CN110157613B

CN110157613B - Layer-frame circulating crawler-type solid-state fermentation equipment and solid-state fermentation method

Info

Publication number: CN110157613B
Application number: CN201910433292.0A
Authority: CN
Inventors: 肖毅; 肖兵南; 王会明; 刘莹莹; 蒋小文
Original assignee: Hunan Minkang Biotechnology Research Institute
Current assignee: Xiao Bingnan
Priority date: 2019-05-23
Filing date: 2019-05-23
Publication date: 2022-08-26
Anticipated expiration: 2039-05-23
Also published as: CN110157613A

Abstract

The invention discloses a shelf circulating crawler-type solid-state fermentation device and a solid-state fermentation method, wherein the solid-state fermentation device comprises a fermentation box, a feed inlet and a discharge outlet are formed in the fermentation box, at least one fermentation bed is arranged in the fermentation box, the fermentation bed further comprises a lifter, the fermentation bed comprises at least two layers of crawler-type shelves, each layer of shelf is sequentially laid in parallel from bottom to top, the moving directions of the crawler belts of the adjacent shelves are opposite, a receiving hopper is arranged at the front end of the shelf at the uppermost layer, inclined material blocking grooves are arranged at the front ends of the rest layers of shelves, a material receiving groove positioned below the feed inlet is formed in the fermentation box, and the rear end of the shelf at the lowermost layer is positioned above the material receiving groove; the elevator has at least one hopper that can move between material receiving groove and material receiving hopper. The invention has compact structure, convenient installation, disassembly and transportation and low relative manufacturing cost; the method has the advantages of circulating material turning, smooth operation, sterile control, optimized fermentation conditions, accurate fermentation, great improvement of fermentation efficiency and product quality, and realization of large-scale high-efficiency solid aerobic fermentation.

Description

Layer-frame circulating crawler-type solid-state fermentation equipment and solid-state fermentation method

Technical Field

The invention belongs to the technical field of solid state fermentation, and particularly relates to a shelf circulating crawler type solid state fermentation device and a solid state fermentation method.

Background

Biological fermentation is classified into aerobic fermentation and anaerobic fermentation according to the supply of oxygen. Anaerobic fermentation mainly plays a role in anaerobic bacterial fermentation, including the hydrolysis of cellulose, saccharides and protein to produce alcohol, acid, methane (biogas) and the like, and is suitable for biological treatment of waste and wastewater, production of food such as wine, vinegar and the like, and the process is slow; aerobic fermentation is the decomposition and transformation of organic matters of aerobic bacteria (bacteria, fungi and actinomycetes) under aerobic conditions, can generate substances required by people under artificial control, has a fast fermentation process, and is applied to industrial production of medicines, feeds, foods, waste treatment and the like. The biological fermentation is divided into solid fermentation and liquid fermentation according to the form, and the general controllable precise fermentation is mostly liquid fermentation at present; the solid state fermentation is extensive fermentation and is widely applied to production and life. Compared with liquid state fermentation, solid state fermentation, especially aerobic solid state fermentation, has significant features and advantages: wide raw material source, large fermentation amount, high efficiency, low production cost, wide applicability and the like. Therefore, the method is widely applied to the fields of biological medicines, biological foods, biological feeds and veterinary medicines, biological pesticides and fertilizers, biochemical engineering, environmental purification and the like.

Fermentation equipment is the basis of fermentation industry, and along with the improvement of fermentation technology level, the requirement controllable accurate fermentation also becomes higher and higher to the requirement of equipment. At present, only liquid fermentation equipment (a fermentation tank system) is researched early, the technology is advanced and complete, and the method can meet the requirements of various industrial production; the research and innovation of the solid-state fermentation equipment is lagged, and no solid-state fermentation equipment with controllable conditions can meet the requirement of industrial production so far, which seriously restricts the research and application of the solid-state fermentation process.

Except for a traditional anaerobic fermentation barrel and a traditional fermentation tank, the existing solid-state fermentation equipment comprises a shallow tray fermentation reactor (low mass transfer and heat transfer rate, high pollution risk and low tray utilization rate are caused), a fluidized bed fermentation reactor (low reactor volume ratio), a rotary drum fermentation reactor (the problems of material agglomeration, wall adhesion and low reactor volume ratio), a disc type fermentation reactor (incapable of aseptic operation), a stirring type fermentation reactor (only suitable for small-scale fermentation), a pressure pulsation solid-state fermentation reactor (high equipment requirement, difficult material preparation and the like); among various solid-state reactors (solid-state fermentation apparatuses), only shallow tray type, rotary drum type and stirring type reactors have been industrially used, and other forms of solid-state reactors have been developed in China. In 2004, a box type solid material fermentation device (patent application No. 200420026272.0) is reported, which is a step conveyor belt type, has large and long floor area and poor adaptability. In 2011 of Jiangsanling and the like, the research of KRH-II type intelligent solid-state microorganism progressive complete equipment is reported, the equipment is a layered fermentation box system, the problems of material mixing, disinfection, feeding, spreading and fermentation process control are solved, the fermentation process cannot be turned, the volume is small (500L), and the KRH-II type intelligent solid-state microorganism progressive complete equipment is only suitable for small-scale tests and strain production; and the material disinfection tank is assembled with the fermentation box and is arranged on the fermentation box, so that the equipment manufacturing cost is high and the operation is inconvenient. ShouYing et al 2015 reported a shelf recycling crawler-type fermentation box (ZL 201510388026.2) and written' 10m ² Manufacturing and performance measurement of layered frame circulating crawler type fermentation box and effect of equipment and process for producing high-activity high-nutrition feed by fermenting dregsAnalysis, published in the 10 th stage 2017 of Hunan agricultural science and the 2018.11 stage of feed industry; the equipment is a double-layer frame conveyor belt, has a more complex structure, is not compact, occupies a large area, and is unsmooth in material conveying; lack of matched material treatment (disinfection and the like) conveying equipment, and easy to cause material pollution in the process.

Solid state fermentation is a natural state fermentation, and is different from liquid state submerged fermentation in many ways, wherein the most remarkable characteristics are low water activity, poor mass transfer and heat transfer properties and uneven fermentation. The growth of the thallus, the absorption of nutrient substances and the secretion of metabolites are not uniform everywhere, so that the detection and control of fermentation parameters are difficult, and a plurality of biosensors for liquid fermentation cannot be applied to solid fermentation. Up to now, the parameters for detecting or controlling solid state fermentation include the water content (water activity) of the medium, pH, air humidity, CO ₂ And O ₂ The content, the temperature, the thallus growth amount and the like of the strain, but a perfect mathematical model about solid-state fermentation is not seen in the literature, and although some kinetic research reports about solid-state fermentation are reported, the kinetic research reports about solid-state fermentation all appear in the form of drawings, and a mature solid-state fermentation parameter detection and regulation system is not available. 2010 and 2011 report that the parameter detection and the optimal control of the solid fermentation process mainly apply a fuzzy mathematical method to analyze the parameter difference of different directions and different times of the fermentation process and theoretically research the optimal control parameters (temperature, humidity and pH value) of the fermentation process; the key detection and adjustment methods are unclear. In fact, for biological fermentation, differences among different parts of the fermentation environment are not searched, and the differences are eliminated, such as effective stirring and stirring, air circulation in a space and the like. The 10M2 layered circulating crawler type fermentation box (dynamic) reported by 2018 of Xiao Yi et al is also only simple in temperature and humidity control and cannot be intelligentized.

The disinfection and the transportation of solid fermentation materials are the key for ensuring that the fermentation process has no mixed bacteria pollution and ensuring the quality of fermentation products, most solid fermentation devices (boxes, tanks and the like) can not be directly disinfected and sterilized at high temperature and high pressure, but the fermentation devices are sterilized by chemical (ozone, disinfector and the like) or physical (steam, ultraviolet rays and the like) firstly, then the materials are disinfected and sterilized by other material disinfection devices and then are manually or mechanically input into the fermentation devices for inoculation and fermentation, so secondary pollution is easily caused, and the fermentation fails. In Jiangxing et al 2011 reported that a disinfection and sterilization tank is arranged at the upper position of a fermentation box, and after materials are sterilized at high temperature, the materials fall down under the action of gravity and are input into the fermentation box for inoculation and fermentation. Although the problem of material sterilization and conveying is solved, the equipment cost is greatly increased (a small fermentation box is matched with an autoclave tank), and the sterilization tank is arranged on the upper position of the fermentation box, so that the position is high, and the production operation is extremely inconvenient.

