Black Dry Apple Chip Processing via Bacillus Fermentation
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Solution Overview
Problem
Current methods for producing black apple chips face issues such as inefficient carbonyl ammonia reaction, nutritional ingredient digestion, unstable temperature and humidity control, high energy consumption, and poor product quality due to sugar content and moisture absorption, leading to harmful substances and pathogenic bacteria growth.
Innovation Solution
A processing method involving ultra-high pressure water jet cutting, high-temperature Bacillus subtilis fermentation, and radio frequency-pulse vacuum dehumidification with maltodextrin addition to promote carbonyl ammonia reaction, inhibit pathogenic bacteria, and maintain nutritional components, including sorting, cleaning, slicing, fermenting, drying, and packaging steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If natural carbonyl ammonia reaction is carried out under high temperature and high humidity conditions, then the reaction can proceed, but the process takes long time and produces uneven color
Solution Approach 1:
The apple slices are pre-treated with enzyme solution before the carbonyl ammonia reaction, which prepares the substrate in advance to accelerate the subsequent reaction process. This preliminary enzymatic treatment breaks down cell walls and releases sugars, enabling faster and more uniform color development during the reaction stage.
Solution Approach 2:
The patent optimizes reaction parameters including temperature (60-80°C), humidity (80-90% RH), and reaction time (4-8 hours) to achieve efficient carbonyl ammonia reaction. By precisely controlling these parameters, the reaction proceeds rapidly with uniform color distribution, avoiding the long processing time and uneven coloration of natural reactions.
2Productivity
If conventional drying methods are used for high sugar content apple slices, then drying can be achieved, but the slices easily agglomerate, adhere and absorb moisture resulting in poor product quality
Solution Approach 1:
Maltodextrin is introduced as an intermediary substance sprayed on the apple slices during drying. This coating layer acts as a barrier that prevents direct contact between high-sugar slice surfaces, thereby preventing agglomeration and adhesion. The maltodextrin layer also reduces moisture absorption from the environment, maintaining product quality throughout the drying process.
3Manufacturing precision
If freeze-drying technology is used for processing, then product quality can be maintained, but the process takes long time and is high in cost
Solution Approach 1:
The apple slices undergo pre-drying treatment before the main drying process, which removes a significant portion of moisture in advance. This preliminary dehydration step reduces the drying load for subsequent processing, enabling faster drying times while maintaining nutritional quality that would otherwise require lengthy freeze-drying.
Solution Approach 2:
The patent employs controlled temperature and humidity parameters during drying (60-80°C with 80-90% RH during reaction, then lower temperatures for drying) to optimize the drying process. These parameter optimizations enable efficient moisture removal that preserves nutritional components without requiring the extended time and high energy consumption of freeze-drying.
4Productivity
If high temperature is used in spray drying technology, then drying speed increases, but instability and ingredient substances are generated affecting product components
Solution Approach 1:
The carbonyl ammonia reaction and enzymatic treatment are completed before the drying stage, which prepares the product structure in advance. This preliminary processing stabilizes the chemical composition and reduces sensitivity to thermal stress during drying, allowing faster drying rates without generating harmful substances or losing nutritional ingredients.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method results in high-bioactivity black dry apple chips with improved digestibility, reduced drying time, and enhanced nutritional retention, while preventing pathogenic infections and maintaining enzyme activity, achieving a more efficient and cost-effective production process.
Implementation Method 1
high-temperature Bacillus subtilis fermentation
Implementation Method 2
Melanoidins generated from carbonyl ammonia reaction is capable of resisting oxidation, free radicals and diseases
Implementation Method 3
ultra-high pressure water jet cutting
Implementation Method 4
radio frequency-pulse vacuum dehumidification
Implementation Method 5
radio frequency-pulse vacuum dehumidification
Implementation Method 6
maltodextrin addition to promote carbonyl ammonia reaction
Data Source
AI summary
The disclosure relates to a high-bioactivity black dry apple chip and a processing technology thereof. The processing process is as follows: fresh fruits→sorting→peeling→slicing→fermenting→drying→packaging→black dry apple chips. According to the disclosure, a high-temperature Bacillus subtilis fermentation broth atomization spray technology is adopted to atomize the processed apple slices under the condition of 60° C.-80° C., the cut apple slices are irradiated with 60 Coy rays at a dose of 4 kGy to promote carbonyl ammonia reaction so as to make apple slices generate burnt black. According to the disclosure, Bacillus subtilis antimicrobial peptide solution is sprayed so as to utilize its bacteriostatic function to avoid pathogen infection during shelf life.