海参微波—冻干联合干燥工艺与机理研究
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摘要
海参(Stichopus japonicus)具有极高的营养和商品价值,是最为昂贵的海产珍品之一。由于海参离开海水很快会自溶,因此必须尽快加工,世界上约80%的海参都被加工成干参。海参体壁的主要成分是胶原蛋白,干燥过程中很容易腐败变质,且高温脱水后会发生硬化,食用前的复水过程经常需2-3天。目前市场流行的海参主要是传统的盐干海参和冻干海参。盐干海参整个过程需要3天以上的时间,质量很差;冻干海参虽然质量很好,但干燥时间长达20 h以上,能耗也很高。因此,本文引入了基于冻干的联合干燥手段加工海参,来代替传统的冷冻干燥技术,实现高品质、低能耗的干燥。
为了缩短传统冷冻干燥的时间,采用了冻干-真空微波分段联合干燥技术。发现联合干燥的海参在产品品质方面接近冷冻干燥产品,同时可缩短冷冻干燥时间约40%;发现转换含水率对分段联合干燥过程的影响最大;通过响应面分析方法给出了联合干燥的具体操作工艺参数;联合干燥方式是一种可以替代传统冷冻干燥来加工海参的新技术,这项技术也非常适合现有冷冻干燥生产线的升级改装,值得进一步推广。
为了缩短传统冷冻干燥的时间,并进一步提高产品质量,采用了微波作为加热源的微波辅助冻干同步联合干燥技术。对干燥室的电场分布进行了有限元模拟,从而使电场分布均匀;通过研究击穿功率密度和干燥压力的关系,发现了干燥过程中低压气体放电的规律;提出了干燥过程的微波加载方案,以获得较快的干燥速度和较好的产品质量;发现了微波冻干过程的杀菌特性,提出了纳米银涂膜结合微波冻干生产活性海参的新工艺;采用微波冷冻干燥保质新工艺生产的海参与传统冻干海参质量没有差别,但干燥时间缩短了近一倍。
为了进一步缩短微波冷冻干燥的时间,对海参的介电特性进行了研究。发现海参的介电常数和介电损耗因子随温度和含水率变化的规律,特别是海参冻结后其介电损耗因子急剧下降,造成微波吸收能力下降;在保证干燥速率的前提下提出了避免热失速的方法,从而使产品不会出现焦糊现象;在不影响产品外观和食品安全的前提下提出了通过纳米钙真空浸渍处理和盐水浸渍处理来改善海参的介电特性的方法,发现纳米钙真空浸渍处理后可显著提高升华速率,而盐水浸渍处理对常压微波干燥较为适用。
为了进一步降低微波冷冻干燥能耗,对海参的冻干前处理技术进行了研究。将渗透脱水技术引入干燥前处理,考虑海参的传统加工工艺,将盐水作为渗透剂,来对海参进行预脱水以降低后期干燥负荷;发现超声波辅助渗透处理可明显提高渗透过程的传质速率,使失水率增加,同时对固形物增加率的提高效果则并不明显,有利于控制海参的含盐量,从而保持海参品质;通过后期的微波冷冻干燥试验,发现超声波辅助渗透预处理可有效降低干燥能耗近20%;通过响应面分析方法给出了海参盐水渗透工艺的具体参数,获得了较高的失水率和较低的固形物增加率。
Sea cucumber (Stichopus japonicus) is always looked on as a delicious and expense dish for its high nutrition and tonic function, and has very high commercial value. It is one of the most expensive marine products. Since the sea cucumber can autolyze after leaving sea water, it is difficult to preserve and transport. As a result, more than 80% of the fresh sea cucumber all over the world is processed to dehydrated product. Because the main component of the body wall of sea cucumber is collagen, dehydration is difficult and deterioration can occur during process. Besides, the dried product rehydration needs about 3 days for incrustation of body wall during drying process.Up to now, most of sea cucumbers are dehydrated by traditional techniques called salt-dehydration which need to add salt, boil again and again and expose to solar radiation for 2-3 days, and the product quality is poor. Another used technique is freeze drying which can ensure very well product quality, but needs more than 20 hours and the energy consumption was very high. As a resut, a new hybrid drying technology based on freeze drying was introduced to replace the traditional freeze drying. The new drying technology need not only ensure good product quality but also cost much lower energy consumption.