The existing solid-state fermentation equipment has respective defects, is particularly not suitable for fermentation of large fungi, and requires shallow fermentation materials, moderate mild turning and long fermentation time (easy to be polluted by mixed bacteria) besides conditions of stable temperature and humidity, sufficient oxygen supply, no mixed bacteria and the like for fermentation of the large fungi; only a tray fermentation reactor, a disc type fermentation reactor and a fluidized bed fermentation reactor can be applied reluctantly in the above equipment, but the requirements of fermentation are difficult to be met strictly, and large-scale safe (pollution-free) production cannot be realized. Therefore, the research and development of novel intelligent large-scale solid-state fermentation equipment is the key for solving the current bottleneck restricting the development of the solid-state fermentation industry.

Disclosure of Invention

The invention aims to provide a layered frame circulating crawler type solid state fermentation device and a solid state fermentation method aiming at the defects of the prior art.

In order to solve the technical problems that the solid state fermentation equipment in the prior art cannot fully stir and can not turn over materials circularly, and the like, so that the mass and heat transfer of materials are difficult, the invention adopts the technical scheme that:

a shelf circulating crawler-type solid-state fermentation device comprises a fermentation box, wherein a feed inlet and a discharge outlet are formed in the fermentation box, and at least one fermentation bed is arranged in the fermentation box; the moving directions of the adjacent shelves are opposite, the front end of the shelf at the uppermost layer is provided with a receiving hopper, and the front ends of the rest shelves except the shelf at the uppermost layer are provided with inclined material blocking grooves; a material receiving groove is formed in the fermentation box and positioned below the feeding hole, and the rear end of the lowest layer frame of the first stirring shaft and the second stirring shaft in the material receiving groove is positioned above the material receiving groove; the elevator has at least one hopper that can move between material receiving groove and material receiving hopper.

By means of the structure, a circulating conveying channel is formed between the motion tracks of the hoister and the multi-layer shelf crawler, so that circulating material turning can be realized, the stirring shaft can be used for fully stirring, the material can be paved by the paving device, the mass and heat transfer can be accelerated, and the fermentation balance and the fermentation efficiency can be greatly improved.

As a preferred mode, the lifting machine is provided with an annular conveying belt, the feeding hopper is arranged on the outer side of the annular conveying belt, one end of the annular conveying belt extends into the material receiving groove, and the other end of the annular conveying belt is connected with the material receiving hopper.

By means of the structure, materials are smoothly lifted, the materials are not easily blocked and scattered, and the space utilization rate is high.

In order to solve the technical problem that the solid state fermentation equipment in the prior art does not have a complete parameter monitoring function in the fermentation process, the invention adopts the technical scheme that:

further, the fermentation box also comprises a controller, wherein a temperature monitoring unit and/or a humidity monitoring unit and/or a pH value monitoring unit and/or an O consisting of conventional sensors are arranged in the fermentation box based on the characteristics of no high temperature and high pressure and through proper technical improvement ₂ Concentration monitoring unit and/or CO ₂ A concentration monitoring unit and/or a pressure monitoring unit and/or a shelf transmission speed monitoring unit; temperature monitoring unit and/or humidity monitoring unit and/or pH value monitoring unit and/or O ₂ Concentration monitoring unit and/or CO ₂ The concentration monitoring unit and/or the pressure monitoring unit and/or the layer frame transmission speed monitoring unit are/is electrically connected with the controller.

By the structure, the temperature, the humidity, the pH value and the O are controlled by the controller ₂ Concentration, CO ₂ The parameters such as concentration, pressure, layer frame transmission speed and the like are monitored, and intelligent control accurate fermentation is realized.

In order to solve the technical problem that the solid state fermentation equipment in the prior art is difficult to ensure the sterile environment, the invention adopts the technical scheme that:

further, still include material disinfection and sterilization transport tank, material disinfection and sterilization transport tank includes special-shaped intermediate layer sterilization pot, sets up material input mouth and bacterial input mouth on the sterilization pot, and the bottom is equipped with the spiral agitator in the sterilization pot, and the export of spiral agitator can with feed inlet dock.

By means of the structure, after the materials are disinfected and sterilized, the materials can be butted with the fermentation box through the spiral stirrer and automatically sent into the fermentation box, and therefore the pollution of mixed bacteria is avoided. Meanwhile, the material disinfection and sterilization conveying tank can be used for a plurality of fermentation boxes. In addition, the prepared material disinfection and sterilization conveying tank can also produce high-pressure steam for the disinfection and sterilization of the fermentation box, the generated high-temperature sterilization, fermentation and humidification are realized, and the machine is multifunctional, energy-saving and economical.

Furthermore, the fermentation box body is formed by assembling a plurality of panels to form a strictly sealed box body, and ultraviolet rays and ozone (ozone content is more than or equal to 40 mg/m) are carried out in the box body ³ ) And high-pressure steam single or multiple disinfection and sterilization, thereby ensuring thorough disinfection and sterilization in the box. The size of the fermentation box can be designed and manufactured as required, the requirements of different production factories are met, and the installation, the disassembly and the transportation are convenient.

Further, the air supply and circulation system comprises an air purification feeding device and an air exhaust device, wherein the air purification feeding device comprises air filtration purification, heating, humidity regulation and the like.

By means of the structure, the air with sterile property, stable temperature and humidity is supplied for the fermentation process, and the air is effectively circulated and discharged in the box.

In a preferable mode, the number of the layers of the crawler-type layer frame is even.

The number of layers of the crawler-type layer frame is even, so that the rear end of the layer frame at the lowest layer is conveniently butted with the material receiving groove.

Based on the same inventive concept, the invention also provides a solid state fermentation method, which is characterized in that the layer frame circulating crawler type solid state fermentation equipment is adopted, and comprises the following steps:

step A1, the inoculation material enters a material receiving groove in the fermentation box from a material inlet;

step A2, the elevator runs, and the feeding hopper conveys the inoculation material in the receiving groove to the receiving hopper;

step A3, inoculating materials enter the front end of the uppermost layer of rack from a receiving hopper;

step A4, moving each shelf, and when the inoculation material reaches the rear end of the upper shelf, falling into the front end of the adjacent shelf of the lower shelf until the inoculation material reaches the rear end of the lowest shelf;

step A5, the inoculation material falls into a material receiving groove from the rear end of the lowest layer shelf;

step A6, repeating the steps A2 to A5 until the fermentation of the inoculated material is completed;

and step A7, sending the fermented materials in the material receiving groove out of the fermentation box from a material outlet.

Preferably, the temperature and/or humidity and/or pH and/or CO of the fermentation chamber is/are adjusted during the fermentation of the inoculated material ₂ Concentration and/or O ₂ Concentration and/or pressure and/or racking speed are monitored, wherein:

the temperature monitoring process comprises the following steps: adjusting beta by controller feedback ₁ The temperature of the fermentation box is between 20 and 45 ℃, wherein, beta ₁ Satisfies the condition SV ₂ (n)＝(1+β ₁ *EV ₁ (n))SV ₁ (n)，SV ₂ (n) is the actual temperature control value of the fermentation box at the moment n,

SV ₁ (n) is a set temperature control value of the fermenter, PV ₁ (n) is the actual temperature value of the fermentation box;

the humidity monitoring process comprises the following steps: adjusting beta by controller feedback ₂ The humidity of the fermentation box is 70-85%, wherein, beta ² Satisfies the condition SH ₂ (n)＝(1+β ₂ *EH ₁ (n))SH ₁ (n)，SH ₂ (n) is the actual humidity control value of the fermentation box at the moment n,

