CN107050067A - 一种蛹虫草水溶粉的工业化制备方法 - Google Patents
一种蛹虫草水溶粉的工业化制备方法 Download PDFInfo
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Abstract
本发明涉及一种蛹虫草水溶粉的工业化制备方法。本方法将经干燥的蛹虫草经破碎后制得粗颗粒，以水为溶媒，将粗颗粒在低料水比、低温、超声辅助条件下进行二次提取，离心后合并滤液，滤液通过陶瓷膜进行精滤，将精滤后所得渗透液浓缩为浸膏，浸膏经低温真空连续带式干燥后经粉碎获得蛹虫草水溶粉。本发明方法的全部加工过程除水以外无任何加工助剂和辅料的使用，保证了产品的质量安全与品质纯正，且全程均在较低的温度下进行，成本低、能耗小。本方法所设计的各工序之间衔接紧密，工艺操作简便，安全高效，适于建立流水线进行工业化连续生产作业。
Description
技术领域
本发明涉及蛹虫草深加工技术领域，具体涉及一种蛹虫草水溶粉的工业化制备方法。
背景技术
蛹虫草，又名北冬虫夏草(Cordyceps militaris(L.)Link)，是属于真菌门(Eumycota)、子囊菌门(Ascomycota)、子囊菌亚门(Ascomycotinia)、粪壳菌纲(Sordariomycetes)、肉座菌亚纲(Hypocreomycetidae)、肉座菌目(Hypocreales)、虫草科(Cordycipitaceae)、虫草属(Cordyceps) 的一种大型药食真菌。蛹虫草与冬虫夏草具有相似的药理学活性成分，如含有虫草素、虫草酸、虫草多糖、麦角甾醇、氨基酸、核苷类物质等，功效与冬虫夏草相似，具有十分广泛的药理学作用。2014年国家卫生计生委发布公告将蛹虫草批准为新食品原料，引起了人们对蛹虫草利用的广泛关注与重视。
目前，关于蛹虫草提取物方面的文献专利多为实验室或小试的成果或简单套用其他提取物的相关技术方法，存在原料处理复杂、工艺激烈、工序繁琐、连续性差、生产成本高等诸多问题。从蛹虫草深加工产业化开发角度，以高效低耗、节能环保、安全卫生为出发点，按工业化连续生产制造流程，建立一套从蛹虫草原料预处理到最终产品的生产制备方法，未见相关具体报道。
另外，蛹虫草粉碎粒度达到60目以上时，经水浸泡后会膨胀***，有一定的粘性，使用工业滤袋式离心机难以实现良好的分离效果，滤渣会在滤袋内形成粘性滤饼层，使得渗透液无法顺利滤出，在工业生产中需要频繁的中止离心，清理滤饼层，使得过滤阶段操作繁杂、效率低下、渗透液损失较多。使用卧式离心机或者管式离心机可以实现较好的分离效果，但是二者在相同的物料处理量下，成本极高，维护及操作远高于滤袋式离心机。
经专利文献检索，专利号CN201310207185.9《一种蛹虫草速溶粉的制备方法》，它的主要工艺是经热水浸提、匀浆、酶解、湿法超微粉碎、均质、喷雾干燥制得，与本专利方法相比，从原料处理、生产工艺到终产品均存在不同之处，其生产工艺能耗较高、工序较为复杂且难以实现连续化，产品复水澄清度差，使用范围受限。
发明内容
本发明针对上述缺陷，目的在于提供一种提高产品的质量安全与品质纯正的一种蛹虫草水溶粉的工业化制备方法。
为此本发明采用的技术方案是：首先将经干燥的蛹虫草在颗粒破碎设备中进行破碎，获长度为2-5mm的蛹虫草粗颗粒，将其放入提取设备，加入该物料重量6-10倍的水，在超声频率24-40KHz、温度45-55℃的条件下，提取2-4小时，然后采用离心设备将滤液与滤渣分离，滤渣按原物料重量加3-5倍水进行二次提取并离心，合并两次提取所得滤液，使用孔径为100-1000nm的陶瓷膜设备对其进行精滤；精滤后所得渗透液使用真空浓缩设备在温度60-80℃，真空度-0.07-0.09MPa的条件下浓缩至获得可溶固形物浓度为52%-62%的浸膏；采用低温真空连续带式干燥设备，将浓缩浸膏在温度50-80℃，真空度-0.1MPa的条件下进行干燥，至获得含水量小于5%的结晶物，将其粉碎后得到蛹虫草水溶粉。
本发明的优点是：
1、本发明方法的原料处理工艺简单，无需将蛹虫草粉碎，仅将其破碎为粗颗粒即可，该工艺易于实现、加工成本低且不影响提取效率，并且很好的解决了由于粉碎粒度过小而造成难以分离的情况，使用低成本的滤袋式离心机即可实现良好初步分离的效果，不需要采用卧式离心机或者管式离心机等成本高、操作及维护复杂的设备；
2、本发明方法的提取工艺中，料水比例较低（辅以超声提取即能保证提取效率），在同等原料处理量的条件下，该工艺对提取设备的型号要求低，可节约其能耗和设备投资，并由于提取液的减少，在下游离心、浓缩工序中，亦可大大减轻物料的处理量和能耗，使得综合生产成本大幅降低、生产效率和资源利用率大幅提高；