In order to reduce drying time of freeze drying, a two-stage combined drying technology,freeze drying-vaccum microwave dyring was used. It was found that the new technology could reduce about 40% of drying time of traditional freeze drying and its product quality was close to freeze drying. Conversion moisture content of sea cucumber was the most important parameter of the combined drying process, and the optimal drying parameters were gotten by a reponse surface analysis method. So the combined drying technology can replace traditional freeze drying, and it also can be used to upgrade the exixting freeze drying productline.
In order to reduce drying time of freeze drying and improve product quality, microwave was used as heating source of freeze drying, which could be called one-stage microwave freeze drying. Electric field distribution of the drying cavity was simulated by finite element method, and thus uniform heating could be ensured. Relationship between discharge power density and drying pressure was investigated, and the rule of low air pressure discharge was found. The rules of microwave loading were brought forward, which could lead to good product quality and short drying time. Sterilization characteristic of microwave freeze drying was found, and nanoscale silver coating combined with microwave freeze drying method was introduced to manufacture active sea cucumber. There was no significant difference between product quality of microwave freze drying and that of traditional freeze drying, wherease microwave frreze drying could reduce almost half of freeze drying time.
In order to reduce more drying time of microwave freeze drying process, dielectric properties of sea cucumber were studied. The change rules of dielectric properties of sea cucumber as a function of temperature and moisture content was investigated, and it was found that the loss factor of frozen sea cucumber rapidly decreasing led to low microwave absorption capability. Some methods were brought forward to avoid thermal run away and material burning. In addion, nanoscale calcium vaccum impregnation and slat impregnation treatments were introduced to improve the dielectric properties of sea cucumber, and the product qulity also could be ensured. In fact, nanoscale calcium vaccum impregnation treatment could improve sublimation rate, and slat impregnation treatment could improve atmospheric microwave drying rate.
In order to reduce more energy consumption, the osmotic pretreatment technology of microwave freeze drying sea cucumber was studied. Considering traditional sea cucumber processing, salt was used as osmotic agent to pre-dehydrate sea cucumber. It was found that ultrasound assisting osmotic pretreatment could lead to relative high water loss rate and solute gain rate increase was not very signifficalt. So ultrasound assisting osmotic pretreatment could had no significant affect on product quality, wherease it could reduce about 20% of microwave freeze drying energy consunmption. The optimal osmotic parameters also were worked out by a response surface analysis method.
为了缩短传统冷冻干燥的时间,采用了冻干-真空微波分段联合干燥技术。发现联合干燥的海参在产品品质方面接近冷冻干燥产品,同时可缩短冷冻干燥时间约40%;发现转换含水率对分段联合干燥过程的影响最大;通过响应面分析方法给出了联合干燥的具体操作工艺参数;联合干燥方式是一种可以替代传统冷冻干燥来加工海参的新技术,这项技术也非常适合现有冷冻干燥生产线的升级改装,值得进一步推广。
为了缩短传统冷冻干燥的时间,并进一步提高产品质量,采用了微波作为加热源的微波辅助冻干同步联合干燥技术。对干燥室的电场分布进行了有限元模拟,从而使电场分布均匀;通过研究击穿功率密度和干燥压力的关系,发现了干燥过程中低压气体放电的规律;提出了干燥过程的微波加载方案,以获得较快的干燥速度和较好的产品质量;发现了微波冻干过程的杀菌特性,提出了纳米银涂膜结合微波冻干生产活性海参的新工艺;采用微波冷冻干燥保质新工艺生产的海参与传统冻干海参质量没有差别,但干燥时间缩短了近一倍。
为了进一步缩短微波冷冻干燥的时间,对海参的介电特性进行了研究。发现海参的介电常数和介电损耗因子随温度和含水率变化的规律,特别是海参冻结后其介电损耗因子急剧下降,造成微波吸收能力下降;在保证干燥速率的前提下提出了避免热失速的方法,从而使产品不会出现焦糊现象;在不影响产品外观和食品安全的前提下提出了通过纳米钙真空浸渍处理和盐水浸渍处理来改善海参的介电特性的方法,发现纳米钙真空浸渍处理后可显著提高升华速率,而盐水浸渍处理对常压微波干燥较为适用。
为了进一步降低微波冷冻干燥能耗,对海参的冻干前处理技术进行了研究。将渗透脱水技术引入干燥前处理,考虑海参的传统加工工艺,将盐水作为渗透剂,来对海参进行预脱水以降低后期干燥负荷;发现超声波辅助渗透处理可明显提高渗透过程的传质速率,使失水率增加,同时对固形物增加率的提高效果则并不明显,有利于控制海参的含盐量,从而保持海参品质;通过后期的微波冷冻干燥试验,发现超声波辅助渗透预处理可有效降低干燥能耗近20%;通过响应面分析方法给出了海参盐水渗透工艺的具体参数,获得了较高的失水率和较低的固形物增加率。
