ensuring the uniformity and stability of the encapsulation protection.

[0036] 3. Protection of heat-sensitive components: Microcapsules form a protective barrier, reducing the damage of heat-sensitive substances such as chlorophyll and aroma components caused by high temperatures, and solving the problems of discoloration and flavor loss caused by traditional sterilization.

[0037] 4. Low-temperature color locking and flavor preservation: The cooling chamber quickly lowers the matcha concentrate to 8-12℃, locking in the natural green color and original flavor, and improving the color stability and flavor retention of the finished product. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the structure of the matcha filling and sterilization device based on microcapsule encapsulation technology of the present invention; Figure 2 This is a schematic diagram of the double-layer ring structure in the matcha filling and sterilization device based on microcapsule encapsulation technology of the present invention; Figure 3 This is a flowchart of the sterilization method of the matcha filling and sterilization device based on microcapsule encapsulation technology of the present invention. Detailed Implementation

[0039] The following detailed description illustrates the specific implementation method: The reference numerals in the accompanying drawings include: 1. Liquid inlet pipe; 2. Sterilization and color preservation tank; 3. Liquid outlet pipe; 4. Storage box; 5. Support frame; 6. Airflow conveying pipe; 7. Steam conveying pipe; 8. Air inlet; 9. Sterilization zone; 10. Color preservation zone; 11. Heating pipe; 12. Encapsulation chamber; 13. Double ring; 14. Cooling chamber; 15. Cold air pipe; 16. Exhaust pipe; 17. Cold air conveying pipe; 18. Microcapsule delivery pipe; 19. Mixing pipe; 20. Base; 21. Support seat; 22. Steam ring cavity; 23. Connecting port; 24. Cold air ring cavity.

[0040] See the example. Figure 1As shown, the matcha filling and sterilization device based on microencapsulation technology in this embodiment includes a base 20. A sterilization and color preservation tank 2 is installed on the top of the base 20. One end of the sterilization and color preservation tank 2 is connected to an inlet pipe 1 for the matcha concentrate to enter the sterilization and color preservation tank 2, and the other end is connected to an outlet pipe 3 for the aseptic filling of matcha concentrate. In order to stably deliver the matcha concentrate into the sterilization and color preservation tank 2, a support frame 5 is installed below the inlet pipe 1. Two upright blocks are welded to the top of the support frame 5 along the axial direction of the inlet pipe 1. The upper surface of the upright blocks is provided with an arc-shaped groove. The two upright blocks are located on the same horizontal plane, and the arc-shaped grooves of the two upright blocks are for the inlet pipe 1 to be placed and fit against the inlet pipe 1, so that the center line of the inlet pipe 1 overlaps with the center line of the sterilization and color preservation tank 2. This allows the inlet pipe 1 and the sterilization and color preservation tank 2 to be kept on the same horizontal plane, so that the matcha concentrate can be stably delivered into the sterilization and color preservation tank 2.

[0041] Furthermore, the matcha concentrate, after being embedded and sterilized in the sterilization and color-preservation tank 2, is transported towards the storage tank 4 via the outlet pipe 3. A storage tank 4 is installed at the rear end of the sterilization and color-preservation tank 2 along the matcha concentrate transport route. The storage tank 4 serves as an intermediate buffer tank during the matcha concentrate production process, allowing the matcha concentrate to be temporarily stored in the storage tank 4 after the color preservation process is completed in the sterilization and color-preservation tank 2. This buffering effect serves to prepare for subsequent aseptic filling. Simultaneously, during storage... A support base 21 is installed near the front end of the storage tank 4, close to the sterilization and color preservation tank 2. The top of the support base 21 is connected to an upward-extending column along the axis of the liquid outlet pipe 3 by bolts and nuts. The top of the column is installed with a flange located between the storage tank 4 and the liquid outlet pipe 3 by bolts and nuts. A connecting pipe is connected to the storage tank 4 in the direction of the liquid outlet pipe 3. The connecting pipe is connected to the liquid outlet pipe 3 through the flange, thereby enabling the sterilization and color preservation tank 2 to stably deliver the sterilized and color-preserved matcha concentrate into the storage tank 4 through the liquid outlet pipe 3.