SH ₁ (n) is the set humidity control value of the fermentation box, PH ₁ (n) is the actual humidity value of the fermenter;

the pH value monitoring process comprises the following steps: adjusting beta by controller feedback ₃ So that the pH value of the fermentation box is 6-8, wherein beta ₃ Satisfies the condition SPH ₂ (n)＝(1+β ₃ *EPH ₁ (n))SPH ₁ (n)，SPH ₂ (n) is the actual pH value control value of the fermentation box at the moment n,

SPH ₁ (n) is a pH control value set for the fermenter, PPH ₁ (n) is the actual pH of the fermenter;

O ₂ the concentration monitoring process comprises the following steps: adjusting beta by controller feedback ₄ So that O of the fermentation tank ₂ The concentration is 5-25%, wherein, beta ₄ Satisfies the condition SO ₂ (n)＝(1+β ₄ *EO ₁ (n))SO ₁ (n)，SO ₂ (n) is the actual O in the fermenter at time n ₂ The concentration of the liquid is controlled by the concentration control value,

SO ₁ (n) is fermenter setting O ₂ Concentration control value, PO ₁ (n) is fermenter actual O ₂ A concentration value;

CO ₂ the concentration monitoring process comprises the following steps: adjusting beta by controller feedback ₅ So that CO of the fermentation tank ₂ The concentration is 300ppm to 400ppm, wherein, beta ₅ Satisfies the condition SCO ₂ (n)＝(1+β ₅ *ECO ₁ (n))SCO ₁ (n)， SCO ₂ (n) is actual CO of fermenter at time n ₂ The concentration of the liquid is controlled by the concentration control value,

SCO ₁ (n) is fermenter set point CO ₂ Concentration control value, PCO ₁ (n) is actual CO of the fermenter ₂ A concentration value;

the pressure monitoring process comprises the following steps: adjusting beta by controller feedback ₆ So that the pressure shaking range of the fermentation box is-0.01 Mpa-0.01Mpa, wherein, beta ₆ Satisfies the condition SF ₂ (n)＝(1+β ₆ *EF ₁ (n))SF ₁ (n)，SF ₂ (n) is the actual pressure control value of the fermentation box at the moment n,

SF ₁ (n) is a set pressure control value of the fermenter, PF ₁ (n) is the actual pressure value of the fermentation tank;

the process of monitoring the transmission speed of the shelf comprises the following steps: adjusting beta by controller feedback ₇ Controlling the difference between the space temperature in the fermentation box and the material temperature within 0.5 ℃, and controlling the temperature of O in the fermentation box ₂ Concentration and Material O ₂ The difference in concentration is within 1%. Beta is a ₇ The satisfied condition u (n) u (n-1) - Δ u (n), u (n) is the output of the PID loop, Δ u (n) is the increment of the control amount at the nth time, and Δ u (n) K _P [e(n)-e(n-1)]+β ₇ K _I e(n)+K _D [e(n)-2e(n-1)+e(n-2)]Delta PV difference between space temperature and material temperature in the fermentation chamber ₁ (n) and O in the fermenter ₂ Concentration and Material O ₂ Difference in concentration Δ PO ₁ And (n) processing and synthesizing e (n) as an input quantity, and using a PID control signal u (n) of the running speed of the motor for controlling the transmission speed of the layer frame as an output quantity.

The material sterilizing and conveying tank comprises a special-shaped interlayer sterilizing pot, a material feeding port and a strain feeding port are formed in the sterilizing pot, a spiral stirrer is arranged at the bottom in the sterilizing pot, and an outlet of the spiral stirrer can be in butt joint with the feeding port;

the obtaining process of the inoculation material in the fermentation box comprises the following steps:

step B1, putting the fermented material into a sterilization pot from a material feeding port;

step B2, sterilizing the fermented material in a sterilizing pot;

step B3, cooling the material sterilizing and conveying tank;

step B4, under the aseptic condition, the outlet of the spiral stirrer is butted with the feed inlet of the fermentation box;

step B5, putting the strains into a sterilization pot from a strain feeding port;

and step B6, operating a spiral stirrer, and feeding the inoculated materials in the sterilizer into the fermentation box through the feed inlet.

Further, the method also comprises the step of utilizing the material sterilization conveying tank to generate steam for sterilization of the fermentation box, and the generated high-temperature sterilization water is used for fermentation and humidification of the materials.

Compared with the prior art, the invention has the following beneficial effects: (1) the hoister is combined with the shelf circulating crawler type fermentation bed, the structure is compact, the material is turned circularly, the operation is smooth, the utilization rate of effective space is high, and the relative manufacturing cost is low; (2) according to the environmental conditions of the fermentation box and proper technical improvement, an intelligent control system consisting of conventional sensors is arranged, the PID control algorithm of the genetic algorithm is used for optimizing the regulation and control parameters, the environment is optimized, accurate fermentation is realized, and the fermentation efficiency and the product quality are greatly improved; (3) the prepared material disinfection and sterilization conveying tank has the functions of disinfection and sterilization, inoculation and stirring, and movable material conveying (one device can be used for a plurality of fermentation boxes); meanwhile, high-pressure steam can be generated for disinfecting and sterilizing the fermentation box while materials are disinfected, and the generated high-temperature sterilized water is used for fermenting and humidifying the materials, so that the multifunctional fermentation box has multiple functions; (4) an air supply and circulation system is prepared, and the system is provided with a three-stage air purification filter, a heater and a humidifier to ensure that the introduced air is sterile, the temperature and the humidity are proper, and the circulation in the box is effective; (5) the method has the advantages of complete control of sterility, convenient operation, large-scale high-efficiency solid aerobic fermentation, suitability for fermentation of fungi with long fermentation period, especially medicinal and edible fungi hypha, and suitability for fermentation of agricultural and sideline products such as traditional Chinese medicinal materials, dregs and other materials; (6) the fermenting case box is assembled by a plurality of shaped panels, so that the fermenting case is convenient to install, disassemble and transport, and the size of the fermenting case box can be designed and manufactured as required, so that the fermenting case box is suitable for the requirements of different production factories.

Drawings

FIG. 1 is a schematic view of the appearance of a fermenter.

FIG. 2 is a main view of the fermentation bed and the lifter.

FIG. 3 is a top view of the fermentation bed and the elevator.

Fig. 4 is a schematic view of the driving system of the present invention.

FIG. 5 is a front view of a fermentation tank with a fermentation bed.

FIG. 6 is a top view of a fermenter with two rows of fermentation beds (top plate removed).

FIG. 7 is a top view of a fermenter with a single row of fermenting beds (with the top plate removed).

Fig. 8 is a front view of the air supply tank system.

Fig. 9 is an appearance view of the material sterilizing and transporting tank.

FIG. 10 is a cross-sectional view of a material sterilization transport tank.

Fig. 11 is a block diagram of an electrical control portion of the present invention.

Fig. 12 is a block diagram of a gantry speed control system.

Wherein, 1 is the fermentation case, 101 is the feed inlet, 102 is drive motor, 103 is the door, 104 is observation window and sample connection, 105 is the air exit, 106 is the discharge gate, 107 is the air valve, 108 is the blown down tank, 2 is the fermentation bed, 201 is the layer frame, 202 is for keeping off the material groove, 203 is the spreader, 3 is the lifting machine, 301 is the hopper, 302 is the endless conveyor, 4 is for connecing the hopper, 5 is for connecing the silo, 501 is first (mixing) shaft, 502 is the second (mixing) shaft, 6 is the controller, 601 is the temperature monitoring unit, 602 is the humidity monitoring unit, 603 is the pH value monitoring unit, 604 is O ₂ Concentration monitoring unit, 605 is CO ₂ A concentration monitoring unit, 606 is a pressure monitoring unit, 607 is a layer rack transmission speed monitoring unit, 608 is a touch screen human-computer interface, 7 is a material disinfection and sterilization conveying tank, 701 is a sterilization pot, 702 is a material input port, 703 is a strain input port, 704 is a spiral stirrer, 705 is an air outlet pipe, 706 is a water outlet pipe valve, 8 is an air purification feeding device, 801 is an air box body, 802 is a main box, 803 is an auxiliary box, 804 is an air filter, 805 is an air blower, 806 is a bag type air filter, 807 is a heater, 808 is an air supply pipe, 809 is a high efficiency air filter, 810 is an air outlet, 9 is a humidifier, 10 is a control cabinet, and 11 is an exhaust fan.

