CN113100429A - Process for producing high-nucleotide super-fresh soy sauce - Google Patents
Process for producing high-nucleotide super-fresh soy sauce Download PDFInfo
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- CN113100429A CN113100429A CN202110582926.6A CN202110582926A CN113100429A CN 113100429 A CN113100429 A CN 113100429A CN 202110582926 A CN202110582926 A CN 202110582926A CN 113100429 A CN113100429 A CN 113100429A
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L27/00—Spices; Flavouring agents or condiments; Artificial sweetening agents; Table salts; Dietetic salt substitutes; Preparation or treatment thereof
- A23L27/50—Soya sauce
Abstract
The invention relates to a production process of high-nucleotide super-fresh soy sauce, belonging to the technical field of brewing of super-fresh soy sauce. The method is characterized by comprising the following steps: s1, preparing materials; preparing soybean meal and raw wheat according to the mass fraction of 55: 45; s1.1, baking and crushing raw wheat to obtain fried wheat flour; s1.2, steaming; putting the soybean meal into a rotary spherical digester, and performing material steaming operation; s1.3, preparing yeast extract according to 0.03-0.05% of the total amount of the feed; s1.4, preparing saline water according to the proportion of 1.6-1.8 times of the total feeding amount; s2 starter propagation; s3 fermenting; s4 squeezing and filtering; s5 aseptic canning. The invention truly realizes the large-scale production of the super-fresh soy sauce without adding high nucleotide, brings a qualitative leap to the whole soy sauce industry, and can also maximize the benefits of both producers and consumers.
Description
Technical Field
The invention belongs to the technical field of brewing of super-fresh soy sauce, and particularly relates to a production process of high-nucleotide super-fresh soy sauce.
Background
With the improvement of living standard of people and the trend of food safety and large environment, the requirements of people on seasonings are higher and higher, the soy sauce sold in the market at present has more varieties, and delicious soy sauce such as light soy sauce, extremely delicious soy sauce and the like occupy the half-wall Jiangshan of the soy sauce, but in order to improve the delicate flavor, most of the soy sauce is added with food delicious agents such as monosodium glutamate, flavor developing nucleotide, scallop essence and the like, or added with food raw materials such as yeast extract with high nucleotide and the like, so that the blending cost is increased, and the soy sauce cannot be accepted by partial consumers.
The soy sauce is a delicious seasoning produced by fermenting soybeans, wheat and the like with various microorganisms such as mould, lactobacillus, yeast and the like, and is fermented by various enzymes of the microorganisms, so that the soy sauce contains a lot of amino acids, polypeptides, polysaccharides, reducing sugars, organic acids and the like, and only lacks of fresh nucleotide substances, scientific researches prove that a lot of nucleic acids and nucleotide substances can be produced after thalli such as the mould, the yeast and the like are autolyzed in soy sauce fermentation, but the produced nucleotide is decomposed into inorganic phosphoric acid and nucleoside by nucleotidase and phosphatase, and no longer has fresh taste, which is a reason for adding flavor-developing nucleotide to the super-fresh soy sauce, otherwise, the fresh taste of components fermented by the soy sauce is not improved to a high degree, and a fermentation process capable of retaining the nucleotide in soy sauce fermentation is urgently needed.
Disclosure of Invention
The invention aims to solve the problems, provides a production process of the high-nucleotide super-fresh soy sauce, and can realize large-scale production of the high-nucleotide super-fresh soy sauce without adding through scientifically optimizing a brewing process. The second technical problem solved by the invention is that the starter propagation quality and efficiency are improved by improving the preparation equipment, in particular a disc machine used in the starter propagation process, and the output quality of the product is further ensured.
The invention relates to a production process of high nucleotide super-fresh soy sauce, which is characterized by comprising the following steps:
s1, preparing materials;
preparing soybean meal and raw wheat according to the mass fraction of 55: 45;
s1.1, baking and crushing raw wheat to obtain fried wheat flour;
s1.2, steaming; putting the soybean meal into a rotary spherical digester, and performing material steaming operation;
s1.3, preparing yeast extract according to 0.03-0.05% of the total amount of the feed;
s1.4, preparing saline water according to the proportion of 1.6-1.8 times of the total feeding amount;
adding 1.6-1.8L saline water into 1Kg of mixture, wherein the temperature of the saline water is 4-6 ℃, and the actual temperature of the saline water is 13-15 ℃ of the sauce mash after the mixture is placed in a tank.
S2 starter propagation;
s3 fermenting;
s4 squeezing and filtering;
s5 aseptic canning.
Preferably, the S1.2 steaming comprises the following steps:
adding water in proportion: total raw material amount for making the koji: water =1:0.6-0.7, the water content of the mixed yeast material is required to be 48% +/-2%;
s1.2.1, feeding: after the soybean meal is put into the balls, the covers are tightly sealed, and the balls are rotated;
s1.2.2 dry steaming: opening a steam valve, carrying out dry steaming for 3 times at the pressure of 0-0.1-0- (0.12-0.16) -0 MPa, and closing the steam exhaust valve after the last steam exhaust pressure is 0 MPa;
s1.2.3 moistening with water: normal temperature water is used for water inflow (the water inflow can form vacuum in the ball, the water inflow speed is faster and faster), the ball rotates for 3 circles after the water inflow is finished, then the steam exhaust valve is opened to discharge the negative pressure to 0, the steam exhaust valve is closed, the ball continues to rotate for water wetting for 10-15 minutes, and the total time of water wetting after the water inflow is finished is 15-20 minutes;
s1.2.4 wet steaming: the material steaming pressure is 0.1MPa for the first time, 0.1MPa for the second time and 0.12-0.16 MPa for the third time, and the pressure is maintained for 8-10 minutes (timing from the pressure of 0.12 MPa);
s1.2.5 pressure relief: after the pressure maintaining of the steamed materials is finished, closing the steam inlet valve, opening the steam exhaust valve to exhaust steam until the pressure is 0 MPa, and closing the steam exhaust valve;
s1.2.6, vacuumizing: starting a vacuum pump, starting a vacuum pumping valve, and vacuumizing to 60-55 ℃; opening an exhaust valve to release pressure to 0 MPa, then closing a vacuum pump, and then closing a vacuum valve;
s1.2.7 opening the cover and steaming to obtain the final product.
