Industrial production of jujube powder does not need drying.
Technological process of industrial jujube powder;
Jujube → fruit washing → soaking → precooking → pulping → fine grinding → extraction → separation → enzymolysis → enzyme inactivation → separation → inorganic membrane filtration → sterilization → concentration → batching → sterilization → spray drying → packaging → finished product.
1 Process: Acceptance of raw and auxiliary materials
Jujube quality inspectors inspect jujube according to the standard and collect qualified jujube into the fruit trough. Unqualified jujubes should be cleaned and delivered from the factory until they are qualified, and then purchased or rejected.
Sterile bags, liquid bags or cans, enzyme preparations and other auxiliary materials are allowed to be put into storage after inspection. Packaging materials should be stored at room temperature and used according to the principle of first-in first-out; Enzymes are stored in cold storage at 0~5℃ and used according to the principle of first-in first-out. After cleaning materials, disinfectants and other auxiliary materials enter the factory, they are put into storage after passing the inspection, stored in categories and clearly marked.
2 technology: fruit trough
Lightly unload the qualified red dates into the fruit troughs one by one according to the number of fruit troughs, and take out the cordless heads, packaging materials and other sundries in the red dates, and keep records of the red dates stored in each fruit trough. During workshop production, the red dates in the pomace should be used correctly according to the purchase order and the principle of first-in first-out. The stevedores are responsible for the sanitation of the fruit trough and the surrounding environment, and must clean it every day and keep it clean all day. The quality inspection of red dates on duty is responsible for implementation.
3 working procedure: once conveying and cleaning.
The jujube is transported from the fruit trough to the first pit through the circulating water in the first pit. During this cycle, red dates were fully soaked and cleaned. At the same time, some heavy substances (sediments, stones, metals, etc. ) sinking into a sedimentation pit, separating water from jujube through a grating, and the jujube enters a second fruit conveying channel. The water flows into the first circulating pool, and the water pump continues to pump into the fruit tank for circulating transportation of dates.
Step 4: Secondary conveying and cleaning.
Circulating water from the secondary core is used to transport red dates from the starting point of the secondary conveying fruit path to the secondary core. During this cycle, the red dates are fully soaked and cleaned, and the water and red dates are separated through the grille. Jujube enters the primary lifting process, water flows into the secondary pit circulating pool, and the pump continues to pump into the beginning of the secondary conveying fruit path to convey jujube circularly. Tap water is used for circulating water in the pit twice every day when the machine is turned on. In the production process, the treated softened water is continuously replenished to the secondary circulating pool according to the water level of the secondary circulating pool, and the surplus circulating water in the secondary circulating pool enters the primary pool to keep the circulating water in the secondary pool clean and hygienic.
5 Process: First-level promotion
Hang the red dates on the picking table with a first-stage spiral hoist. By adjusting the gearbox of the hoist, the feeding speed of raw materials is adjusted to ensure the production needs.
6 Process: Pick up the goods
Picking out rotten fruits and impurities with the rolling of red dates on the picking table, this process ensures that the rotten fruit rate is controlled below 2% after picking, and the red dates are placed in a single layer on the fruit selection table, and each fruit selection table is guaranteed to be more than per square meter 1 fruit selector. Monitor the rotten fruit rate every 2 hours and make records. The selected raw fruits enter the three-stage conveying and cleaning process.
7 process: rotten fruit conveying
Impurities such as rotten red dates picked up by the sorting table are transported out of the workshop by the spiral elevator for non-consumption.
8 process: floating washing
In this circulation process, the red dates turn with the water flow in the floating washing machine, and after being fully soaked and cleaned, they enter the disinfection pool.
9 Process: Secondary hoisting
At the end of the floating washing machine, the raw fruit is transported to the roller conveyor by the elevator, and the washing water is pumped back to the floating washing machine to continue circulating, and the washing water is separated from the raw fruit at the same time.
10 process: disinfection
In the disinfection pool, disinfectant (generally chlorine dioxide) is mainly used to kill acid-resistant and heat-resistant bacteria and some microorganisms on the surface of jujube.
1 1 Process: drum spray cleaning.
Raw fruits are washed with high-pressure water spray on the roller conveyor belt.
12 process: three-level promotion
Hang the red dates on the pulverizer with a three-stage crane.
13 process: crushing
The washed red dates are crushed into 4-6mm pulp by a crusher (the crushing granularity is adjusted according to the maturity of the red dates, the hardness of the first fruit is high, the crushing granularity is small, and the crushing granularity is large when fructose is stored). It is required to replace the crushing screen in three stages, namely, the first, middle and final stages, and use small, medium and large screens respectively. According to the maturity of jujube, decide whether to add fruit pulp enzyme and its dosage or temporary process considerations. The pulp is pumped into the pulp heater through a stainless steel tube.
14 technology: fruit pulp heating
The pulp heater raises the temperature of the pulp to 20-35 degrees, which is beneficial to the enzymatic hydrolysis and pressing of the pulp and improves the juice yield. The use of the pulp heater depends on the temperature of the pulp.
15 process: temporary storage of fruit pulp
After heating and adding enzyme, the fruit pulp is pumped into the fruit pulp tank through the pipeline and kept for a certain time, so that the fruit pulp is fully hydrolyzed and the juice yield is improved. There are two fruit pulp tanks, one for enzymatic hydrolysis of fruit pulp and the other for normal production, and the enzymatic hydrolysis time must be more than 30 minutes.
