Granulation apparatus and granulation method for starch-based crispy particles

Abstract

A granulation apparatus for starch-based crispy particles, the apparatus comprising a pretreatment unit, a granulation unit and a drying unit, wherein the pretreatment unit comprises a reactor vessel; the granulation unit comprises an extrusion granulator, which comprises an extrusion nozzle and a first adjusting device, which is used for adjusting an extrusion pressure; the drying unit comprises a hot-air drying oven; a hot air blower and a drying tunnel are arranged in the hot-air drying oven; the hot-air drying oven is provided with a temperature adjustment device; the reactor vessel is connected to the extrusion granulator by means of a conveying pipe; the conveying pipe is provided with a second adjusting device for adjusting a conveying pressure; and the extrusion granulator is connected to the hot-air drying oven by means of a conveyor belt. The granulation apparatus in the present invention can effectively ensure the stability of a starch-based product and improve the quality of the product, and has a high degree of automation and high production efficiency. The present invention further relates to a granulation method for starch-based crispy particles, the method being suitable for industrial promotion and production of starch-based products.

Description

A starch-based crispy granule granulation device and granulation method Technical Field

[0001] The invention relates to the technical field of food processing equipment, and in particular to starch-based crispy granule granulation equipment and a granulation method. Background Art

[0002] Due to the structural and property limitations of starch-based raw materials, crispy products made from starch-based raw materials typically require high-temperature frying, baking, and microwave cooking to achieve a puffy, crunchy texture. This process rapidly heats up the liquid within the processed material, vaporizes it, and pressurizes it to expand. This expansion force then drives the structural denaturation of the polymer components. During these processes, large amounts of food additives are added to enhance appearance and texture. Furthermore, products prepared through high-temperature frying or baking are high in calories. Long-term consumption can lead to excessive intake of oil, salt, and sugar, tooth decay, and oral problems.

[0003] In recent years, the extrusion and puffing of starch-based foods has been widely used. During the extrusion and puffing process, the material is squeezed forward with the help of the driving force of the extruder screw. The material is mixed, stirred, rubbed, and subjected to high shear, which causes the starch granules to disintegrate. At the same time, the temperature and pressure of the machine cavity increase, and then it is instantly extruded through a die hole of a certain shape, suddenly dropping from high temperature and high pressure to low temperature and low pressure. The free water in it is rapidly vaporized under this pressure, and the raw starch is converted into cooked starch at the moment of puffing, and becomes a lamellar and loose sponge, with the volume expanding several to dozens of times.

[0004] In this process, extrusion and puffing equipment plays a key role in the quality and production efficiency of puffed foods. Extensive research has been conducted on extrusion equipment in the prior art. For example, Chinese Patent Publication No. CN215270523U discloses an extrusion and puffing machine for food processing. This integrated device primarily addresses the problem of easy clogging during material transportation. Chinese Patent Publication No. CN214386032U discloses an extrusion and puffing machine for puffed food production and processing. This machine uses an ultraviolet disinfection lamp to disinfect the interior of the box with ultraviolet light. Two high-temperature disinfection heating wires, respectively, cooperate with two heat conducting plates to facilitate high-temperature disinfection of the interior of the box. Combined with other structural improvements, these improvements improve the efficiency and durability of the extrusion and puffing equipment. However, these extrusion and puffing machines are either complex in structure and have high manufacturing and purchase costs, or have low automation and complex operation, or have high energy consumption and are unable to improve the quality of the puffed products. Therefore, improvements are urgently needed.

[0005] Summary of the Invention

[0006] The technical problem solved by the present invention is to provide a starch-based crisp granule granulation device to improve the degree of automation and enhance product quality.

[0007] The technical problem solved by the present invention is also to provide a starch-based crisp granule granulation method to improve the degree of automation in the preparation of starch-based crisp granules while improving product quality and reducing energy consumption.

[0008] The technical problem solved by the present invention is achieved by adopting the following technical solutions:

[0009] A starch-based crisp granule granulation device, comprising:

[0010] Pretreatment unit, granulation unit and drying unit;

[0011] The pretreatment unit includes a reactor;

[0012] The granulation unit includes an extrusion granulator, and the extrusion granulator includes an extrusion nozzle and a first regulating device for regulating the extrusion pressure;

[0013] The drying unit comprises a hot air drying box, a hot air blower and a drying tunnel are arranged in the hot air drying box, and the hot air drying box is provided with a temperature regulating device;

[0014] The reactor is connected to the extrusion granulator via a feed pipe, and the feed pipe is provided with a second regulating device for regulating the delivery pressure;

[0015] The extrusion granulator is connected to the hot air drying box through a conveyor belt.

[0016] In the present invention, the reactor is equipped with a heating device, and a stirring device is provided inside the reactor.