Preferably, the S2 koji making comprises the steps of:
s2.1, discharging and cooling: opening a discharging port, adjusting the discharging speed in time, starting a conveying auger, conveying the material to the discharging port, and feeding the material to an air cooler through a conveying mesh belt;
s2.2, inoculating, mixing and frying wheat flour and adding yeast: uniformly stirring the yeast seeds with a small amount of wheat flour (reference value: about 25 kg per ball), inoculating by an inoculating machine, controlling the inoculation amount to be 0.03-0.06%, and controlling the inoculation temperature to be less than 38 ℃; uniformly mixing the wheat flour with the fried wheat flour by a uniformly mixing auger, and then dropping the wheat flour into a koji making disc of a disc koji making device by a conveyer belt; each layer is 4-5 cm thick; culturing the yeast at 24-36 deg.C;
s2.3, starter making and turning management: the first yeast turning is carried out for 10-14 hours after the materials are fed, and the second yeast turning is carried out for 14-20 hours after the materials are fed. Turning over the yeast according to the actual growth condition; the starter propagation time is 40-44 hours, and the inlet air humidity is more than 92%.
Preferably, the S3 fermentation comprises the following steps:
s3.1 brine preparation:
salt dry steaming: after the salt is put into the salt pond, a steam valve at the bottom of the salt pond is opened until steam is emitted from the surface of the salt pile, and the salt is steamed for 50 to 60 minutes to kill microorganisms in the salt and reduce the content of infectious microbes in the soy sauce; after the salt is dried and steamed, the salt is converted into saturated salt water which is pumped into a saturated salt water tank. Pre-adjusting the concentration of saline water to 24.5-26g/100 ml; filtering with ceramic membrane with pore diameter of 0.18-0.22 μm for sterilization, and refrigerating; adjusting the temperature of saline water by a refrigerator to 4-6 ℃ (the temperature of the saline water is adjusted to 13-15 ℃ after yeast making and mash making);
s3.2, mash preparation: uniformly mixing the cultured finished koji with saline water by a mixing auger, and pumping into a fermentation tank;
s3.3 pre-fermentation: day 1: turning on an air pipe for stirring while the fermented soybean is put into a tank, keeping the fermented soybean uniformly turned over, and carrying out air stirring once for 30 minutes after the fermented soybean is put into the tank; stirring for 30 minutes again after 4 to 5 hours;
day 2-3: stirring once in the morning and afternoon for 30 minutes, wherein the stirring interval of the two times is not less than 4 hours;
day 4-7: stirring once a day for 10 minutes;
day 7: rechecking the salt content of the sauce mash, wherein the error exceeds the standard 0.5 percent, and timely adjusting;
sampling every 15 days to detect indexes of the soy sauce mash, and slightly stirring once every 7-10 days according to the surface condition of the soy sauce mash to remove mold until no white film on the surface can be seen;
temperature management of pre-fermentation:
the temperature of the tank is required to be 13-15 ℃; keeping the temperature at 13-15 ℃ in 1-15 days, and starting to increase the temperature of the product on day 16;
the temperature control method comprises the following steps: starting a fermentation tank heating and heat-preserving system, controlling the temperature of hot water to be 55-65 ℃, circularly heating the hot water, and stirring once every 3-4 days in the heating process, namely stirring for one cycle for 5 minutes, wherein each air pipe is 1 minute; gradually heating to 30 deg.C within 16-30 days, maintaining the temperature for about 45 days, detecting that the content of amino acid is not increased, and ending the primary fermentation;
s3.5, heating and inactivating enzyme: pumping the sauce mash into a tube type sterilizer through a thick slurry pump, rapidly raising the temperature of the sauce mash to 95 ℃, keeping the temperature for 30-45 seconds, then rapidly cooling to 28-30 ℃, and pumping into another new fermentation tank, wherein the stage is a heating enzyme deactivation stage of nucleotidase and phosphatase;
s3.6, after-fermentation:
after the primary fermentation is finished and the enzymes are deactivated, adding high nucleic acid aroma-enhancing yeast, wherein the high nucleic acid aroma-enhancing yeast accounting for 10 percent of the total amount of the raw materials is added into each tank of fermented mash, and the yeast number is required to be more than or equal to 3 hundred million/ml; adding yeast and stirring: continuously stirring for 3 days after adding one yeast every time, once a day, and circulating for 1 minute in each air pipe every time; controlling the temperature at 28-30 ℃, fermenting for 30-35 days, after the surface of soy sauce mash is calm, indicating that the yeast fermentation is finished, starting autolysis of thalli, then adding nuclease with the total feeding amount of 0.05-0.1% and adenosine deaminase with the total feeding amount of 0.02-0.05%, gradually reducing the temperature to 24-26 ℃, entering a nucleic acid decomposition stage and a post-maturation stage, wherein the time of the stage is about 50-60 days, detecting the content of four main flavor nucleotides of 5 '-IMP, 5' -CMP, 5 '-GMP and 5' -AMP to reach more than 0.8%, and finishing the post-fermentation.
Preferably, the S4 press filtration comprises the following steps: after the fermentation is finished, filtering the fermented mash by using a vertical squeezer, collecting crude clear oil, and discharging soy sauce residues;
performing centrifugal sterilization and sediment removal on raw clear oil: and (3) the raw clear oil enters a disc type centrifuge, and is subjected to high-speed centrifugation at 6000-6500 rpm to remove bacteria, yeast, mould and other miscellaneous bacteria and further remove micro molecular proteins, starch, dextrin and other precipitates.
Preferably, the raw clear oil after centrifugation and impurity removal is filtered by a ceramic membrane (the aperture is 0.18-0.22 μm) to remove 99.9% of mixed bacteria, and the raw oil is further sterilized and clarified to obtain the super-fresh mellow soy sauce.
Preferably, the raw clear oil after centrifugation and impurity removal is subjected to ultrahigh temperature instantaneous sterilization at the temperature of 130-.
Preferably, the disc koji making device comprises an outer bin body, a disc assembly and a lifting feeding device, wherein the disc assembly and the lifting feeding device are both arranged in the outer bin body, eight sides of the outer bin body are closed, and a temperature sensor and a humidity sensor are arranged on the inner wall of the outer bin body; the sealed bin door that can open and shut is set up on the outer storehouse body, sets up more than one ventilation window on the lateral wall in the outer storehouse body, installs the blast deflector valve that ventilates on the ventilation window.