[0042] Meanwhile, the sterilization and color preservation tank 2 is connected to a mixing pipe 19 that uses airflow to impinge and transport the mixed microcapsules. The sterilization and color preservation tank 2 is divided into a sterilization zone 9 and a color preservation zone 10 along its axial direction. The sterilization zone 9 has a containment chamber 12 connected to the inlet pipe 1, which is simultaneously connected to the mixing pipe 19. The containment chamber 12 receives and mixes the matcha concentrate and microcapsules, with the microcapsules encapsulating the matcha concentrate molecules for protection during sterilization. The color preservation zone 10 has a cooling chamber 14 connected to the outlet pipe 3, which is used to cool the matcha concentrate. To ensure the sterilization temperature within the encapsulation chamber 12 of the sterilization zone 9 and the low-temperature color-locking temperature within the cooling chamber 14 of the color-preserving zone 10, nine sponge strips are arranged on the outer surface of the sterilization and color-preserving tank 2. The sponge strips are flat strips, and each sponge strip is arranged sequentially around the outer surface of the sterilization and color-preserving tank 2 along the axial direction. All sponge strips are located in the encapsulation chamber 12 of the sterilization zone 9 and the cooling chamber 14 of the color-preserving zone 10, so as to keep the sterilization temperature in the encapsulation chamber 12 of the sterilization zone 9 and the low temperature in the cooling chamber 14 of the color-preserving zone 10.

[0043] Furthermore, the sterilization and color-preserving tank 2 contains a cylindrical processing barrel arranged horizontally, such that the sterilization area 9 and the color-preserving area 10 are both located within the processing barrel. An insulated chamber exists between the processing barrel and the sterilization and color-preserving tank 2. A double-layered ring 13 is fitted into the middle of the processing barrel within the insulated chamber. The outer wall of the double-layered ring 13 along its circumferential direction is embedded in the inner wall of the sterilization and color-preserving tank 2. The double-layered ring 13 divides the insulated chamber into a hot air chamber and a cold air chamber. The position of the hot air chamber corresponds to the position of the sterilization area 9, and the position of the cold air chamber corresponds to the position of the color-preserving area 10. See also... Figure 2 As shown, the double-layer ring 13 includes a steam ring and a cold air ring, with a steam ring cavity 22 formed inside the steam ring and a cold air ring cavity 24 formed inside the cold air ring.

[0044] In this embodiment, a heating ring is fitted around the end of the processing barrel located in the sterilization zone 9. The position of the heating ring corresponds to the position of the steam ring facing the heating ring. There is a certain distance between the heating ring and the steam ring, and the length of the distance defines the length of the wrapping chamber 12. The processing barrel has several heating tubes 11 wrapped around the periphery of the wrapping chamber 12. The two ends of the heating tubes 11 are connected to the steam ring chambers 22 of the heating ring and the steam ring through the connecting ports 23, respectively. At the same time, at the end of the processing barrel in the sterilization zone 9, the first seal of the sterilization and color preservation tank 2 is connected to the liquid inlet pipe 1, so that the liquid inlet pipe 1 is connected to the internal space of the processing barrel. The side of the cover facing the internal space of the processing barrel is welded to the heating ring. The side of the first cover away from the internal space of the processing barrel has several air inlets 8 evenly distributed along its circumference. All air inlets 8 are connected to the heating ring separately and together. One air inlet 8 is connected to the steam delivery pipe 7, which is connected to the steam generator. The remaining air inlets 8 are equipped with graphite wound gaskets with inner rings. Nuts for tightening the graphite wound gaskets with inner rings pass through the air inlets 8. A steam exhaust pipe passing through the sterilization and color preservation tank 2 is connected to the steam ring. The steam exhaust pipe is connected to the steam ring cavity 22 in the steam ring. The cooled steam is delivered to the refrigeration unit through the steam exhaust pipe.