Detailed Description

The invention relates to a layer frame circulating crawler-type solid-state fermentation device, which comprises: the fermentation box 1, the shelf crawler fermentation bed 2, the disinfection system, the gas supply system, the parameter detection and regulation system, the material sterilization and transportation and the like, and has complete configuration, compact structure, coordination and applicability.

1, fermentation box: the fermentation box 1 is made of heat-preservation, temperature-resistant and corrosion-resistant materials and is formed by assembling 6 large (or small assembled large) panels, namely 4 walls: two ends are provided with doors 103, the middle lower part of one side is provided with a purified air inlet (behind the air purification feeding device 8), one side is provided with a feed inlet 101, a transmission motor 102 (a motor shaft mechanical sealing hole), a steam access hole, an observation window and a sampling port 104, and the other side is provided with a discharge port 106; 2 upper and lower top plate bottom plates: the top plate is provided with an air valve 107 and an air outlet 105 with a fan, and an ultraviolet lamp and an ozone generator are arranged in the air outlet 105; the bottom plate is provided with a bedstead fixing device and a pipe hole which can be closed by sewage drainage; the joints of the plates are fixed by hard materials and screws, so that the plates are easy to assemble, disassemble and transport. See fig. 1 and 5.

Layer frame crawler-type fermentation bed 2 and hoisting device:

(1) shelf crawler-type fermentation bed 2: the layer frame crawler fermentation bed 2 consists of double layers (4 layers or 6 layers) which are composed of a synchronous conveyer belt and a stainless steel bracket made of corrosion-resistant and high-temperature-resistant food-grade materials (PVC, PU, EP, silica gel, nylon, stainless steel and the like), wherein two sides of each layer are provided with a material baffle plate with the height of 10-20cm, the front end of the layer frame 201 at the uppermost layer is provided with a material receiving hopper 4, and one or more stirring planners (shafts) are arranged behind the material receiving hopper 4; the running directions of the adjacent 2 layers are opposite, and the two layers are connected with a chain through gears and driven by an external box motor (see figures 2 and 4).

Fermentation bed 2 includes two-layer crawler-type layer frame 201 at least, and each layer frame 201 from bottom to top tiles in proper order, and adjacent layer frame 201's moving direction is opposite, and blanking department is equipped with keeps off silo 202, is equipped with in the fermenting case 1 to be located the feed inlet 101 below and connects silo 5, and the rear end of lower floor layer frame 201 is located and connects silo 5 top.

Each box is internally provided with 1 set (single-row type) or 2 sets (double-row type) of fermentation bed frames.

(2) A lifting device: comprises a gourd ladle type lifter 3 and a receiving groove 5. The elevator 3 has at least one feed hopper 301 which can be moved between a receiving chute 5 and a receiving hopper 4. The elevator 3 is provided with an annular conveying belt 302, the feeding hopper 301 is arranged on the outer side of the annular conveying belt, and the feeding hopper 301 is shaped like melon pulp. One end of the annular conveyor belt 302 is arranged in the material receiving groove 5, and the other end of the annular conveyor belt 302 is connected with the material receiving hopper 4.

The hoister 3 is a material hoisting device (see figure 3) formed by fixing a gourd ladle with a pad bottom (track) on a stainless steel chain; then the lifting device is arranged on a strip-shaped (side view) bracket and is driven by a motor outside the box. The material receiving groove 5 is in a long strip shape, is arranged at the head end of a layer of the fermentation bed frame below the lifting machine 3, receives the primary input material outside the fermentation box 1 and the fermentation material transmitted by the operation of the conveying belt of the fermentation bed 2, and is lifted by the lifting machine 3; 2 stirring shafts are arranged in the material receiving groove 5, the first stirring shaft 501 is arranged at the far end of the fermentation bed 2, is in an interrupted spiral shape and is mainly responsible for mixing and spreading of materials input outside the fermentation box 1 in the material receiving groove and transferring of the materials after fermentation is finished; the second stirring shaft 502 is a stirring shaft with teeth at the near end of the fermentation bed 2 and is mainly responsible for stirring the falling materials of the conveyer belt. One end of the material receiving groove is provided with a closable baffle plate, and the baffle plate is connected with the material discharging groove 108.

The material is input into a receiving groove 5 at the lower end of a lifter 3 through an outer feeding pipe of the fermentation box 1, the material is stirred and spread by an inner stirring shaft in the receiving groove 5, the material is lifted to a receiving hopper 4 of the uppermost layer frame 201 (the fourth layer from bottom to top) by the lifter 3, the material is stirred and spread by a third stirring shaft 204, and then the material is conveyed backwards by a fermentation bed belt and falls into the front end of the third layer frame 201; the third layer of shelves 201 rotates backwards, and materials are conveyed to fall into the front ends of the second layer of shelves 201; the second layer of shelves 201 rotates backwards again, and the materials are conveyed to fall into the front ends of the first layer of shelves 201; the first layer of shelves 201 is operated backwards to convey the materials to the receiving groove 5 at the lower part of the lifter 3, and then the materials are lifted to the receiving hopper 4 at the upper part of the fermentation bed 2 by the lifter 3 to enter the next conveying period (see fig. 2). In order to ensure that the material on the upper layer of shelves 201 accurately falls into the lower layer of shelves 201, the front ends of the other layers of shelves 201 except the uppermost layer of shelves 201 are provided with material blocking grooves 202.

The fermented material is pushed to one end (the movable baffle is put down) by a stirring shaft in a material receiving groove 5 under a lifter 3 (the clutch is separated and the operation is stopped), and is conveyed out of the box (single-row bedstead) or out of a box end gate (double-row bedstead) through a movable chute 106.

(3) A driving system: the bed frame fermentation bed 2 and a lifting machine system are driven by a motor and connected by gears and chains; the lifter 3 is provided with a clutch in a transmission way, and the clutch is separated during discharging, so that the lifting of the material is interrupted, and the material is output from the discharging hole 106 (see figure 3), and the clutch can also be driven by two motors respectively.

The solid state fermentation apparatus further comprises:

(1) air purification conveyor: an air purification feeding device 8 is arranged outside the fermentation box 1 and comprises an air box body 801, the air box body 801 is divided into a main box 802 and an auxiliary box 803, a blower 805 is arranged in the main box 802, an air primary filter 804 is arranged at an air inlet of the main box 802, a secondary bag type air filter 806 is arranged at the joint of the main box 802 and the auxiliary box 803, a heater 807 is arranged behind the secondary bag type air filter, the auxiliary box 803 is connected with an air supply pipe 808, and a tertiary efficient air filter 810 is arranged in a pipeline outlet 809 of the air supply pipe extending into the fermentation box 1. The air is filtered, purified, heated and sterilized for 3 times and then is sent into the fermentation box 1, so that the air inlet is ensured to be sterile and to be at proper temperature. See fig. 8.

(2) A heating device: heating devices are also arranged on two sides in the box and are mainly used for initial heating and auxiliary heating.

(3) A humidifying device: a humidifier 9 (fig. 6 and 7) made of water absorbing material is arranged at the air outlet of the purified air to humidify the blown dry air, and an ultrasonic atomizer is arranged in the fermentation box 1 to assist in humidifying.

(4) A pH adjusting device: an acid solution bottle and an alkali solution bottle (connected with an atomizer by rubber tubes) are arranged in the fermentation box 1 and respectively contain weak acid solution (carbonic acid, organic acid and the like) and weak alkali solution (ammonia water, soda water and the like).

(5) Air exhaust and cooling device: the air outlets 502 at four corners of the top of the fermentation box 1 are provided with exhaust fans 11. Fresh purified air enters the box from the bottom or the center of the top of the box, is exhausted from the air outlet after diffusion circulation, and realizes quick air exchange, cooling and dehumidification.

(6) A pressure adjusting device: a throttle valve 107 is installed at the center of the top of the fermentation tank 1 for regulating the pressure in the tank.