Preferably, the disc assembly comprises an upper bearing mounting seat and a lower bearing mounting seat, the upper bearing mounting seat and the lower bearing mounting seat are respectively fixed on the upper top surface and the lower bottom surface of the outer bin body, disc rotating shafts are vertically mounted in the upper bearing mounting seat and the lower bearing mounting seat, and more than three koji making discs are sleeved on the disc rotating shafts; a rotating shaft driven belt wheel is sleeved at the lower part of the rotating shaft of the rotating disc, a rotating shaft driving motor is arranged on the bottom surface of the outer bin body, a rotating shaft driving belt wheel is sleeved on a motor shaft of the rotating disc driving motor, and an annular rotating shaft driving belt group is sleeved on the rotating shaft driven belt wheel and the rotating shaft driving belt wheel; when the rotating shaft driving motor is started, the disk rotating shaft and each koji making disk rotate around the central axis of the disk rotating shaft and each koji making disk can be driven by the rotating shaft driving belt pulley, the rotating shaft driving belt group and the rotating shaft driven belt pulley;
a group of refining devices are arranged at the upper part of each koji making disc, and a group of ventilation devices are arranged at the lower part of each koji making disc;
the material refining device comprises a material refining lifting sleeve, the material refining lifting sleeve is sleeved on a disc rotating shaft at the upper part of the koji making disc and can move up and down along the disc rotating shaft, a material refining electric rotating ring is sleeved on the periphery of the material refining lifting sleeve, a material refining supporting arm is welded on the periphery of the material refining electric rotating ring, and a plurality of material refining rods are uniformly arranged on the material refining supporting arm at intervals; the refining electric rotating ring can drive the refining supporting arm to rotate around the refining lifting sleeve and the disc rotating shaft, and meanwhile, the refining rod can rotate to stir and homogenize the materials in the koji making disc;
the ventilation device comprises a ventilation lifting sleeve, the ventilation lifting sleeve is sleeved on a disc rotating shaft at the lower part of the koji making disc and can move up and down along the disc rotating shaft, and a ventilation sleeve support is fixedly sleeved at the upper end of the ventilation lifting sleeve; the ventilation sleeve support comprises more than three circular ring-shaped ventilation ring pipes, the ventilation ring pipes are concentrically arranged in a coplanar manner, and the ventilation ring pipes are fixed into a whole through a ventilation branch pipe; the upper part of each ventilation ring pipe is vertically provided with an air outlet vertical pipe, and the air outlet vertical pipe is provided with a plurality of ventilation and air blowing holes; the upper end or the lower end of the disc rotating shaft is connected with the front end of an air guide pipe through a rotary joint, and the rear end of the air guide pipe is connected with an air source through an air pump; air outlet holes are formed in the disc rotating shaft corresponding to the sets of ventilation devices, and one-way air outlet valves are mounted on the air outlet holes; air inlet holes are correspondingly formed in the inner peripheral wall of the innermost-ring ventilation ring pipe of the ventilation sleeve support; a disc through hole is arranged on the annular bottom surface of the koji making disc corresponding to each air outlet vertical pipe; a silica gel pad body is laid on the annular bottom surface of the koji making disc, and a cross-shaped strip seam is arranged at the position of the silica gel pad body corresponding to the disc through hole;
in an initial state, the ventilation lifting device drives the ventilation sleeve support to be positioned below the koji making disc, and the one-way air outlet valve is in a closed state; when the ventilation lifting device drives the ventilation sleeve support to move upwards to an upper limit, each air outlet vertical pipe can penetrate through the disc through hole on the koji making disc and push open the cross-shaped seam on the silica gel pad body, and each ventilation air blowing hole is positioned above the bottom surface of the koji making disc; the air inlet hole on the innermost ventilation ring pipe of the ventilation sleeve support is in butt joint with the air outlet hole on each disc rotating shaft, and the air pump is started at the moment, so that air flow meeting the temperature and humidity requirements enters the disc rotating shafts, enters the ventilation sleeve through the air outlet holes and is blown out outwards through the ventilation air blowing holes in the air outlet vertical pipe.
Preferably, the lifting feeding device comprises a pre-storage bin, the pre-storage bin is fixed on the upper top wall of the outer bin body, a discharge port is formed in the lower portion of the pre-storage bin, and the lower end of the discharge port is connected with the feeding end of the spiral feeder through a flexible telescopic guide pipe; the discharge end of the spiral feeder faces the upper part of the koji making disc; the spiral feeder is fixed on a sliding nut through a fixer, the sliding nut is sleeved on a sliding lead screw, two ends of the sliding lead screw are horizontally fixed on a lifting support through a lead screw mounting bearing seat, a lead screw driven gear is fixed at one end of the lead screw, which is far away from a bending disc, a lead screw driving motor is arranged on the lifting support, a lead screw driving gear is sleeved on a motor shaft of the lead screw driving motor, and the lead screw driving gear is meshed with the lead screw driven gear; when the screw rod driving motor is started to rotate forwards or reversely, the screw nut can drive the fixer and the screw feeder to be close to the inner periphery or the outer periphery of the koji making disc by driving the screw rod to rotate forwards or reversely;
one end of the lifting support far away from the koji making disc is connected with a wheeled lifter, one end of the lifting support near the koji making disc is connected with the lower end of a lifting cable, the upper end of the lifting cable is wound on an electric winding wheel, and the electric winding wheel is hoisted on the upper top wall of the outer bin body; the belt wheel type lifter and the electric winding wheel are started to drive the lifting support to move up and down, and then the discharge port of the spiral feeder is aligned to the koji making discs with different heights to carry out feeding operation.
The beneficial effects are as follows:
compared with the prior art, the invention has the beneficial effects that:
1. at present, the method for realizing the production of the super-fresh soy sauce without adding the high nucleotide on a large scale has a profound significance for the current traditional fermented seasonings in China. Firstly, the appearance of the method enables us to really return to trueness and nature. In addition, the soy sauce plays a role in keeping original source of health for the traditional fermented seasoning, namely the soy sauce. The high-end fermented seasoning which accords with the ecological, nutritional and healthy scientific ideas can be really enjoyed by vast consumers with very little cost.
2. Maximization of the benefit: if we really realize the large-scale production of the super-fresh soy sauce without adding the high nucleotide, the method will bring a qualitative leap to the whole soy sauce industry and also can maximize the benefits of both producers and consumers. That is to say, the product with the highest cost performance can be bought by the consumer, and the product with the highest cost performance can be bought by the producer, so that the secondary addition is reduced, the cost is reduced, the profit is improved, and the maximization of the benefits of all parties is realized in an all-round manner.
3. Because each koji making disc of the disc koji making machine automatically rotates in the feeding process, and the spiral feeder can move from inside to outside along the radius direction of the koji making discs, the fed materials can be uniformly distributed.
In the feeding and refining processes, the ventilation device is in an initial state, namely the ventilation lifting device drives the ventilation sleeve support to be positioned below the koji making disc, and the one-way air outlet valve is in a closed state; at the moment, the cross-shaped strip seam on the silica gel pad body is closed, and the materials cannot penetrate through the cross-shaped strip seam and the through hole of the disc to be exposed out of the koji making disc.