[0045] In this embodiment, a cooling ring is fitted around the end of the processing barrel located in the color-preserving area 10. The position of the cooling ring corresponds to the position of the cooling air ring facing the cooling ring. There is a certain distance between the cooling ring and the cooling air ring, and the length of the distance defines the length of the cooling chamber 14. The processing barrel has several cooling air pipes 15 wrapped around the cooling chamber 14. The two ends of the cooling air pipes 15 are connected to the cooling ring cavity 24 of the cooling ring and the cooling air ring respectively through the connecting port 23. The number of cooling air pipes 15 is three times the number of heating pipes 11. At the same time, the end of the processing barrel located in the color-preserving area 10 passes through the second cover of the sterilization and color-preserving tank 2 and is connected to the liquid outlet pipe 3, so that the liquid outlet pipe 3 is connected to the internal space of the processing barrel. The side of the second cover facing the internal space of the processing barrel is welded to the cooling ring, and the side of the second cover facing away from the cooling ring is welded to the cooling ring. Several cold air vents are evenly distributed along the circumference of the side of the internal space of the barrel. All cold air vents are connected to the cooling ring, one of which is connected to the cold air delivery pipe 17, which is connected to the refrigeration unit. The remaining cold air vents are equipped with graphite-wound gaskets with inner rings. Nuts for tightening the graphite-wound gaskets with inner rings pass through the cold air vents. The cold air ring is connected to the exhaust pipe 16, which passes through the sterilization and color preservation tank 2. The exhaust pipe 16 is connected to the cold air ring cavity 24 of the cold air ring, which discharges the heated airflow and delivers it to the steam generator. This creates a hot and cold air circulation system: steam generator → steam delivery pipe 7 → heating ring → heating pipe 11 → steam ring → exhaust pipe → refrigeration unit → cold air delivery pipe 17 → cooling ring → cold air pipe 15 → cold air ring → exhaust pipe 16 → steam generator.

[0046] Meanwhile, in this embodiment, the mixing tube 19 includes a mixing tube 19 that passes through the sterilization and color preservation tank 2 and extends toward the encapsulation chamber 12. The bottom of the mixing tube 19 is welded to the communication port 23 opened in the processing barrel, so that the mixing tube 19 communicates with the encapsulation chamber 12 inside the processing barrel. The top of the mixing tube 19 is connected to a microcapsule delivery pipe 18 through a flange, which leads to the addition of microcapsules into the mixing tube 19. The side of the microcapsule delivery pipe 18 is welded with an outwardly extending connecting pipe. The connecting pipe is connected to the microcapsule delivery pipe 18 through a flange. The connecting pipe is connected to an airflow delivery pipe 6 through the flange, which delivers the mixed microcapsules into the microcapsule delivery pipe 18 by airflow impact. The microcapsules are sodium carboxymethyl cellulose-pectin composite microcapsules. The sodium carboxymethyl cellulose-pectin composite microcapsules are compounded from sodium carboxymethyl cellulose and pectin in a mass ratio of 3:2-5:1, and a matrix with a three-dimensional network structure is formed by solution blending-ionic crosslinking method.

[0047] Because sodium carboxymethyl cellulose-pectin composite microcapsules combine the good water solubility of sodium carboxymethyl cellulose and the gel stability of pectin, the sodium carboxymethyl cellulose-pectin composite microcapsules are transported by airflow into the encapsulation chamber 12 inside the processing tank of the sterilization and color preservation tank 2. During this process, the liquid inlet pipe 1 transports the matcha concentrate into the encapsulation chamber 12 inside the processing tank of the sterilization and color preservation tank 2. Before the matcha concentrate enters the encapsulation chamber 12, the temperature inside the encapsulation chamber 12 is maintained at 100-120℃ by the heating pipe 11.

[0048] As the matcha concentrate enters the encapsulation chamber 12, airflow propels sodium carboxymethyl cellulose (CMC)-pectin composite microcapsules into the matcha concentrate. This causes the CMC-pectin microcapsules to adhere to the surface of the matcha concentrate molecules using the adhesive properties of CMC. Multiple CMC-pectin microcapsules adhere to the periphery of the matcha concentrate molecules, encapsulating them. The pectin enhances the heat resistance of the matcha concentrate molecules, thus achieving sterilization while reducing the thermal degradation and oxidative inactivation of chlorophyll within the matcha concentrate molecules. This preserves the content of aromatic volatile substances and core nutrients, maintaining the quality and application value of the matcha concentrate.