[0017] In the present invention, the pressure regulating device is a pressure regulator, and the pressure regulator is connected to the pressure digital control panel.

[0018] In the present invention, the conveyor belt is a mesh conveyor belt, which includes a receiving area, a drying area and a cooling area that are connected or integrally formed. The receiving area is arranged at the bottom of the extrusion nozzle, the drying area is arranged inside the drying box, and the cooling area extends outward from the discharge port of the drying box. The surface heights of the receiving area, the drying area and the cooling area are kept consistent.

[0019] In the present invention, an air outlet is provided on the side of the hot air drying box, an air guide groove is provided at the bottom of the drying zone of the mesh conveyor belt, and the air outlet is connected to the air guide groove through a pipeline.

[0020] In the present invention, the air guide groove is adapted to the drying zone, the air nozzles of the hot air blower are opened on both sides of the air guide groove, and a plurality of air nozzles are arranged at intervals along the conveying direction of the conveyor belt.

[0021] In the present invention, a blast belt is provided on the upper side of the receiving area of ​​the mesh conveyor belt, and an air collecting trough is provided at the bottom of the receiving area of ​​the mesh conveyor belt. The air collecting trough is connected to the air inlet of the hot air blower through a pipeline.

[0022] In the present invention, the mesh holes on the mesh conveyor belt are evenly distributed, and the mesh hole diameter is 4 to 6 mm.

[0023] In the present invention, the cavity of the hot air drying box is an arched structure with a high middle and low sides.

[0024] A method for granulating starch-based crisp granules is prepared using the starch-based crisp granule granulation equipment, comprising the following steps:

[0025] Pretreatment: Add edible starch-based powder and edible liquid into the reactor at a material-liquid ratio of 1:5-16, stir evenly and heat to form starch-based paste;

[0026] Extrusion granulation: The starch-based paste is transported to the extrusion granulator, and the pressure of the extrusion granulator is adjusted before extrusion molding.

[0027] Hot air drying: The pressurized particles are passed through the receiving area, drying area and cooling area of ​​the conveyor belt in sequence, and then packaged.

[0028] Beneficial effects: The starch-based crisp granule granulation equipment of the present invention has a reasonable configuration and a compact structure. It can prevent material blockage during material transportation and ensure uniform feeding. The pressure and temperature are accurately regulated during the starch-based crisp granule manufacturing process, thereby effectively ensuring the stability of the product and improving product quality. It has a high degree of automation and is suitable for industrial production.

[0029] The starch-based crispy granule granulation equipment of the present invention provides a buffer area for sufficient cooling and expansion of the extruded granules through the different partitioning arrangements on the conveyor belt. The expanded granules can enter the drying area for sufficient drying, and the dried food can be cooled on the conveyor belt. The degree of automation is further improved, the structure of the device is made more compact, and the equipment cost is reduced.

[0030] The starch-based crisp granule granulation equipment of the present invention circulates hot air through the unique arrangement of the hot air drying box air outlet and air guide grooves, fully utilizes heat, reduces energy consumption, and simultaneously dries the granules evenly, ensuring taste and quality.

[0031] The starch-based crisp granule granulation method of the present invention has a high degree of automation and low energy consumption in the preparation process, and the prepared product is stable and has improved quality, and is suitable for industrial promotion and production. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG1 is a schematic structural diagram of a preferred embodiment 1 of the present invention.

[0033] FIG2 is a schematic structural diagram of an improved preferred embodiment 1 of the present invention.

[0034] FIG3 is a schematic diagram of the side structure of the cavity of the hot air drying oven in the preferred embodiment 1 of the present invention.

[0035] Among them: 1. Reactor; 2. Heating device; 3. Feed port; 4. Air hole; 5. Stirring device; 6. Pressure pump; 7. Extrusion granulator; 8. Extrusion nozzle; 9. Electric gate; 10. Pressure CNC panel; 11. Hot air drying oven; 12. Hot air blower; 13. Air outlet; 14. Temperature regulating device; 15. Receiving area; 16. Drying area; 17. Cooling area; 18. Air guide trough; 19. Blowing belt; 20. Air collecting trough; 21. Cavity. DETAILED DESCRIPTION

[0036] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below with reference to specific embodiments.

[0037] Example 1

[0038] A starch-based crisp granule granulation device comprises a pretreatment unit, a granulation unit and a drying unit.

[0039] The pretreatment unit includes a reactor 1. The reactor 1 is provided with a feed port 3, a discharge port, and an air hole 4. The feed port 3 and the air hole 4 are provided at the top of the reactor 1, and the discharge port is provided at the bottom of the reactor 1. The reactor 1 is equipped with a heating device 2, which can be an electric heating device 2 or a steam heating device 2, for maintaining the reaction temperature in the reactor 1. The reactor 1 is provided with a stirring device 5.