After the feeding and the refining are finished, the ventilation lifting device drives the ventilation sleeve support to move upwards to an upper limit position, each air outlet vertical pipe can penetrate through a disc through hole on the koji making disc and push open a cross-shaped seam on the silica gel pad body, and each ventilation air blowing hole is positioned above the bottom surface of the koji making disc; the air inlet hole on the innermost ventilation ring pipe of the ventilation sleeve support is in butt joint with the air outlet hole on each disc rotating shaft, and the air pump is started at the moment, so that air flow meeting the temperature and humidity requirements enters the disc rotating shafts, enters the ventilation sleeve through the air outlet holes and is blown out outwards through the ventilation air blowing holes in the air outlet vertical pipe. The structure setting of ventilation unit is different from traditional bent ventilation equipment, but through the air-out riser horizontal or the air-out of slant, can pierce through thicker material layer to make bent operation in-process material ventilation state good, warm and humid environmental condition is stable.
The invention improves the starter propagation quality and efficiency by improving the preparation equipment, in particular to a disc starter propagation device used in the starter propagation process, and further ensures the output quality of the product.
Drawings
FIG. 1 is a flow chart of the production process of the present invention;
FIG. 2 is a schematic structural view of a disc koji making apparatus;
FIG. 3 is a schematic structural view of a koji making disc (ventilation state);
FIG. 4 is a schematic structural view of a koji making disc (refining state);
FIG. 5 is a schematic structural view of a vent sleeve mount;
in the figure: 1. a material homogenizing device; 2. an upper bearing mount; 3. a screw feeder; 4. an electric wire winding wheel; 5. a lifting cable; 6. a pre-storage bin; 7. a holder; 8. an outer bin body; 9. a sliding lead screw; 10. a lead screw driven gear; 11. a belt-pulley elevator; 12. a rotating shaft driving belt wheel; 13. the rotating shaft drives the motor; 14. the rotating shaft drives the belt set; 15. a turntable spindle; 16. a rotating shaft driven belt wheel; 17. a lower bearing mount; 18. a ventilation device; 19. a koji making disc; 20. a ventilation diversion valve; 21. a material homogenizing rod; 22. a refining support arm; 23. material homogenizing electric rotary ring; 24. a refining lifting sleeve; 25. a one-way air outlet valve; 26. a ventilation lifting sleeve; 27. a silica gel pad body; 28. an air outlet vertical pipe; 29. ventilating and blowing holes; 30. an air inlet hole; 31. a ventilation ring pipe; 32. a ventilation branch pipe; 33. a lead screw is provided with a bearing seat; 34. sliding a screw nut; 35. a lifting support; 36. a lead screw driving gear; 37. the lead screw drives the motor.
Detailed Description
The present invention will be further described with reference to specific examples, which are not intended to limit the invention.
Example 1
As shown in figure 1, the process for producing the high nucleotide super-fresh soy sauce comprises the following steps:
s1, preparing materials;
preparing soybean meal and raw wheat according to the mass fraction of 55: 45;
s1.1, baking and crushing raw wheat to obtain fried wheat flour;
s1.2, steaming; putting the soybean meal into a rotary spherical digester, and performing material steaming operation; s1.2 steaming comprises the following steps:
adding water in proportion: total raw material amount for making the koji: water =1:0.6-0.7, the water content of the mixed yeast material is required to be 48% +/-2%;
s1.2.1, feeding: after the soybean meal is put into the balls, the covers are tightly sealed, and the balls are rotated;
s1.2.2 dry steaming: opening a steam valve, carrying out dry steaming for 3 times at the pressure of 0-0.1-0- (0.12-0.16) -0 MPa, and closing the steam exhaust valve after the last steam exhaust pressure is 0 MPa;
s1.2.3 moistening with water: normal temperature water is used for water inflow (the water inflow can form vacuum in the ball, the water inflow speed is faster and faster), the ball rotates for 3 circles after the water inflow is finished, then the steam exhaust valve is opened to discharge the negative pressure to 0, the steam exhaust valve is closed, the ball continues to rotate for water wetting for 10-15 minutes, and the total time of water wetting after the water inflow is finished is 15-20 minutes;
s1.2.4 wet steaming: the material steaming pressure is 0.1MPa for the first time, 0.1MPa for the second time and 0.12-0.16 MPa for the third time, and the pressure is maintained for 8-10 minutes (timing from the pressure of 0.12 MPa);
s1.2.5 pressure relief: after the pressure maintaining of the steamed materials is finished, closing the steam inlet valve, opening the steam exhaust valve to exhaust steam until the pressure is 0 MPa, and closing the steam exhaust valve;
s1.2.6, vacuumizing: starting a vacuum pump, starting a vacuum pumping valve, and vacuumizing to 60-55 ℃; opening an exhaust valve to release pressure to 0 MPa, then closing a vacuum pump, and then closing a vacuum valve;
s1.2.7 opening the cover and steaming to obtain the final product.
S1.3, preparing yeast extract according to 0.03-0.05% of the total amount of the feed;
s1.4, preparing saline water according to the proportion of 1.6-1.8 times of the total feeding amount;
adding 1.6-1.8L saline water into 1Kg of mixture, wherein the temperature of the saline water is 4-6 ℃, and the actual temperature of the saline water is 13-15 ℃ of the sauce mash after the mixture is placed in a tank.
S2 starter propagation;
the starter propagation method comprises the following steps:
s2.1, discharging and cooling: opening a discharging port, adjusting the discharging speed in time, starting a conveying auger, conveying the material to the discharging port, and feeding the material to an air cooler through a conveying mesh belt;
s2.2, inoculating, mixing and frying wheat flour and adding yeast: uniformly stirring the yeast seeds with a small amount of wheat flour (reference value: about 25 kg per ball), inoculating by an inoculating machine, controlling the inoculation amount to be 0.03-0.06%, and controlling the inoculation temperature to be less than 38 ℃; uniformly mixing the wheat flour with the fried wheat flour by a uniformly mixing auger, and then dropping the wheat flour into a koji making disc of a disc koji making device by a conveyer belt; each layer is 4-5 cm thick; culturing the yeast at 24-36 deg.C;
s2.3, starter making and turning management: the first yeast turning is carried out for 10-14 hours after the materials are fed, and the second yeast turning is carried out for 14-20 hours after the materials are fed. Turning over the yeast according to the actual growth condition; the starter propagation time is 40-44 hours, and the inlet air humidity is more than 92%.