[0049] More specifically, in this embodiment, the sodium carboxymethyl cellulose-pectin composite microcapsules are composed of sodium carboxymethyl cellulose and pectin. A matrix with a three-dimensional network structure is formed by solution blending-ionic crosslinking. The sodium carboxymethyl cellulose used is food-grade sodium carboxymethyl cellulose, and the pectin used is food-grade high-methoxyl pectin. The methoxyl content of the food-grade high-methoxyl pectin is ≥70%. Therefore, the sodium carboxymethyl cellulose and pectin are compounded in the following weight components: 30-50 parts of food-grade sodium carboxymethyl cellulose, 10-20 parts of food-grade high-methoxyl pectin, 90-110 parts of deionized water, and 1-2 parts of calcium chloride.

[0050] In this embodiment, the preferred composition of sodium carboxymethyl cellulose (CCMC) and pectin is 40 parts of food-grade CCMC, 15 parts of food-grade high-methoxyl pectin, 100 parts of deionized water, and 1 part of calcium chloride. The CCMC-pectin composite microcapsules are made by blending CCMC and pectin in a mass ratio of 3:2-5:1, and can be further formulated to create a hydrogen-bonded cross-linked network structure between the molecules of food-grade CCMC and food-grade high-methoxyl pectin. The preparation method of the CCMC-pectin composite microcapsules includes dissolving food-grade CCMC and food-grade high-methoxyl pectin in deionized water, stirring at 60-70℃ for 30-40 minutes until completely dissolved, cross-linking with calcium chloride solution at a dropping rate of 1-2 mL / min, cross-linking temperature of 50-60℃ for 30 minutes, centrifuging, washing, and drying at 70℃ for 5 hours to obtain microcapsules with a particle size of 30-60 μm.

[0051] In this embodiment, sodium carboxymethyl cellulose-pectin composite microcapsules are attached to the surface of matcha concentrate molecules, thereby enhancing the mechanical strength and thermal stability of the matcha concentrate molecular wall material. This prevents the sodium carboxymethyl cellulose-pectin composite microcapsules from rupturing when mixed with matcha concentrate molecules. At the same time, it also prevents the sodium carboxymethyl cellulose-pectin composite microcapsules from agglomerating during airflow mixing, ensuring a uniform and stable mixture system with the matcha concentrate.

[0052] The sterilization method of the matcha filling and sterilization device based on microencapsulation technology includes the following steps: Step 1: The matcha concentrate to be sterilized is transported to the sterilization zone 9 in the sterilization and color preservation tank 2 through the liquid inlet pipe 1. The encapsulated chamber 12 in the sterilization zone 9 is heated and sterilized by the heating tube 11 wrapped in the sterilization zone 9 to maintain the temperature at 100-120℃. Step 2: During the sterilization process in Step 1, microcapsules are transported by airflow through the mixing tube 19 toward the sterilization area 9 and the encapsulation chamber 12, and the microcapsules impact the matcha concentrate in the encapsulation chamber 12, so that the microcapsules and the molecules in the matcha concentrate are evenly mixed, and several microcapsules adhere to the periphery of the molecules in the matcha concentrate and encapsulate the molecules in the concentrated tea concentrate. Step 3: The sterilization time in Step 2 is 7-10 seconds for instantaneous sterilization, and the matcha concentrate is introduced into the color preservation area 10 of the sterilization and color preservation tank 2 with fluidity. In the color preservation area 10, the surrounding cold air pipe 15 cools the matcha concentrate in the cooling chamber 14 at a rate of 4-5℃ / min to 8-12℃, locking in the color of the chlorophyll molecules of the matcha concentrate and the flavor of the strong tea concentrate.

[0053] Meanwhile, the bottom of the sterilization and color preservation tank 2 is equipped with a pressure sensor and a temperature probe. The pressure sensor is used to monitor the pressure in the wrapping chamber 12 and the cooling chamber 14 in real time, which is 0.12-0.15MPa. The temperature probe is used to monitor the sterilization temperature in the wrapping chamber 12 and the cooling temperature in the cooling chamber 14 in real time, and feeds the monitoring data back to the PLC control system to adjust the steam temperature, the cold air temperature, the steam flow rate in the steam delivery pipe 7, and the cold air flow rate in the cold air delivery pipe 17.