[0040] The granulation unit includes an extrusion granulator 7, which is preferably a double-roller extrusion granulator 7. The extrusion granulator 7 includes an extrusion nozzle 8 and a first regulating device for regulating the extrusion pressure, wherein the pressure regulating device is a pressure regulator, and the pressure regulator is connected to a pressure numerical control panel 10, thereby realizing intelligent control of the extrusion pressure. At least one row of the extrusion nozzles 8 is provided at the bottom of the extrusion granulator 7, and the multiple extrusion nozzles 8 are arranged at intervals, and the openings of the extrusion nozzles 8 are arranged downward. In some preferred schemes, the extrusion shapes of the multiple extrusion nozzles 8 are different, and brittle particles of different shapes can be produced by extruding simultaneously through different extrusion nozzles 8, thereby better meeting market needs.

[0041] The reactor 1 is connected to the extrusion granulator 7 through a feed pipe, and a second regulating device for regulating the delivery pressure is provided on the feed pipe; the second regulating device is preferably a pressure pump 6, which keeps the delivery pressure within a predetermined range, thereby ensuring smooth delivery of materials in the feed pipe to prevent blockage, and keeping the feed pressure of the extrusion granulator 7 stable. The second regulating device combined with the first regulating device can reduce product adhesion and blockage, making the product extrusion efficient and stable.

[0042] The extrusion granulator 7 is connected to the hot air drying oven 11 via a conveyor belt. The conveyor belt is a mesh conveyor belt with evenly distributed mesh holes, specifically ensuring that the extruded material on the mesh surface does not leak. In this embodiment, the mesh hole diameter is preferably 4 to 6 mm. The mesh conveyor belt includes a receiving area 15, a drying area 16, and a cooling area 17 that are connected or integrally formed. The receiving area 15 is located at the bottom of the extrusion nozzle 8, the drying area 16 is located inside the drying oven, and the cooling area 17 extends outward from the discharge port of the drying oven. The surface heights of the receiving area 15, the drying area 16, and the cooling area 17 are consistent.

[0043] The drying unit includes a hot air drying oven 11, which houses a hot air blower 12 and a drying tunnel. An air outlet 13 is provided on the side of the hot air drying oven 11. An air guide trough 18 is provided at the bottom of the drying zone 16 of the mesh conveyor belt, adapted to the drying zone 16. The hot air blower 12 has air nozzles located on either side of the air guide trough 18, with multiple nozzles spaced apart along the conveying direction of the conveyor belt, and the spacing between the multiple nozzles is consistent. Hot air generated by the hot air blower 12 passes through the multiple nozzles from the bottom of the air guide trough 18, through the mesh holes in the mesh conveyor belt, and dries the particles on the mesh conveyor belt. The hot air is evenly directed upward from the bottom, gently blowing and lifting and flipping the particles, achieving more uniform heat exchange, thereby achieving faster and more uniform drying. Furthermore, the evenly distributed mesh holes in the mesh conveyor belt evenly distribute the hot air, further ensuring uniform drying.

[0044] The air outlet 13 is connected to the air guide groove 18 through a pipe. In actual application, a dehydration device is provided on the pipe. After dehydration, the hot air with more waste heat from the air outlet 13 further enters the air guide groove 18 for circulation heating, so that the heat is fully utilized and energy loss is reduced.

[0045] The hot air drying box 11 is provided with a temperature regulating device 14 . The temperature regulating device 14 includes a temperature sensor provided in the hot air drying box 11 and a control box provided on the hot air drying box 11 . The control box is also connected to the hot air blower 12 .

[0046] As a further improvement to this embodiment, a blast belt 19 is provided on the upper side of the receiving area 15 of the mesh conveyor belt. The blast belt 19 is connected to the blower via a pipe. An air collecting trough is provided at the bottom of the receiving area 15 of the mesh conveyor belt. The air collecting trough is connected to the air inlet of the hot air blower 12 via a pipe. Consequently, the air generated by the blast belt 19 rapidly cools the extruded particles, allowing them to more quickly cool from the high temperature and high pressure within the extruder to the low temperature and low pressure, further increasing the temperature difference. The expanded lamellar sponge becomes more porous, resulting in a better expansion effect and a crispier texture. In actual applications, a water absorption device is provided on the pipe. The heat from the particles is removed, dehydrated, and then further used to generate hot air, which helps save and reduce energy consumption.

[0047] In some preferred embodiments, as shown in Figure 3, the cavity 21 of the hot air drying oven has an arched structure with a high center and low sides. Uneven wind speed and temperature distribution within the cavity 21 of the hot air drying oven can lead to high drying energy consumption, low efficiency, and uneven drying. The wind speed field within the cavity 21 is distributed as follows: low wind speed at the center and high wind speed at the edges. The wind speed rapidly decreases after the hot air enters the material tray, and the wind speed within the tunnel is generally stable but partially chaotic. A mesh conveyor belt ensures continuous material transport and increases the contact area between the material and the hot air within the hot air drying oven cavity, facilitating the stability of the wind speed field within the cavity and ensuring a more even distribution of the hot air within the drying tunnel. The arched structure of the cavity 21 with a high center and low sides further reduces the wind speed and temperature differences between the edges and the interior of the tunnel. Combined with the mesh conveyor belt, the material can be dried more evenly and quickly, improving product quality and reducing drying energy consumption.