In order to realize intelligent control, a control cabinet 10 is fixed outside the fermentation box 1, and a controller is arranged in the control cabinet 10And 6, the controller 6 is a PLC or a single chip microcomputer, and performs man-machine interaction with the controller 6 through a touch screen man-machine interface 608. A temperature monitoring unit 601, a humidity monitoring unit 602, a pH value monitoring unit 603 and an O are also arranged in the fermentation box 1 ₂ Concentration monitoring unit 604, CO ₂ A concentration monitoring unit 605, a pressure monitoring unit 606 and a layer frame transmission speed monitoring unit 607; temperature monitoring unit 601, humidity monitoring unit 602, pH value monitoring unit 603, and O ₂ Concentration monitoring unit 604, CO ₂ The concentration monitoring unit 605, the pressure monitoring unit 606, and the gantry transmission speed monitoring unit 607 are all electrically connected to the controller 6 (see fig. 11). Specifically, the PLC or the single chip microcomputer, a temperature sensor, a regulating electric heater, a heating device of an air supply box, a space humidity sensor, a material water content (water activity) sensor, an air inlet humidity regulator, an atomization device, a pH value sensor, a weak acid-base regulating device, a pressure sensor, an exhaust valve and O ₂ Sensor, CO ₂ The sensor, the air supply box blower, the exhaust fan, the bed belt motor speed regulator and the like.

The solid state fermentation equipment further comprises a movable (or fixed) material disinfection and sterilization conveying tank 7, the material disinfection and sterilization conveying tank 7 comprises a special-shaped interlayer high-pressure sterilization pot 701, a material feeding port 702 and a strain feeding port 703 are formed in the sterilization pot 701, a spiral stirrer 704 (shown in fig. 9 and 10) is arranged at the bottom in the sterilization pot 701, and an outlet of the spiral stirrer 704 can be in butt joint with the feeding port 101. The material disinfection and sterilization conveying tank 7 is provided with a support and wheels, and is movable and convenient to feed. Namely, after the materials to be fermented are sterilized by steam high pressure, the temperature is rapidly reduced (the interlayer hot water is changed into cold water), the material sterilization conveying tank 7 is pushed to the fermentation box 1, the outlet of the spiral stirrer 704 is butted with the feeding hole 101 of the fermentation box 1 under the aseptic condition (on flame), the strains are inoculated, and the spiral stirring shaft is started, so that the strains and the materials are mixed and sent into the fermentation box 1. An air outlet pipe 705 with a valve is arranged on the top of the material disinfection and sterilization conveying tank 7 and is used for supplying air and disinfecting the fermentation box 1; a water outlet pipe valve 706 is also arranged at the lower part of the side surface of the material sterilizing and transporting tank 7 and is used for supplying sterile water.

A disinfection system:

on the basis of installing an ultraviolet lamp on the inner top surface of the fermentation box 1 for sterilization, one or two of the following two sterilization methods are selected according to conditions for reinforced sterilization;

firstly, steam sterilization, namely, high-pressure steam existing in factories or the material sterilization conveying tank 7 of the invention is used for generating steam, and the steam is introduced into the fermentation box 1 for high-pressure steam sterilization;

secondly, ozone disinfection, namely arranging an ozone generator outside the box, introducing the generated ozone into the box for disinfection, wherein the ozone amount is more than or equal to 40mg/m ³ The C of 100 grade is more than 20 ppm.

The method for performing solid state fermentation by adopting the layer frame circulating crawler type solid state fermentation equipment comprises the following steps:

step A1, the inoculation material enters a material receiving groove 5 in the fermentation box 1 from a material inlet 101;

step A2, the elevator 3 runs, and the feeding hopper 301 conveys the inoculation material in the receiving groove 5 to the receiving hopper 4;

step A3, inoculating materials enter the front end of the uppermost layer frame 201 from the receiving hopper 4;

step A4, moving each shelf 201, and dropping the inoculation material into the front end of the next shelf 201 when the inoculation material reaches the rear end of the upper shelf 201 until the inoculation material reaches the rear end of the lowest shelf 201;

step A5, the inoculation material falls into a receiving groove 5 from the rear end of the lowest layer frame 201;

and step A7, the fermented materials in the material receiving groove 5 are sent out of the fermentation box 1 from the material outlet 106 through the material outlet groove 108.

In the process of inoculating material fermentation, the temperature, humidity, pH value and CO of the fermentation box 1 are measured ₂ Concentration, O ₂ Concentration, pressure and layer frame transmission speed are monitored, wherein:

temperature monitoring: the temperature control input and output configuration is composed of a temperature sensor, an electric heater, a hot air device and an exhaust fan, the existing mature closed loop PID (proportion, integral and derivative) controller 6 is adopted for control, and certain appropriate parameter adjustment is carried out according to the characteristics of the fermentation equipment, so that the advantages of high control precision, high energy consumption saving and the like are achieved.

The controller 6 uses a prior function to set the value of the temperature control proportion on the basis of the existing PID control algorithm based on the genetic algorithm, and the specific parameter adjustment mode is as follows:

SV ₁ (n) is a set temperature control value of the fermentation tank 1, PV ₁ (n) is the actual temperature value of the fermentation tank 1,

β ₁ is the temperature deviation amplification factor, and the difference limit value is assumed to be alpha ₁ ，0＜α ₁ ≤0.05。α ₁ Value of (a) and beta ₁ In inverse ratio, α ₁ The smaller the temperature deviation amplification factor increases.

Such as-alpha ₁ ≤EV ₁ (n)≤α ₁ And then, amplifying the error:

EV ₂ (n)＝β ₁ *EV ₁ (n) (2)

for EV ₂ (n) setting the range: | EV ₂ (n) | ≦ 0.05, i.e., the allowable temperature error is + -5%, SV in formula (3) ₂ (n) is the actual temperature control value at time n:

SV ₂ (n)＝(1+β ₁ *EV ₁ (n))SV ₁ (n) (3)

continuously feeding back and adjusting beta by a closed-loop controller ₁ So that the temperature of the fermentation box 1 is between 20 and 45 ℃.

And (3) humidity monitoring: the input and output configuration of humidity control is formed by a space humidity and material water content (or water activity) sensor, a humidity regulator and an atomization device, and the real-time regulation and control of the humidity in the fermentation box 1 are realized on the basis of the existing PID control algorithm based on the genetic algorithm. The value of the humidity control ratio is set by using the antecedent function, and the specific parameter adjustment mode is as follows:

SH ₁ (n) is a set humidity control value, PH, of the fermenter 1 ₁ (n) is the actual humidity value of the fermentation box 1;

β ₂ is the humidity deviation amplification factor, and the difference limit value is assumed to be alpha ₂ ，0＜α ₂ ≤0.1。α ₂ Value of and beta ₂ In inverse ratio, α ₂ The smaller the temperature deviation amplification factor increases.

Such as-alpha ₂ ≤EH ₁ (n)≤α ₂ And then, amplifying the error:

EH ₂ (n)＝β ₂ *EH ₁ (n) (5)

feed EH ₂ (n) setting the range: i EH ₂ (n) | ≦ 0.1, i.e., the humidity error is. + -. 10%, SH in equation (6) ₂ (n) is the actual humidity control value of the fermentation box 1 at the moment n:

SH ₂ (n)＝(1+β ₂ *EH ₁ (n))SH ₁ (n) (6)

continuously feeding back and adjusting beta by a closed-loop controller ₂ So that the humidity of the fermentation box 1 is 70-85%.

And (3) pH value monitoring: the pH value sensor (additional water dripping head for ensuring the material at the measured part to contain a certain amount of water) and the adjusting device (implemented by an atomizer) of weak acid alkali liquor (carbonic acid, organic acid, ammonia water, soda water and the like) form an input and output configuration of pH value control, and the existing PID control algorithm based on the genetic algorithm is adopted as the basis to realize real-time regulation and control of the pH value in the fermentation box 1. The value of the pH value control proportion is set by using a prior function, and the specific parameter adjustment mode is as follows:

SPH ₁ (n) is a pH control value set for the fermenter 1, PPH ₁ (n) is the actual pH of the fermenter 1;

β ₃ is a pH deviation amplification factor, and the difference limit value is assumed to be alpha ₃ ，0＜α ₃ ≤0.05。α ₃ Value of (a) and beta ₃ In inverse ratio, α ₃ The smaller the pH deviation amplification factor increases.