[0054] To further verify the quality of the produced matcha concentrate, the oxidative stability, high temperature resistance, dispersibility, taste, and shelf life of ordinary matcha concentrate produced by existing equipment and microcapsule concentrated matcha concentrate produced by the device in this embodiment were compared. The comparison is shown in Table 1.

[0055] The above are merely embodiments of this solution. Commonly known technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solution of this solution. These modifications and improvements should also be considered within the scope of protection of this solution, and will not affect the effectiveness of the implementation of this solution or the practicality of the patent. The scope of protection claimed in this application shall be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A matcha filling and sterilization device based on microencapsulation technology, characterized in that, The device includes a sterilization and color-preserving tank. One end of the tank is connected to an inlet pipe for introducing matcha concentrate into the tank, and the other end is connected to an outlet pipe for aseptically filling matcha concentrate. The tank is also connected to a mixing pipe that uses airflow to impinge and mix microcapsules. The tank is divided into a sterilization zone and a color-preserving zone along its axial direction. The sterilization zone has an encapsulation chamber connected to the inlet pipe, which is simultaneously connected to the mixing pipe. The encapsulation chamber receives and mixes the matcha concentrate and microcapsules, with the microcapsules encapsulating the matcha concentrate molecules for protection during sterilization. The color-preserving zone has a cooling chamber connected to the outlet pipe, which is used for low-temperature color locking of the matcha concentrate.

2. The matcha filling and sterilization device based on microencapsulation technology according to claim 1, characterized in that: The sterilization and color preservation tank has a cylindrical processing barrel arranged horizontally, so that the sterilization area and the color preservation area are located in the processing barrel. There is an insulated chamber between the processing barrel and the sterilization and color preservation tank. A double-layer ring is fitted in the middle of the processing barrel and located in the insulated chamber. The outer wall of the double-layer ring along its circumferential direction is embedded in the inner wall of the sterilization and color preservation tank. The double-layer ring divides the insulated chamber into a hot air chamber and a cold air chamber. The position of the hot air chamber corresponds to the position of the sterilization area, and the position of the cold air chamber corresponds to the position of the color preservation area.

3. The matcha filling and sterilization device based on microencapsulation technology according to claim 2, characterized in that: The processing barrel is fitted with a heating ring at the end of the sterilization area, the position of which corresponds to the position of the double-layer ring. The double-layer ring has a steam ring facing the heating ring, and there is a certain distance between the heating ring and the steam ring. The length of the distance is used to define the length of the wrapping chamber. The processing barrel has several heating tubes wrapped around the periphery of the wrapping chamber, and the two ends of the heating tubes are respectively connected to the heating ring and the steam ring.

4. The matcha filling and sterilization device based on microencapsulation technology according to claim 3, characterized in that: The processing barrel is connected to the liquid inlet pipe at the end of the sterilization zone through the first cover of the sterilization and color preservation tank, so that the liquid inlet pipe is connected to the internal space of the processing barrel. The side of the first cover facing the internal space of the processing barrel is welded to the heating ring. Several air inlets are evenly distributed along the circumferential direction on the side of the first cover away from the internal space of the processing barrel. All air inlets are connected to the heating ring separately and together. One air inlet is connected to the steam delivery pipe. The remaining air inlets are equipped with graphite wound gaskets with inner rings. Nuts for pressing the graphite wound gaskets with inner rings pass through the air inlets. The steam ring is connected to the exhaust pipe that passes through the sterilization and color preservation tank.

5. The matcha filling and sterilization device based on microencapsulation technology according to claim 2, characterized in that: The processing barrel is fitted with a cooling ring at the end of the color-preserving area. The position of the cooling ring corresponds to the position of the double-layer ring. The double-layer ring has a cooling air ring facing the cooling ring. There is a certain distance between the cooling ring and the cooling air ring. The length of the distance is used to define the length of the cooling chamber. The processing barrel has several cooling air pipes wrapped around the periphery of the cooling chamber. The two ends of the cooling air pipes are respectively connected to the cooling ring and the cooling air ring. The number of cooling air pipes is three times the number of heating pipes.