S3 fermenting;
s3.1 brine preparation:
salt dry steaming: after the salt is put into the salt pond, a steam valve at the bottom of the salt pond is opened until steam is emitted from the surface of the salt pile, and the salt is steamed for 50 to 60 minutes to kill microorganisms in the salt and reduce the content of infectious microbes in the soy sauce; after the salt is dried and steamed, the salt is converted into saturated salt water which is pumped into a saturated salt water tank. Pre-adjusting the concentration of saline water to 24.5-26g/100 ml; filtering with ceramic membrane with pore diameter of 0.18-0.22 μm for sterilization, and refrigerating; adjusting the temperature of saline water by a refrigerator to 4-6 ℃ (the temperature of the saline water is adjusted to 13-15 ℃ after yeast making and mash making);
s3.2, mash preparation: uniformly mixing the cultured finished koji with saline water by a mixing auger, and pumping into a fermentation tank;
s3.3 pre-fermentation: day 1: turning on an air pipe for stirring while the fermented soybean is put into a tank, keeping the fermented soybean uniformly turned over, and carrying out air stirring once for 30 minutes after the fermented soybean is put into the tank; stirring for 30 minutes again after 4 to 5 hours;
day 2-3: stirring once in the morning and afternoon for 30 minutes, wherein the stirring interval of the two times is not less than 4 hours;
day 4-7: stirring once a day for 10 minutes;
day 7: rechecking the salt content of the sauce mash, wherein the error exceeds the standard 0.5 percent, and timely adjusting;
sampling every 15 days to detect indexes of the soy sauce mash, and slightly stirring once every 7-10 days according to the surface condition of the soy sauce mash to remove mold until no white film on the surface can be seen;
temperature management of pre-fermentation:
the temperature of the tank is required to be 13-15 ℃; keeping the temperature at 13-15 ℃ in 1-15 days, and starting to increase the temperature of the product on day 16;
the temperature control method comprises the following steps: starting a fermentation tank heating and heat-preserving system, controlling the temperature of hot water to be 55-65 ℃, circularly heating the hot water, and stirring once every 3-4 days in the heating process, namely stirring for one cycle for 5 minutes, wherein each air pipe is 1 minute; gradually heating to 30 deg.C within 16-30 days, maintaining the temperature for about 45 days, detecting that the content of amino acid is not increased, and ending the primary fermentation;
s3.5, heating and inactivating enzyme: pumping the sauce mash into a tube type sterilizer through a thick slurry pump, rapidly raising the temperature of the sauce mash to 95 ℃, keeping the temperature for 30-45 seconds, then rapidly cooling to 28-30 ℃, and pumping into another new fermentation tank, wherein the stage is a heating enzyme deactivation stage of nucleotidase and phosphatase;
s3.6, after-fermentation:
after the primary fermentation is finished and the enzymes are deactivated, adding high nucleic acid aroma-enhancing yeast, wherein the high nucleic acid aroma-enhancing yeast accounting for 10 percent of the total amount of the raw materials is added into each tank of fermented mash, and the yeast number is required to be more than or equal to 3 hundred million/ml; adding yeast and stirring: continuously stirring for 3 days after adding one yeast every time, once a day, and circulating for 1 minute in each air pipe every time; controlling the temperature at 28-30 deg.C, fermenting for 30-35 days, standing the surface of fermented soy sauce, allowing yeast fermentation to finish, allowing thallus to autolyze, adding nuclease 0.05-0.1% and adenosine deaminase 0.02-0.05%, gradually cooling to 24-26 deg.C, decomposing nucleic acid and ripening for 50-60 days, detecting the content of four main flavor nucleotides 5 '-IMP, 5' -CMP, 5 '-GMP, and 5' -AMP above 0.8%, and finishing after fermentation
S4 squeezing and filtering;
the squeezing and filtering process includes the following steps: after the fermentation is finished, filtering the fermented mash by using a vertical squeezer, collecting crude clear oil, and discharging soy sauce residues;
performing centrifugal sterilization and sediment removal on raw clear oil: and (3) the raw clear oil enters a disc type centrifuge, and is subjected to high-speed centrifugation at 6000-6500 rpm to remove bacteria, yeast, mould and other miscellaneous bacteria and further remove micro molecular proteins, starch, dextrin and other precipitates.
Filtering the crude clear oil after centrifugation and impurity removal by a ceramic membrane (the aperture is 0.18-0.22 mu m) to remove 99.9% of mixed bacteria, and further sterilizing and clarifying the crude oil to obtain the super-fresh mellow soy sauce.
And (3) instantly sterilizing the raw clear oil subjected to centrifugation and impurity removal at the ultrahigh temperature of 130 plus 132 ℃ to obtain the ultra-fresh cooked soy sauce with rich sauce fragrance.
S5 aseptic canning.
The innovation points of the invention are as follows:
1. the fermented grains are dried and steamed by salt by adopting steam, and more than 90 percent of marine microorganisms brought by the salt are killed.
2. The brine is filtered by a ceramic membrane filter with the aperture of 0.15-0.22 mu m to remove impurities and microorganisms in the brine, and the brine is commercially sterile.
3. The starter propagation process adopts the internationally leading disc starter propagation equipment and technology, the constant temperature, the constant pressure and the constant humidity control are carried out in a closed space, the soy sauce starter grows well, and the introduction of mixed bacteria is reduced.
4. The soy sauce fermentation amino acid generation reaches a peak, the soy sauce mash is subjected to high-temperature instantaneous sterilization when the amino acid content does not rise any more, nucleotidase and phosphatase for decomposing flavor-developing nucleotide are inactivated, the flavor-developing nucleotide generated in the later period is prevented from being decomposed, and meanwhile, soy sauce mash is sterilized, more than 90% of mixed bacteria are killed, and the growth and fermentation of high-nucleic-acid yeast in the later period are facilitated.
5. The high nucleic acid aroma-enhancing yeast is used for replacing the traditional soy sauce aroma-enhancing yeast, meanwhile, nuclease is added to assist in decomposing nucleic acid substances released by yeast and mould, and adenosine deaminase is added to convert part of AMP into IMP with better delicate flavor, so that the content of the AMP which becomes flavor-developing nucleotide is increased, and the delicate flavor of soy sauce is improved.
The high-nucleotide super-fresh soy sauce produced by the method has the following characteristics:
(1) no monosodium glutamate, flavor nucleotide, scallop essence and other flavoring agents are added, and the freshness can reach more than 5 times of the traditional soy sauce raw juice.
(2) Is purely natural, has no any additive, and has delicious taste.
Example 2
As shown in fig. 2-5, the disc koji making device comprises an outer bin body, a disc assembly and a lifting feeding device, wherein the disc assembly and the lifting feeding device are both arranged in the outer bin body, the outer bin body is eight-side closed, and a temperature sensor and a humidity sensor are arranged on the inner wall of the outer bin body; the sealed bin door that can open and shut is set up on the outer storehouse body, sets up more than one ventilation window on the lateral wall in the outer storehouse body, installs the blast deflector valve that ventilates on the ventilation window.