[0048] Example 2

[0049] A method for granulating starch-based crisp granules is prepared using the starch-based crisp granule granulation equipment, comprising the following steps:

[0050] Pretreatment: Add edible starch-based powder and edible liquid into reactor 1 at a material-liquid ratio of 1:10, stir evenly and heat at 100°C for 20 minutes to prepare starch-based paste; in this embodiment,

[0051] Extrusion granulation: The starch-based paste is transported to the extrusion granulator 7, and the pressure of the extrusion granulator 7 is adjusted and then extruded into a single shape;

[0052] Hot air drying: The pressurized particles are sequentially passed through the receiving area 15, the drying area 16 and the cooling area 17 of the conveyor belt. The extruded particles are cooled in the receiving area 15 and then dried in the drying area 16 at a drying temperature of 150°C for 15 minutes. The dried particles are cooled in the cooling area 17 and then directly packaged. The process has a high degree of automation.

[0053] In this embodiment, the edible starch-based powder is dry-ground early indica rice powder, and the obtained product is early indica rice paste crispy grains.

[0054] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A starch-based crisp granule granulation device, characterized in that: include: Pretreatment unit, granulation unit and drying unit; The pretreatment unit includes a reaction kettle; The granulation unit comprises an extrusion granulator, and the extrusion granulator comprises an extrusion nozzle and a first regulating device for regulating the extrusion pressure; The drying unit comprises a hot air drying box, a hot air blower and a drying tunnel are arranged in the hot air drying box, and the hot air drying box is provided with a temperature regulating device; The reactor is connected to the extrusion granulator through a feed pipe, and the feed pipe is provided with a second regulating device for regulating the delivery pressure; The extrusion granulator is connected to the hot air drying box through a conveyor belt.

2. The starch-based crisp granule granulation equipment according to claim 1, characterized in that: The reactor is equipped with a heating device, and a stirring device is arranged inside the reactor.

3. The starch-based crisp granule granulation equipment according to claim 1, characterized in that: The pressure regulating device is a pressure regulator, and the pressure regulator is connected to a pressure digital control panel.

4. The starch-based crisp granule granulation equipment according to claim 1, characterized in that: The conveyor belt is a mesh conveyor belt, which includes a receiving area, a drying area and a cooling area that are connected or integrally formed. The receiving area is arranged at the bottom of the extrusion nozzle, the drying area is arranged inside the drying box, and the cooling area extends outward from the discharge port of the drying box. The surface heights of the receiving area, the drying area and the cooling area are kept consistent.

5. The starch-based crisp granule granulation equipment according to claim 4, characterized in that: An air outlet is provided on the side of the hot air drying box, and an air guide groove is provided at the bottom of the drying area of ​​the mesh conveyor belt, and the air outlet is connected to the air guide groove through a pipeline.

6. The starch-based crisp granule granulation equipment according to claim 5, characterized in that: The air guide groove is adapted to the drying area, and the air nozzles of the hot air blower are arranged on both sides of the air guide groove, and a plurality of air nozzles are arranged at intervals along the conveying direction of the conveyor belt.

7. The starch-based crisp granule granulation equipment according to claim 5, characterized in that: A blast belt is arranged on the upper side of the receiving area of ​​the mesh conveyor belt, and an air collecting trough is arranged at the bottom of the receiving area of ​​the mesh conveyor belt. The air collecting trough is connected to the air inlet of the hot air blower through a pipeline.

8. The starch-based crisp granule granulation equipment according to claim 1, characterized in that: The mesh holes on the mesh conveyor belt are evenly distributed, and the mesh hole diameter is 4-6 mm.

9. The starch-based crisp granule granulation equipment according to claim 8, characterized in that: The cavity of the hot air drying box is an arched structure with a high middle and low sides.

10. A method for granulating starch-based crisp granules, characterized in that: The starch-based crisp granule granulation device is used to prepare the crisp granule granulation device, comprising the following steps: Pretreatment: Add edible starch-based powder and edible liquid into the reactor at a material-liquid ratio of 1:5-16, stir evenly and heat to form starch-based paste; Extrusion granulation: The starch-based paste is transported to the extrusion granulator, and the pressure of the extrusion granulator is adjusted to form the paste in one extrusion process; Hot air drying: The pressed particles are passed through the receiving area, drying area and cooling area of ​​the conveyor belt in sequence, and then packaged.

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