Such as-alpha ₃ ≤EPV ₁ (n)≤α ₃ And then, amplifying the error:

EPH ₂ (n)＝β ₃ *EPH ₁ (n) (8)

for EPH ₂ (n) setting the range: i EPH ₂ (n) | ≦ 0.05, i.e., the pH error is allowed to be + -5%, SPH in formula (9) ₂ (n) is the actual pH value control value of the fermentation box 1 at the moment of n

SPH ₂ (n)＝(1+β ₃ *EPH ₁ (n))SPH ₁ (n) (9)

Continuously feeding back and adjusting beta by a closed-loop controller ₃ So that the pH value of the fermentation box 1 is 6-8.

Pressure monitoring: the pressure sensor and the exhaust valve form an input and output configuration of pressure control, and the pressure value in the fermentation box 1 is regulated and controlled in real time on the basis of the existing PID control algorithm based on the genetic algorithm.

The value of the pressure value control proportion is set by using a prior function, and the specific parameter adjustment mode is as follows:

SF ₁ (n) is a set pressure control value of the fermenter 1, PF ₁ (n) is the actual pressure value of the fermentation box 1;

β ₆ is the temperature deviation amplification factor, and the difference limit value is assumed to be alpha ₆ ，0＜α ₆ ≤0.01。α ₆ Value of (a) and beta ₆ In inverse ratio, α ₆ The smaller the pressure deviation amplification factor increases.

Such as-alpha ₆ ≤EF ₁ (n)≤α ₆ And then, amplifying the error:

EF ₂ (n)＝β ₆ *EF ₁ (n) (11)

to EF ₂ (n) setting the range: | EF ₂ (n) less than or equal to 0.01, namely the error of the pressure value is allowed to be within. + -. 1% of SF in formula (12) ₂ (n) is the actual pressure control value of the fermentation box 1 at the moment n:

SF ₂ (n)＝(1+β ₆ *EF ₁ (n))SF ₁ (n) (12)

continuously feeding back and adjusting beta by a closed-loop controller ₆ So that the pressure shaking range of the fermentation box 1 is-0.01 Mpa to 0.01 Mpa.

Monitoring the gas concentration: from O ₂ 、CO ₂ The sensor, the flow of the air inlet blower and the flow of the air outlet blower form the input and output configuration of control, and the existing PID control algorithm based on the genetic algorithm is adopted to control the O in the box body of the fermentation box 1 ₂ 、CO ₂ And the concentration value is regulated and controlled in real time. Use a look-ahead function to set O ₂ 、CO ₂ The value of the concentration value control ratio, the specific parameter adjustment mode (in terms of O) ₂ Concentration control as an example) as follows:

SO ₁ (n) is the setting O of the fermentation tank 1 ₂ Concentration control value, PO ₁ (n) is actual O of fermenter 1 ₂ A concentration value;

β ₄ is O ₂ Concentration deviation amplification factor, difference limit value is assumed as alpha ₄ ，0＜α ₄ ≤0.05。α ₄ Value of and beta ₄ In inverse ratio, α ₄ Smaller is O ₂ The concentration deviation amplification factor increases.

Such as-alpha ₄ ≤EO ₁ (n)≤α ₄ And then, amplifying the error:

EO ₂ (n)＝β ₄ *EO ₁ (n) (14)

to EO ₂ (n) setting the range: | EO ₂ (n) | ≦ 0.05, i.e., allowing O ₂ Concentration error is +/-5%, and SO in formula (15) ₂ (n) is the actual O in the fermenter 1 at time n ₂ Concentration control value:

SO ₂ (n)＝(1+β ₄ *EO ₁ (n))SO ₁ (n) (15)

continuously feeding back and adjusting beta by a closed-loop controller ₄ So that O of the fermenter 1 ₂ The concentration is 5-25%.

In the same way, CO ₂ The concentration monitoring process comprises the following steps: adjusting beta by controller feedback ₅ So that CO of the fermentation tank 1 ₂ The concentration is 300ppm to 400ppm, wherein, beta ₅ Satisfies the condition SCO ₂ (n)＝(1+β ₅ *ECO ₁ (n))SCO ₁ (n)，SCO ₂ (n) is actual CO of fermenter 1 at time n ₂ The concentration of the liquid is controlled by the concentration control value,

SCO ₁ (n) CO is set for the fermenter 1 ₂ Concentration control value, PCO ₁ (n) is actual CO of fermenter 1 ₂ The concentration value.

Monitoring the transmission of the shelves: the difference between the temperature of the space in the fermentation box 1 and the temperature of the material is used as the temperature of the O in the fermentation box 1 ₂ Concentration and Material O ₂ The difference of concentration is used as input quantity, the running speed of a motor for controlling the transmission speed of the shelf 201 is used as output quantity, the input quantity and the output quantity form an input-output configuration, the difference between the space temperature in the fermentation box 1 and the material temperature is controlled within 0.5 ℃, and O in the fermentation box 1 is controlled ₂ Concentration and Material O ₂ The difference in concentration is within 1%.

The traditional system using analog quantity as speed feedback parameter is affected by non-linearity, temperature variation and element aging, so it is difficult to meet the requirement of rapidity and accuracy of control process. Therefore, a high-performance mode of completing feedback by digital quantity and combining with a traditional PID control algorithm to realize high-speed and high-precision control should be considered.

The speed control system of the shelf 201 consists of 4 parts of a computer, a PID control module, an alternating current servo system and a sensor detection unit. The computer is connected with the encoder of the PID control module through the ISA bus, and can send speed or position commands, set PID adjusting parameters and carry out digital-to-analog (D/A) conversion through the ISA bus. The converted analog signal is amplified by an AC servo amplifier and then drives an AC motor. The motor shaft end is equipped with incremental photoelectric encoder, provides feedback signal through the encoder, and the count card accumulates the number of feedback pulses, forms the speed feedback of servo system after comparing with the instruction pulse representing given speed, constitutes a closed loop system. After the computer gives the deviation between the speed and the actual speed (i.e. the fed-back speed), corresponding PID parameter setting is adopted according to the deviation range, the speed control signal is converted into analog control voltage through digital-to-analog conversion and is output to the servo amplifier, the running speed of the motor is adjusted, and the expected speed control requirement is completed. A closed loop control system block diagram is shown in fig. 12.

As shown in fig. 12, the PID controller can adjust the loop output to bring the system to steady state. The relation between the deviation e and the input quantity r and the output quantity c, wherein n is the temperature value t in the box body and the oxygen content value O monitored by the sensor ₂ At a certain time:

e(n)＝r(n)-c(n) (16)

the output of the PID controller is:

in the formula (17), u (n) is the output of the PID loop; k is _P Is a scale factor; t is a unit of _i Is the integration time; t is _d Is the differential time.

The transfer function of the PID regulator is:

in order to facilitate the computer to process the function relation, the continuous function needs to be discretized, a differential equation describing a continuous time PID algorithm is changed into a differential equation describing a discrete time PID, and different output values at n moment and n-1 moment are respectively obtained:

in order to eliminate integral accumulation caused by deviation generated by system output in a short time when the process is started or ended or a set value is greatly increased or decreased, avoid large overshoot and even oscillation of the system and reduce the influence of integral correction on the dynamic performance of a control system in the running process of a motor, an integral separation PID control algorithm is adopted. The equation is modified to a time-based control quantity increment equation:

u(n)＝u(n-1)-Δu(n) (21)

Δu(n)＝K _P [e(n)-e(n-1)]+βK _I e(n)+K _D [e(n)-2e(n-1)+e(n-2)] (22)

where Δ u (n) is an increment of the control amount corresponding to the nth time, and β is a switching coefficient of the integral term. The integral separation PID control algorithm needs to set an integral separation threshold value epsilon. When | e (n) | > epsilon, i.e., the deviation value is large, PID control is adopted. The overshoot is reduced, so that the servo system has quick response; when | e (n) | is less than or equal to epsilon, namely the deviation value is small, PID control is adopted to ensure the speed control precision of the servo motor.