The disc assembly comprises an upper bearing mounting seat and a lower bearing mounting seat, the upper bearing mounting seat and the lower bearing mounting seat are respectively fixed on the upper top surface and the lower bottom surface of the outer bin body, disc rotating shafts are vertically mounted in the upper bearing mounting seat and the lower bearing mounting seat, and more than three koji making discs are sleeved on the disc rotating shafts; a rotating shaft driven belt wheel is sleeved at the lower part of the rotating shaft of the rotating disc, a rotating shaft driving motor is arranged on the bottom surface of the outer bin body, a rotating shaft driving belt wheel is sleeved on a motor shaft of the rotating disc driving motor, and an annular rotating shaft driving belt group is sleeved on the rotating shaft driven belt wheel and the rotating shaft driving belt wheel; when the rotating shaft driving motor is started, the disk rotating shaft and each koji making disk rotate around the central axis of the disk rotating shaft through the rotating shaft driving belt wheel, the rotating shaft driving belt group and the rotating shaft driven belt wheel.
A group of refining devices are arranged at the upper part of each koji making disc, and a group of ventilation devices are arranged at the lower part of each koji making disc.
The material refining device comprises a material refining lifting sleeve, the material refining lifting sleeve is sleeved on a disc rotating shaft at the upper part of the koji making disc and can move up and down along the disc rotating shaft, a material refining electric rotating ring is sleeved on the periphery of the material refining lifting sleeve, a material refining supporting arm is welded on the periphery of the material refining electric rotating ring, and a plurality of material refining rods are uniformly arranged on the material refining supporting arm at intervals; the electronic change of refining can drive the rotation of refining support arm around refining lift sleeve and disc pivot, and meanwhile, the refining pole can rotate and dial the material in the even bent disc of system.
The ventilation device comprises a ventilation lifting sleeve, the ventilation lifting sleeve is sleeved on a disc rotating shaft at the lower part of the koji making disc and can move up and down along the disc rotating shaft, and a ventilation sleeve support is fixedly sleeved at the upper end of the ventilation lifting sleeve; the ventilation sleeve support comprises more than three circular ring-shaped ventilation ring pipes, the ventilation ring pipes are concentrically arranged in a coplanar manner, and the ventilation ring pipes are fixed into a whole through a ventilation branch pipe; the upper part of each ventilation ring pipe is vertically provided with an air outlet vertical pipe, and the air outlet vertical pipe is provided with a plurality of ventilation and air blowing holes; the upper end or the lower end of the disc rotating shaft is connected with the front end of an air guide pipe through a rotary joint, and the rear end of the air guide pipe is connected with an air source through an air pump; air outlet holes are formed in the disc rotating shaft corresponding to the sets of ventilation devices, and one-way air outlet valves are mounted on the air outlet holes; air inlet holes are correspondingly formed in the inner peripheral wall of the innermost-ring ventilation ring pipe of the ventilation sleeve support; a disc through hole is arranged on the annular bottom surface of the koji making disc corresponding to each air outlet vertical pipe; a silica gel pad body is laid on the annular bottom surface of the koji making disc, and a cross-shaped strip seam is arranged at the position of the silica gel pad body corresponding to the disc through hole.
The lifting feeding device comprises a pre-storage bin, the pre-storage bin is fixed on the upper top wall of the outer bin body, a discharge port is formed in the lower portion of the pre-storage bin, and the lower end of the discharge port is connected with the feeding end of the spiral feeder through a flexible telescopic guide pipe; the discharge end of the spiral feeder faces the upper part of the koji making disc; the spiral feeder is fixed on a sliding nut through a fixer, the sliding nut is sleeved on a sliding lead screw, two ends of the sliding lead screw are horizontally fixed on a lifting support through a lead screw mounting bearing seat, a lead screw driven gear is fixed at one end of the lead screw, which is far away from a bending disc, a lead screw driving motor is arranged on the lifting support, a lead screw driving gear is sleeved on a motor shaft of the lead screw driving motor, and the lead screw driving gear is meshed with the lead screw driven gear; when the screw driving motor is started to rotate forwards or reversely, the screw can drive the fixing device and the screw feeder to be close to the inner periphery or the outer periphery of the koji making disc by driving the screw to rotate forwards or reversely.
One end of the lifting support far away from the koji making disc is connected with a wheeled lifter, one end of the lifting support near the koji making disc is connected with the lower end of a lifting cable, the upper end of the lifting cable is wound on an electric winding wheel, and the electric winding wheel is hoisted on the upper top wall of the outer bin body; the belt wheel type lifter and the electric winding wheel are started to drive the lifting support to move up and down, and then the discharge port of the spiral feeder is aligned to the koji making discs with different heights to carry out feeding operation.
The specific working process of the disc koji making device is as follows:
and adjusting the temperature and humidity in the outer bin body to meet the brewing process requirement, and then throwing the inoculated materials into the pre-storage bin through the conveying belt. When the rotating shaft driving motor is started, the disk rotating shaft and each koji making disk rotate around the central axis of the disk rotating shaft and each koji making disk can be driven by the rotating shaft driving belt pulley, the rotating shaft driving belt group and the rotating shaft driven belt pulley; meanwhile, the belt wheel type lifter and the electric winding wheel are started to drive the lifting support to move up and down, and then the discharge port of the spiral feeder is aligned to the koji making discs with different heights to carry out feeding operation. When the materials are fed, the spiral feeder and the screw rod driving motor are required to be started simultaneously, a discharge hole of the spiral feeder can continuously discharge materials outwards, the driving screw rod is driven to rotate forwards or reversely, and the nut drives the fixing device and the spiral feeder to be close to the inner periphery or the outer periphery of the koji making disc. Because each koji making disc automatically rotates in the feeding process, and the spiral feeder can move from inside to outside along the radius direction of the koji making discs, the fed materials can be uniformly distributed.
After the feeding is finished, the refining lifting sleeve drives the refining supporting arm and the refining rod to move downwards along the disc rotating shaft until the refining rod is inserted into the material; and then starting the refining electric rotating ring to drive the refining supporting arm to rotate around the refining lifting sleeve and the disc rotating shaft, meanwhile, the refining rod can be used for rotationally stirring the materials in the koji making disc, and after the refining step is completed, the refining lifting sleeve drives the refining supporting arm and the refining rod to move upwards to an upper limit position.
In the feeding and refining processes, the ventilation device is in an initial state, namely the ventilation lifting device drives the ventilation sleeve support to be positioned below the koji making disc, and the one-way air outlet valve is in a closed state; at the moment, the cross-shaped strip seam on the silica gel pad body is closed, and the materials cannot penetrate through the cross-shaped strip seam and the through hole of the disc to be exposed out of the koji making disc.