16 process: pressing
The crushed fruit pulp is squeezed by a juicer, and the squeezed juice enters the first-stage filtration process, and the fruit residue is extracted with water in this machine and enters the second-stage squeezing.
17 process: primary filtration
Squeeze the squeezed juice through a rotating filter screen to remove larger particles of water-insoluble pulp and pomace, and the permeated juice enters the first pasteurization process. When cleaning, visually check the integrity of the primary filter once a day and make records.
18 process: apple pomace discharge
After the second pressing, the pomace is sent out of the workshop by the screw conveyor, continuously discharged, and shipped out of the factory for non-edible use (feed, etc.). ).
19 process: raw juice temporary storage
The primary filtered raw juice is pumped to the raw juice temporary storage tank.
Step 20: Pre-pasteurization
Fruit juice is kept in a pasteurization device at 98 2℃ (or according to the temporary process notice) for 30 seconds to kill bacteria (but not spores), thus inactivating the inherent enzymes in jujube and gelatinizing the starch contained in jujube. The pre-pasteurized juice enters a cooling plate through a pipeline, is rapidly cooled to 50-53 DEG C, and then is sent to an enzymolysis clarification tank through a pipeline.
2 1 process: enzymatic clarification
Under the action of pectinase and amylase, pectin and starch in juice are decomposed into soluble small molecular substances (to prevent precipitation and turbidity of juice). The concentration of enzyme, enzymolysis temperature and enzymolysis time vary with the quality of jujube. Generally, the temperature of enzymolysis is 50-53℃ and the time is 90 minutes. The juice after enzymolysis is pumped to the ultrafiltration circulation tank through the secondary filtration device.
Step 22: Secondary filtration
The secondary filtering device is a filter installed on the pipeline between the enzymolysis tank and the ultrafiltration circulating tank, with the aperture of about 1.5mm, and is used to remove possible large pulp particles or other impurities. When cleaning ultrafiltration, the integrity of the filter is visually cleaned once a day, and records are made.
Step 23: Ultrafiltration
The pore size of ultrafiltration membrane is 0.02um, and impurities such as water-insoluble substances, substances with molecules larger than 0.02um (including microorganisms) and possible metal chips are removed by ultrafiltration. The ultrafiltered juice is transported to the clear juice temporary storage tank by a pump through a pipeline.
Step 24: sugar extraction
When the solid content in the ultrafiltration circulating liquid reaches 30%, soft water should be added to the ultrafiltration circulating liquid to leach the sugar in the circulating liquid.
Step 25: Solid discharge
After the sugar is extracted by ultrafiltration, press the automatic slag discharge button, and the trapped solids will be discharged from the circulation system.
Step 26: Adsorption
After removing tannins and phenols from fruit juice by resin adsorption, the fruit juice is pumped into the four-stage filtration process.
Decolorization resin requirements: (1) 3 sets of adsorption columns, 1 set of adsorption column operation, 1 set of regeneration, 1 set of standby.
Step 27: Four-stage filtration
The juice after resin adsorption is removed by a 50um metal filter, and the permeated juice is transported to the evaporation and concentration process by a pump through a pipeline. During the weekly cleaning, open the filter, visually check the integrity of the four-stage filter, and make records.
Step 28: Evaporation and concentration
Using falling film evaporation device, the water in fruit juice was evaporated and separated, and the condensed water (soft water) was used as jujube washing water, squeezing extraction water and ultrafiltration extraction water to concentrate the fruit juice, and the sugar content was concentrated from 9~ 18BX to 70.3 0.2brix.
Step 29: Temporary storage of thick juice
The cooled product is pumped into the batching tank for temporary storage. When the liquid level reaches the blender, the juice is stirred while entering. When the tank is full, the evenly stirred juice is pumped into the cardboard filtration system as a batch through the pipeline. When the juice needs to be stored, it enters the cooling process.
Step 30: Cooling
When the concentrated juice needs to be stored, the juice cooled to about 25℃ will be cooled to about 5- 10℃ through the heat exchanger again, and then transported to the storage tank by the pump through the pipeline.
3 1 process: cold storage
Refrigerate the products in the storage tank in the cold storage below 5℃. When filling is needed, the juice is pumped into the batching tank through the pipeline.
Step 32: Pasteurization for the second time
The juice entering the second pasteurization equipment will kill bacteria, Escherichia coli and pathogenic bacteria. (but it can't kill spores), the sterilized juice is sent to a cooling device through a pipeline to be quickly cooled to below 20℃, and then sent to a five-stage filtration process through a pipeline.
Step 33: Five-stage filtration
Five-stage filtration is to install a 300-mesh metal pipeline filter on the pipeline to intercept possible impurities, and the permeated juice enters the aseptic filling process through the pipeline. Every time you clean, visually check the integrity of the filter and make records.
Step 34: aseptic filling
The process adopts FBR aseptic filling machine, and the concentrated juice is transported to the aseptic filling machine through pipeline. Under the sterilization condition that the inner cavity temperature of the filling head of the filling machine is more than or equal to 95℃, the juice is poured into a sterile bag (with a protective bag and a steel drum around it), and the filling weight is controlled by a mass flowmeter.