The process for obtaining the inoculation material in the fermentation box 1 comprises the following steps:

step B1, putting the fermented material into the sterilization pot 701 from the material feeding port 702;

step B2, sterilizing the fermented material in a sterilizing pot 701;

step B3, cooling the material sterilizing and conveying tank 7;

step B4, under the aseptic condition, the outlet of the spiral stirrer 704 is butted with the feed inlet 101 of the fermentation box 1;

step B5, putting the strains into a sterilization pot 701 from a strain feeding port 703;

step B6, the helical agitator 704 works to mix the sterilized materials in the sterilizer 701 with the inoculated strains and feed the mixed materials into the fermentation box 1 through the feed inlet 101.

The invention also comprises a steam generated by the material disinfection and sterilization conveying tank 7 for disinfection and sterilization of the fermentation box 1, and high-temperature sterilization water (interlayer water) generated for fermentation and humidification.

The invention combines the tray charging of tray fermentation device and the material turning of dynamic solid fermentation device such as disc type fermentation device, and designs complete automatic control, and the matched material disinfection and sterilization conveying device and air supply device for air purification and heating can perform full-automatic solid aerobic fermentation, especially suitable for fungus fermentation.

In the embodiment, the gourd ladle type hoister 3 for material circulation is combined with the layer-frame crawler fermentation bed 2, and other types of hoists 3 and layer-frame crawler fermentation beds 2 can be used; in the embodiment, air blowing and air supply are adopted, and a sterile air conditioner can also be used; in this embodiment, a PLC controller system is adopted, and a control system composed of intelligent controllers such as PAC and DCS, various specialized instruments, sensors, and networks may also be adopted, so as to realize the automatic control of the entire process of industrial production.

The following provides an example of the application of the present invention in a health oral liquid, wherein the medicine residue is directionally fermented to prepare a bacterial feed additive.

1. Fermentation equipment:

adopt intelligent double-row shelf circulation crawler-type fermentation equipment: area of fermentation bed 2: 1.5m × 5m × 4 layers × 2 columns, and the volume of the material sterilizing and conveying tank 7: 500L.

2. The herb residue raw materials and the test method are as follows:

2.1 culture medium preparation: fresh medicine dregs collected from Wang Chinese health food company are dried and crushed at 60-70 ℃, 20% of nutrient base material (corn flour: wheat bran: soybean meal ═ 4:3:3) and proper amount of water are added to prepare culture base material, and the culture base material is sterilized at 121 ℃ for standby.

2.2 fermentation Process

And (3) first fermentation: inoculating liquid Candida utilis strain into autoclaved Chinese medicinal residue culture medium according to 5%, feeding into fermentation box 1 (material thickness 5.0CM), and culturing at constant temperature of 30 deg.C for 2d until culture medium is full of white thallus.

And (3) secondary fermentation: inoculating 10% liquid Pleurotus Tuber Regium strain into the first cultured Chinese medicinal residue mycoplasm via the feed inlet 101 of the incubator, and culturing at constant temperature of 28 deg.C for 2-3 days until white hypha grows; oven drying at 60 deg.C, pulverizing, and packaging.

2.3 detection assay

(1) And (3) detecting physical and chemical properties: the physical and chemical properties of color, smell, pH value (water extract) and the like are measured.

(2) Detection of main functional components:

and (3) polysaccharide content determination: and (3) determining the content of the polysaccharide by combining a sulfuric acid-phenol method with a DNS colorimetric method.

And (3) total saponin content determination: total soap was measured by UV (vanillin-perchloric acid colorimetry).

(3) And (3) determination of nutrient components: protein, cellulose, fat, energy, amino acid, mineral elements and the like are measured by a conventional method.

(4) And (3) determining the bacteriostatic force: adding acid protease into a sample for hydrolysis, extracting filtrate, performing ultrafiltration sterilization, and determining the antibacterial effect by an oxford cup method.

3. Test results

3.1 growth conditions of the bacteria

Both yeasts and macrofungi were able to grow normally in their medium and their environment in both fermentations (see table 1).

TABLE 1 growth of bacteria in healthy oral liquid dregs culture medium

Note: a small amount of visible bacteria, "+ +" -a large amount of scattered colonies/shreds, "+ + + + + + +" a fragmented colonies/shreds, "+ + + + + + + + + + + +" the bacteria are full.

3.2 determination of principal Components

(1) Measuring functional components and physical properties: after secondary fermentation, the extraction amount of polysaccharide and saponin is greatly increased; the pH value is reduced, and the tea is fine, fragrant and glossy (see table 2).

TABLE 2 measurement results of contents of mycoplasm polyose and saponin and physicochemical properties of the twice fermented medicinal residues (average value of 3 times)

(2) And (3) determination of antibacterial activity: the fermented residue and mycoplasm extractive solution has strong bacteriostatic power on 5 kinds of bacteria except streptococcus, and is shown in table 3.

Table 3 bacteriostatic test result units of the secondary fermentation dregs mycoplasm leach liquor: cm

(3) And (3) determination of nutrient components:

and (3) conventional nutrient content determination: after the dregs of a decoction are fermented for the second time, the protein is increased by 48.75 percent; there was also some variation (see table 4).

TABLE 4 conventional nutrient content (%)

And (3) amino acid content determination: after the dregs are fermented, various amino acids are in an upward trend, the content of the total amino acids is improved by 52.8 percent, wherein the content of aromatic amino acids is improved by 98.7 percent, the content of branched chain amino acids is improved by 55.7 percent, the content of straight chain amino acids is improved by 32.7 percent, the content of acidic amino acids is improved by 45.45 percent, the content of basic amino acids is improved by 61.6 percent, and the content of hydroxyl amino acids is improved by 56.4 percent (see table 5).

TABLE 5 amino acid content (%)

While the embodiments of the present invention have been described in connection with the drawings, the present invention is not limited to the above-described embodiments, which are intended to be illustrative rather than restrictive, and many modifications may be made by one skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. The utility model provides a shelf circulating crawler-type solid state fermentation equipment, includes fermenting case (1), sets up feed inlet (101) and discharge gate (106) on fermenting case (1), be equipped with at least one fermentation bed (2) in fermenting case (1), its characterized in that still includes lifting machine (3), fermentation bed (2) include at least two-layer crawler-type layer frame (201), and each layer frame (201) is parallel to be laid from bottom to top in proper order, respectively installs one on each layer frame (201) and paves ware (203), and the moving direction of adjacent layer frame (201) is opposite, and the front end of the superiors layer frame (201) is equipped with and connects hopper (4), and other layer frame (201) front end except that the superiors layer frame (201) is equipped with fender silo (202), is equipped with in fermenting case (1) and is located feed inlet (101) below and connects silo (5), connect and be equipped with first (mixing) and second (mixing) shaft (502) in silo (5), the first stirring shaft (501) is arranged at the far end of the fermentation bed (2) and is used for mixing and spreading materials input outside the fermentation box (1) in the material receiving groove and discharging the materials after fermentation is finished, and the second stirring shaft (502) is arranged at the near end of the fermentation bed (2) and is used for stirring the materials falling down by the conveying belt; the rear end of the lowest layer frame (201) is positioned above the material receiving groove (5); the elevator (3) is provided with at least one feeding hopper (301) which can move between the receiving groove (5) and the receiving hopper (4);

wherein, the box body of the fermentation box (1) is formed by assembling a plurality of shaped panels.

2. The continuous track type solid state fermentation equipment of claim 1, wherein the lifter (3) is provided with an annular conveyor belt (302), the hopper (301) is arranged on the outer side of the annular conveyor belt, one end of the annular conveyor belt (302) extends into the receiving groove (5), and the other end of the annular conveyor belt (302) is connected with the receiving hopper (4).

3. The rack-circulating crawler-type solid state fermentation apparatus of claim 1, further comprising a controller (6), wherein a temperature monitoring unit(s) (C and C) is further disposed in the fermentation tank (1)601) And/or a humidity monitoring unit (602) and/or a pH monitoring unit (603) and/or O ₂ Concentration monitoring unit (604) and/or CO ₂ A concentration monitoring unit (605) and/or a pressure monitoring unit (606) and/or a gantry transmission speed monitoring unit (607); the monitoring units are electrically connected with a controller (6).