6. The matcha filling and sterilization device based on microencapsulation technology according to claim 5, characterized in that: The processing barrel located at the end of the color-preserving area passes through the second cover of the sterilization and color-preserving tank and is connected to the liquid outlet pipe, so that the liquid outlet pipe is connected to the internal space of the processing barrel. The side of the second cover facing the internal space of the processing barrel is welded to the cooling ring. Several cold air ports are evenly distributed along the circumferential direction on the side of the second cover away from the internal space of the processing barrel. All cold air ports are connected to the cooling ring separately and together. One cold air port is connected to the cold air delivery pipe. The remaining cold air ports are equipped with graphite wound gaskets with inner rings. Nuts for pressing the graphite wound gaskets with inner rings pass through the cold air ports. An exhaust pipe passing through the sterilization and color-preserving tank is connected to the cold air ring.

7. The matcha filling and sterilization device based on microencapsulation technology according to claim 1, characterized in that: The mixing pipeline includes a mixing tube that passes through the sterilization and color preservation tank and extends toward the encapsulation chamber. The bottom of the mixing tube is welded to a communication port opened in the processing barrel, so that the mixing tube communicates with the encapsulation chamber inside the processing barrel. The top of the mixing tube is connected to a microcapsule delivery pipeline through a flange, which leads to the addition of microcapsules into the mixing tube. A connecting pipe extending outward is welded to the side of the microcapsule delivery pipeline. The connecting pipe is connected to the microcapsule delivery pipeline through a flange, which is a pneumatic delivery pipeline that delivers mixed microcapsules into the microcapsule delivery pipeline by airflow impact.

8. The matcha filling and sterilization device based on microencapsulation technology according to claim 7, characterized in that: The microcapsules are sodium carboxymethyl cellulose-pectin composite microcapsules, which are composed of sodium carboxymethyl cellulose and pectin in a mass ratio of 3:2-5:1, and form a matrix with a three-dimensional network structure through solution blending-ionic crosslinking.

9. A sterilization method for a matcha filling and sterilization device based on microencapsulation technology, applied to the matcha filling and sterilization device based on microencapsulation technology as described in any one of claims 1-8, characterized in that: Includes the following steps: Step 1: The matcha concentrate to be sterilized is transported to the sterilization area of ​​the sterilization and color preservation tank through the inlet pipe. The encapsulated chamber in the sterilization area is heated and sterilized by the surrounding heating tubes to maintain the temperature at 100-120℃. Step 2: During the sterilization process in Step 1, microcapsules are transported by airflow through the mixing pipe toward the encapsulation chamber in the sterilization area and impact the matcha concentrate in the encapsulation chamber. This causes the microcapsules to be evenly mixed with the molecules in the matcha concentrate, and several microcapsules adhere to the periphery of the molecules in the matcha concentrate and encapsulate the molecules in the concentrated tea concentrate. Step 3: The sterilization time in Step 2 is 7-10 seconds for instantaneous sterilization. The matcha concentrate is then introduced into the color preservation area of ​​the sterilization and color preservation tank with fluidity. In the color preservation area, a surrounding cold air pipe cools the temperature of the sterilized matcha concentrate to 8-12℃ at a rate of 4-5℃ / min in the cooling chamber of the color preservation area, thus locking in the color of the chlorophyll molecules in the matcha concentrate and the flavor of the concentrated tea.

10. The sterilization method of the matcha filling and sterilization device based on microencapsulation technology according to claim 9, characterized in that: The bottom of the sterilization and color preservation tank is equipped with a pressure sensor and a temperature probe. The pressure sensor is used to monitor the pressure in the wrapping chamber and the cooling chamber in real time, which is 0.12-0.15MPa. The temperature probe is used to monitor the sterilization temperature in the wrapping chamber and the cooling temperature in the cooling chamber in real time, and feeds the monitoring data back to the PLC control system to adjust the steam temperature, the cold air temperature, the steam flow rate in the steam delivery pipe, and the cold air flow rate in the cold air delivery pipe.

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