3、本发明方法的过滤工艺采用陶瓷膜技术，其可滤除水不溶性微小固体颗粒，陶瓷膜的孔径经过试验及验证，选择澄清度高、过滤速度快及有效物质截留程度小的孔径，使得虫草素等小分子活性成分损失少，且可最大程度保障蛹虫草中水溶性活性成分的完整保留，直接使得产品复水后的澄清度极佳；
4、本发明方法的干燥工艺采用真空带式干燥技术，相较于常规的喷雾干燥160℃的进风温度，且需要添加可溶性淀粉、麦芽糊精等干燥助剂，真空带式干燥温度大大降低，物料损失小，能耗低，且无需添加助剂，保障产品安全和纯正，干燥所得物料即呈疏松多孔，且含水量小于5%，利于贮藏；
5、本发明方法的全部加工过程除水以外无任何加工助剂和辅料的使用，保证了产品的质量安全与品质纯正，且全程均在较低的温度下进行，成本低、能耗小；
6、本发明方法的整体工艺中，提取温度、浓缩温度、干燥温度温和，整个工艺流程都在较低的温度下进行，减少高温对蛹虫草活性成分的影响，可以最大程度保留蛹虫草提取成分的活性；
7、本发明方法所设计的各工序之间衔接紧密，工艺操作简便，安全高效，适于建立流水线进行工业化连续生产作业；
8、本发明方法制得的蛹虫草水溶粉呈疏松多孔，水溶性极好，冷热水均可速溶，且其复水后澄清度高，清亮透明，无任何沉淀；
9、本发明方法制得的蛹虫草水溶粉富含虫草素、腺苷、多糖等多种生物活性物质，适于功能食品、饮料、口服液、含片、日化、美容等领域应用。
附图说明
图1蛹虫草水溶粉的状态图。
图2为蛹虫草水溶粉用50/100/200/300份水复溶图(图中从左至右)。
具体实施方式
实施例（一）：
（1）粉碎：将蛹虫草经进行破碎，获得5mm粗颗粒；
（2）一次提取：蛹虫草粗颗粒放入提取罐中，向其中加入8倍质量的水，加热到45℃，使用28KHz的超声辅助提取2h；
（3）分离：使用离心机分离料液，获得一次提取滤液和滤渣；
（4）二次提取：将滤渣投入提取罐中，向其中加入4倍原蛹虫草粗颗粒质量的水，加热到45℃，使用28KHz的超声辅助提取2h；
（5）分离：使用离心机分离料液，获得二次提取滤液和滤渣；
（6）精滤：合并一次提取和二次提取滤液，使用500nm孔径的陶瓷膜设备进行精滤，获取澄清的渗透液。
（7）浓缩：使用单效外循环浓缩器进行浓缩，浓缩温度60℃，真空度-0.078MPa，浓缩至55%的固含量浓度。
（8）干燥：使用低温真空连续带式干燥设备干燥，干燥条件60℃、真空度-0.1MPa，获得干燥的结晶物，将其粉碎后得到蛹虫草水溶粉。
实施例（二）：
（1）粉碎：将蛹虫草经进行破碎，获得3mm粗颗粒；
（2）一次提取提：蛹虫草粗颗粒放入提取罐中，向其中加入7倍质量的水，加热到55℃，使用28KHz的超声辅助提取2h，提取2次；
（3）分离：使用离心机分离料液，获得一次提取滤液和滤渣；
（4）二次提取：将滤渣投入提取罐中，向其中加入3.5倍原蛹虫草粗颗粒质量的水，加热到55℃，使用28KHz的超声辅助提取2h；
（5）分离：使用离心机分离料液，获得二次提取滤液和滤渣；
（6）精滤：合并一次提取和二次提取滤液，使用800nm孔径的陶瓷膜设备进行精滤，获取澄清的渗透液。
（7）浓缩：使用单效外循环浓缩器进行浓缩，浓缩温度60℃，真空度-0.078MPa，浓缩至62%的固含量浓度。
（8）干燥：使用低温真空连续带式干燥设备干燥，干燥条件60℃、真空度-0.1MPa，获得干燥的结晶物，将其粉碎后得到蛹虫草水溶粉。
Claims (2)
1.一种蛹虫草水溶粉的工业化制备方法，其特征在于，包括以下步骤：
（1）经干燥的蛹虫草在颗粒破碎设备中进行破碎，获长度为2-5mm的蛹虫草粗颗粒；
（2）将蛹虫草粗颗粒放入提取设备，加入物料重量6-10倍的水，在超声频率24-40KHz、温度45-55℃的条件下，提取2-4小时后采用离心设备将滤液与滤渣分离；
（3）使用孔径为100-1000nm的陶瓷膜设备对滤液进行精滤，精滤后所得渗透液使用真空浓缩设备在温度60-80℃，真空度-0.07-0.09MPa的条件下，浓缩至获得可溶固形物浓度为52%-62%的浸膏；
（4）采用低温真空连续带式干燥设备，将浓缩浸膏在温度50-80℃，真空度-0.1MPa的条件下进行干燥，至获得含水量小于5%的结晶物，将其粉碎后得到蛹虫草水溶粉。
2.根据权利要求1所述的一种蛹虫草水溶粉的工业化制备方法，其特征在于，所述2）步骤中，一次提取离心后，将滤渣按原物料重量加3-5倍的水进行二次提取并离心，超声频率24-40KHz、温度45-55℃，合并两次提取所得滤液。
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| CN105294796A (zh) * | 2015-11-11 | 2016-02-03 | 湖南炎帝生物工程有限公司 | 从蛹虫草固体培养基残基中提取虫草素和虫草多糖的方法 |
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