Sea cucumber (Stichopus japonicus) is always looked on as a delicious and expense dish for its high nutrition and tonic function, and has very high commercial value. It is one of the most expensive marine products. Since the sea cucumber can autolyze after leaving sea water, it is difficult to preserve and transport. As a result, more than 80% of the fresh sea cucumber all over the world is processed to dehydrated product. Because the main component of the body wall of sea cucumber is collagen, dehydration is difficult and deterioration can occur during process. Besides, the dried product rehydration needs about 3 days for incrustation of body wall during drying process.Up to now, most of sea cucumbers are dehydrated by traditional techniques called salt-dehydration which need to add salt, boil again and again and expose to solar radiation for 2-3 days, and the product quality is poor. Another used technique is freeze drying which can ensure very well product quality, but needs more than 20 hours and the energy consumption was very high. As a resut, a new hybrid drying technology based on freeze drying was introduced to replace the traditional freeze drying. The new drying technology need not only ensure good product quality but also cost much lower energy consumption.
In order to reduce drying time of freeze drying, a two-stage combined drying technology,freeze drying-vaccum microwave dyring was used. It was found that the new technology could reduce about 40% of drying time of traditional freeze drying and its product quality was close to freeze drying. Conversion moisture content of sea cucumber was the most important parameter of the combined drying process, and the optimal drying parameters were gotten by a reponse surface analysis method. So the combined drying technology can replace traditional freeze drying, and it also can be used to upgrade the exixting freeze drying productline.
In order to reduce drying time of freeze drying and improve product quality, microwave was used as heating source of freeze drying, which could be called one-stage microwave freeze drying. Electric field distribution of the drying cavity was simulated by finite element method, and thus uniform heating could be ensured. Relationship between discharge power density and drying pressure was investigated, and the rule of low air pressure discharge was found. The rules of microwave loading were brought forward, which could lead to good product quality and short drying time. Sterilization characteristic of microwave freeze drying was found, and nanoscale silver coating combined with microwave freeze drying method was introduced to manufacture active sea cucumber. There was no significant difference between product quality of microwave freze drying and that of traditional freeze drying, wherease microwave frreze drying could reduce almost half of freeze drying time.
In order to reduce more drying time of microwave freeze drying process, dielectric properties of sea cucumber were studied. The change rules of dielectric properties of sea cucumber as a function of temperature and moisture content was investigated, and it was found that the loss factor of frozen sea cucumber rapidly decreasing led to low microwave absorption capability. Some methods were brought forward to avoid thermal run away and material burning. In addion, nanoscale calcium vaccum impregnation and slat impregnation treatments were introduced to improve the dielectric properties of sea cucumber, and the product qulity also could be ensured. In fact, nanoscale calcium vaccum impregnation treatment could improve sublimation rate, and slat impregnation treatment could improve atmospheric microwave drying rate.
In order to reduce more energy consumption, the osmotic pretreatment technology of microwave freeze drying sea cucumber was studied. Considering traditional sea cucumber processing, salt was used as osmotic agent to pre-dehydrate sea cucumber. It was found that ultrasound assisting osmotic pretreatment could lead to relative high water loss rate and solute gain rate increase was not very signifficalt. So ultrasound assisting osmotic pretreatment could had no significant affect on product quality, wherease it could reduce about 20% of microwave freeze drying energy consunmption. The optimal osmotic parameters also were worked out by a response surface analysis method.
引文
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