4. The rack-circulating crawler-type solid state fermentation equipment of claim 1, further comprising a material sterilizing and conveying tank (7), wherein the material sterilizing and conveying tank (7) comprises a sterilizing pan (701), a material feeding port (702) and a strain feeding port (703) are formed in the sterilizing pan (701), a spiral stirrer (704) is arranged at the bottom in the sterilizing pan (701), and an outlet of the spiral stirrer (704) can be butted with the feeding port (101).

5. The rack-circulating crawler-type solid state fermentation equipment of claim 1, further comprising an air supply and circulation system, wherein the air supply and circulation system comprises an air purification feeding device (8) and an exhaust fan (11), and the air purification feeding device (8) comprises a wind box body (801), a main box (802), an auxiliary box (803), an air filter (804), a blower (805), a bag type air filter (806), a heater (807), an air supply pipe (808), a high efficiency air filter (809), an air outlet (810) and a humidifier (9).

6. The stacked frame circulating crawler type solid state fermentation apparatus according to any one of claims 1 to 5, wherein the first stirring shaft (501) is in an interrupted spiral shape, and the second stirring shaft (502) is a stirring shaft with teeth.

7. A solid state fermentation method, characterized in that the layer frame circulating crawler type solid state fermentation apparatus according to any one of claims 1 to 6 is adopted, comprising:

step A1, the inoculation material enters a material receiving groove (5) in the fermentation box (1) from a material inlet (101);

step A2, the elevator (3) runs, and the feeding hopper (301) conveys the inoculation materials in the receiving groove (5) to the receiving hopper (4);

step A3, inoculating materials enter the front end of the uppermost layer rack (201) from the receiving hopper (4);

step A4, moving each layer of shelf (201), and when the inoculation material reaches the rear end of the upper layer of shelf (201), dropping the inoculation material into the front end of the lower layer of adjacent shelf (201) through a material blocking groove (202) until the inoculation material reaches the rear end of the lowest layer of shelf (201);

step A5, the inoculation material falls into a material receiving groove (5) from the rear end of the lowest layer rack (201);

and step A7, the fermented materials in the material receiving groove (5) are sent out of the fermentation box (1) from the material outlet (106).

8. Solid state fermentation process according to claim 7, characterized in that during the fermentation of the inoculated material, the temperature and/or humidity and/or pH and/or CO of the fermentation tank (1) is/are controlled ₂ Concentration and/or O ₂ Concentration and/or pressure and/or racking speed are monitored, wherein:

the temperature monitoring process comprises the following steps: beta is feedback regulated by a controller (6) ₁ The temperature of the fermentation box (1) is between 20 and 45 ℃, wherein beta ₁ Satisfies the condition SV ₂ (n)＝(1+β ₁ *EV ₁ (n))SV ₁ (n)，SV ₂ (n) is the actual temperature control value of the fermentation box (1) at the moment n,

SV ₁ (n) is a set temperature control value of the fermenter (1), PV ₁ (n) is the actual temperature value of the fermentation box (1);

the humidity monitoring process comprises the following steps: beta is feedback regulated by a controller (6) ₂ So that the humidity of the fermentation box (1) is 70-85 percent, wherein beta ₂ Satisfies the condition SH ₂ (n)＝(1+β ₂ *EH ₁ (n))SH ₁ (n)，SH ₂ (n) is the actual humidity control value of the fermentation box (1) at the moment n,

SH ₁ (n) is the set humidity control value, PH, of the fermentation box (1) ₁ (n) is the actual humidity value of the fermentation box (1);

the pH value monitoring process comprises the following steps: beta is feedback regulated by a controller (6) ₃ So that the pH value of the fermentation box (1) is 6-8, wherein beta ₃ Satisfies the condition SPH ₂ (n)＝(1+β ₃ *EPH ₁ (n))SPH ₁ (n)，SPH ₂ (n) is the actual pH value control value of the fermentation box (1) at the moment n,

SPH ₁ (n) is a pH value control value set for the fermenter (1), PPH ₁ (n) is the actual pH value of the fermentation box (1);

O ₂ the concentration monitoring process comprises the following steps: beta is feedback regulated by a controller (6) ₄ So that O of the fermentation tank (1) ₂ The concentration is 5-25%, wherein, beta ₄ Satisfies the condition SO ₂ (n)＝(1+β ₄ *EO ₁ (n))SO ₁ (n)，SO ₂ (n) is the actual O of the fermentation box (1) at the time of n ₂ The concentration of the liquid is controlled by the concentration control value,

SO ₁ (n) is the setting of O in the fermentation tank (1) ₂ Concentration control value, PO ₁ (n) is actual O of fermenter (1) ₂ A concentration value;

CO ₂ the concentration monitoring process comprises the following steps: beta is feedback regulated by a controller (6) ₅ So that CO in the fermentation tank (1) ₂ The concentration is 300ppm to 400ppm, wherein, beta ₅ Satisfies the condition SCO ₂ (n)＝(1+β ₅ *ECO ₁ (n))SCO ₁ (n)，SCO ₂ (n) is the actual CO of the fermentation tank (1) at time n ₂ The concentration of the liquid is controlled by the concentration control value,

SCO ₁ (n) CO is set for the fermenter (1) ₂ Concentration control value, PCO ₁ (n) is actual CO of the fermenter (1) ₂ A concentration value;

the pressure monitoring process comprises the following steps: by controllingFeedback regulation beta of the device (6) ₆ The pressure of the fermentation box (1) is vibrated within the range of-0.01 Mpa to 0.01Mpa, wherein beta is ₆ Satisfies the condition SF ₂ (n)＝(1+β ₆ *EF ₁ (n))SF ₁ (n)，SF ₂ (n) is the actual pressure control value of the fermentation box (1) at the moment n,

SF ₁ (n) is a set pressure control value of the fermenter (1), PF ₁ (n) is the actual pressure value of the fermentation box (1);

the process of monitoring the transmission speed of the shelf comprises the following steps: beta is feedback regulated by a controller (6) ₇ Controlling the difference between the space temperature in the fermentation box (1) and the material temperature within 0.5 ℃, and controlling the temperature of O in the fermentation box (1) ₂ Concentration and Material O ₂ The difference in concentration is within 1%; beta is a ₇ U (n) (n-1) Δ u (n) is the output of the PID loop, Δ u (n) is the increment of the controlled variable at the nth time, and Δ u (n) K (n) is the output of the PID loop _P [e(n)-e(n-1)]+β ₇ K _I e(n)+K _D [e(n)-2e(n-1)+e(n-2)]Delta PV difference between space temperature and material temperature in the fermentation tank (1) ₁ (n) and O in the fermentation tank (1) ₂ Concentration and Material O ₂ Difference in concentration Δ PO ₁ (n) processing and synthesizing e (n) as input quantity, and using a motor running speed PID control signal u (n) for controlling the transmission speed of the layer frame (201) as output quantity.

9. The solid state fermentation method according to claim 7, further comprising a material sterilization conveying tank (7), wherein the material sterilization conveying tank (7) comprises a sterilization pot (701), the sterilization pot (701) is provided with a material input port (702) and a strain input port (703), a spiral stirrer (704) is arranged at the bottom in the sterilization pot (701), and an outlet of the spiral stirrer (704) can be butted with the feed port (101);

the process for obtaining the inoculation material in the fermentation box (1) comprises the following steps:

step B1, putting the fermented material into the sterilization pot (701) from the material feeding port (702);

step B2, sterilizing the fermented material in a sterilization pot (701) at high temperature and high pressure;

step B3, cooling the material sterilizing and conveying tank (7);

step B4, under the aseptic condition, the outlet of the spiral stirrer (704) is butted with the feed inlet (101) of the fermentation box (1);

step B5, putting the strain into a sterilization pot (701) from a strain feeding port (703);

and step B6, operating a spiral stirrer (704), mixing the materials in the sterilization pot (701) with the inoculated strains and feeding the materials into the fermentation box (1) through the feed inlet (101).

10. A solid state fermentation process according to claim 9, further comprising using the material sterilization transport tank (7) to generate steam for sterilization of the fermentation tank (1) and high temperature sterilized water for humidification of the fermentation tank (1).