After the feeding and the refining are finished, the ventilation lifting device drives the ventilation sleeve support to move upwards to an upper limit position, each air outlet vertical pipe can penetrate through a disc through hole on the koji making disc and push open a cross-shaped seam on the silica gel pad body, and each ventilation air blowing hole is positioned above the bottom surface of the koji making disc; the air inlet hole on the innermost ventilation ring pipe of the ventilation sleeve support is in butt joint with the air outlet hole on each disc rotating shaft, and the air pump is started at the moment, so that air flow meeting the temperature and humidity requirements enters the disc rotating shafts, enters the ventilation sleeve through the air outlet holes and is blown out outwards through the ventilation air blowing holes in the air outlet vertical pipe. The structure setting of ventilation unit is different from traditional bent ventilation equipment, but through the air-out riser horizontal or the air-out of slant, can pierce through thicker material layer to make bent operation in-process material ventilation state good, warm and humid environmental condition is stable.
The foregoing is directed to preferred embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. Any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present invention, without departing from the technical solution of the present invention, still belong to the protection scope of the technical solution of the present invention.
Claims (10)
1. A production process of high nucleotide super-fresh soy sauce is characterized by comprising the following steps:
s1, preparing materials;
preparing soybean meal and raw wheat according to the mass fraction of 55: 45;
s1.1, baking and crushing raw wheat to obtain fried wheat flour;
s1.2, steaming; putting the soybean meal into a rotary spherical digester, and performing material steaming operation;
s1.3, preparing yeast extract according to 0.03-0.05% of the total amount of the feed;
s1.4, preparing saline water according to the proportion of 1.6-1.8 times of the total feeding amount;
s2 starter propagation;
s3 fermenting;
s4 squeezing and filtering;
s5 aseptic canning.
2. The process for producing the high nucleotide ultra-fresh soy sauce according to claim 1, wherein the S1.2 steaming comprises the steps of:
adding water in proportion: total raw material amount for making the koji: water =1:0.6-0.7, the water content of the mixed yeast material is required to be 48% +/-2%;
s1.2.1, feeding: after the soybean meal is put into the balls, the covers are tightly sealed, and the balls are rotated;
s1.2.2 dry steaming: opening a steam valve, carrying out dry steaming for 3 times at the pressure of 0-0.1-0-0 MPa, and closing the steam exhaust valve after the last steam exhaust pressure is 0 MPa;
s1.2.3 moistening with water: water is fed by normal temperature water, the water is rotated for 3 circles after water feeding is finished, then the steam exhaust valve is opened to discharge negative pressure to 0, the steam exhaust valve is closed, the ball is rotated continuously to moisten water for 10 to 15 minutes, and the total time of moistening water after water feeding is finished is 15 to 20 minutes;
s1.2.4 wet steaming: the material steaming pressure is 0.1MPa for the first time, 0.1MPa for the second time and 0.12-0.16 MPa for the third time, and the pressure is maintained for 8-10 minutes;
s1.2.5 pressure relief: after the pressure maintaining of the steamed materials is finished, closing the steam inlet valve, opening the steam exhaust valve to exhaust steam until the pressure is 0 MPa, and closing the steam exhaust valve;
s1.2.6, vacuumizing: starting a vacuum pump, starting a vacuum pumping valve, and vacuumizing to 60-55 ℃; opening an exhaust valve to release pressure to 0 MPa, then closing a vacuum pump, and then closing a vacuum valve;
s1.2.7 opening the cover and steaming to obtain the final product.
3. The process for producing the high nucleotide ultra-fresh soy sauce according to claim 2, wherein the S2 koji making comprises the following steps:
s2.1, discharging and cooling: opening a discharging port, adjusting the discharging speed in time, starting a conveying auger, conveying the material to the discharging port, and feeding the material to an air cooler through a conveying mesh belt;
s2.2, inoculating, mixing and frying wheat flour and adding yeast: uniformly stirring the koji seeds with a small amount of fried wheat flour, inoculating the koji seeds through an inoculating machine, controlling the inoculation amount to be 0.03-0.06%, and controlling the inoculation temperature to be less than 38 ℃; uniformly mixing the wheat flour with the fried wheat flour by a uniformly mixing auger, and then dropping the wheat flour into a koji making disc of a disc koji making device by a conveyer belt; culturing the yeast at 24-36 deg.C;
s2.3, starter making and turning management: the first yeast turning is carried out for 10-14 hours after the materials are fed, and the second yeast turning is carried out for 14-20 hours after the materials are fed;
turning over the yeast according to the actual growth condition; the starter propagation time is 40-44 hours, and the inlet air humidity is more than 92%.
4. The process for producing the high nucleotide ultra-fresh soy sauce according to claim 3, wherein the S3 fermentation comprises the following steps:
s3.1 brine preparation:
salt dry steaming: after the salt is put into the salt pond, a steam valve at the bottom of the salt pond is opened until steam is emitted from the surface of the salt pile, and the salt is steamed for 50 to 60 minutes to kill microorganisms in the salt and reduce the content of infectious microbes in the soy sauce; after being dry-steamed, the salt is converted into saturated salt water which is pumped into a saturated salt water tank; pre-adjusting the concentration of saline water to 24.5-26g/100 ml; filtering with ceramic membrane with pore diameter of 0.18-0.22 μm for sterilization, and refrigerating; adjusting the temperature of the brine to 4-6 ℃ by using a refrigerator;
s3.2, mash preparation: uniformly mixing the cultured finished koji with saline water by a mixing auger, and pumping into a fermentation tank;
s3.3 pre-fermentation:
day 1: turning on an air pipe for stirring while the fermented soybean is put into a tank, keeping the fermented soybean uniformly turned over, and carrying out air stirring once for 30 minutes after the fermented soybean is put into the tank; stirring for 30 minutes again after 4 to 5 hours;
day 2-3: stirring once in the morning and afternoon for 30 minutes, wherein the stirring interval of the two times is not less than 4 hours;
day 4-7: stirring once a day for 10 minutes;
day 7: rechecking the salt content of the sauce mash, wherein the error exceeds the standard 0.5 percent, and timely adjusting;
sampling every 15 days to detect indexes of the soy sauce mash, and slightly stirring once every 7-10 days according to the surface condition of the soy sauce mash to remove mold until no white film on the surface can be seen;
temperature management of pre-fermentation:
the temperature of the tank is required to be 13-15 ℃; keeping the temperature at 13-15 ℃ in 1-15 days, and starting to increase the temperature of the product on day 16;
the temperature control method comprises the following steps: starting a fermentation tank heating and heat-preserving system, controlling the temperature of hot water to be 55-65 ℃, circularly heating the hot water, and stirring once every 3-4 days in the heating process, namely stirring for one cycle for 5 minutes, wherein each air pipe is 1 minute; gradually heating to 30 deg.C within 16-30 days, maintaining the temperature for about 45 days, detecting that the content of amino acid is not increased, and ending the primary fermentation;
s3.5, heating and inactivating enzyme: pumping the sauce mash into a tube type sterilizer through a thick slurry pump, rapidly raising the temperature of the sauce mash to 95 ℃, keeping the temperature for 30-45 seconds, then rapidly cooling to 28-30 ℃, and pumping into another new fermentation tank, wherein the stage is a heating enzyme deactivation stage of nucleotidase and phosphatase;
s3.6, after-fermentation:
after the primary fermentation is finished and the enzymes are deactivated, adding high nucleic acid aroma-enhancing yeast, wherein the high nucleic acid aroma-enhancing yeast accounting for 10 percent of the total amount of the raw materials is added into each tank of fermented mash, and the yeast number is required to be more than or equal to 3 hundred million/ml; adding yeast and stirring: continuously stirring for 3 days after adding one yeast every time, once a day, and circulating for 1 minute in each air pipe every time; controlling the temperature at 28-30 ℃, fermenting for 30-35 days, after the surface of soy sauce mash is calm, indicating that the yeast fermentation is finished, starting autolysis of thalli, then adding nuclease with the total feeding amount of 0.05-0.1% and adenosine deaminase with the total feeding amount of 0.02-0.05%, gradually reducing the temperature to 24-26 ℃, entering a nucleic acid decomposition stage and a post-maturation stage, wherein the time of the stage is about 50-60 days, detecting the content of four main flavor nucleotides of 5 '-IMP, 5' -CMP, 5 '-GMP and 5' -AMP to reach more than 0.8%, and finishing the post-fermentation.
5. The process for producing the high nucleotide ultra-fresh soy sauce according to claim 4, wherein the S4 press filtration comprises the following steps: after the fermentation is finished, filtering the fermented mash by using a vertical squeezer, collecting crude clear oil, and discharging soy sauce residues; performing centrifugal sterilization and sediment removal on raw clear oil: the raw clear oil enters a disc centrifuge and is subjected to 6000-6500 rpm high-speed centrifugation to further remove the mixed bacteria and the precipitate.
6. A process for preparing the super-fresh soy sauce with high nucleotide content as claimed in claim 5, wherein the clean oil after centrifugal separation is filtered by ceramic membrane to remove 99.9% of mixed bacteria, and the clean oil is further sterilized and clarified to obtain the super-fresh mellow soy sauce.
7. The process for producing super-fresh soy sauce as claimed in claim 5, wherein the super-fresh cooked soy sauce with rich sauce flavor is obtained by subjecting the raw clear oil after centrifugation and impurity removal to ultra-high temperature instantaneous sterilization at 132 ℃ under 130-.
8. The process for producing the high-nucleotide ultra-fresh soy sauce as claimed in claim 7, wherein the disc koji-making device comprises an outer chamber body, a disc assembly and a lifting and feeding device, the disc assembly and the lifting and feeding device are both arranged in the outer chamber body, the outer chamber body is eight-sided closed, and a temperature sensor and a humidity sensor are arranged on the inner wall of the outer chamber body; the sealed bin door that can open and shut is set up on the outer storehouse body, sets up more than one ventilation window on the lateral wall in the outer storehouse body, installs the blast deflector valve that ventilates on the ventilation window.
9. The process for producing high-nucleotide super-fresh soy sauce according to claim 8, wherein the disc assembly comprises an upper bearing mounting seat and a lower bearing mounting seat, the upper bearing mounting seat and the lower bearing mounting seat are respectively fixed on the upper top surface and the lower bottom surface of the outer bin body, a disc rotating shaft is vertically arranged in the upper bearing mounting seat and the lower bearing mounting seat, and more than three koji-making discs are sleeved on the disc rotating shaft; a rotating shaft driven belt wheel is sleeved at the lower part of the rotating shaft of the rotating disc, a rotating shaft driving motor is arranged on the bottom surface of the outer bin body, a rotating shaft driving belt wheel is sleeved on a motor shaft of the rotating disc driving motor, and an annular rotating shaft driving belt group is sleeved on the rotating shaft driven belt wheel and the rotating shaft driving belt wheel; when the rotating shaft driving motor is started, the disk rotating shaft and each koji making disk rotate around the central axis of the disk rotating shaft and each koji making disk can be driven by the rotating shaft driving belt pulley, the rotating shaft driving belt group and the rotating shaft driven belt pulley;
a group of refining devices are arranged at the upper part of each koji making disc, and a group of ventilation devices are arranged at the lower part of each koji making disc;
the material refining device comprises a material refining lifting sleeve, the material refining lifting sleeve is sleeved on a disc rotating shaft at the upper part of the koji making disc and can move up and down along the disc rotating shaft, a material refining electric rotating ring is sleeved on the periphery of the material refining lifting sleeve, a material refining supporting arm is welded on the periphery of the material refining electric rotating ring, and a plurality of material refining rods are uniformly arranged on the material refining supporting arm at intervals; the refining electric rotating ring can drive the refining supporting arm to rotate around the refining lifting sleeve and the disc rotating shaft, and meanwhile, the refining rod can rotate to stir and homogenize the materials in the koji making disc;
the ventilation device comprises a ventilation lifting sleeve, the ventilation lifting sleeve is sleeved on a disc rotating shaft at the lower part of the koji making disc and can move up and down along the disc rotating shaft, and a ventilation sleeve support is fixedly sleeved at the upper end of the ventilation lifting sleeve; the ventilation sleeve support comprises more than three circular ring-shaped ventilation ring pipes, the ventilation ring pipes are concentrically arranged in a coplanar manner, and the ventilation ring pipes are fixed into a whole through a ventilation branch pipe; the upper part of each ventilation ring pipe is vertically provided with an air outlet vertical pipe, and the air outlet vertical pipe is provided with a plurality of ventilation and air blowing holes; the upper end or the lower end of the disc rotating shaft is connected with the front end of an air guide pipe through a rotary joint, and the rear end of the air guide pipe is connected with an air source through an air pump; air outlet holes are formed in the disc rotating shaft corresponding to the sets of ventilation devices, and one-way air outlet valves are mounted on the air outlet holes; air inlet holes are correspondingly formed in the inner peripheral wall of the innermost-ring ventilation ring pipe of the ventilation sleeve support; a disc through hole is arranged on the annular bottom surface of the koji making disc corresponding to each air outlet vertical pipe; a silica gel pad body is laid on the annular bottom surface of the koji making disc, and a cross-shaped strip seam is arranged at the position of the silica gel pad body corresponding to the disc through hole;
in an initial state, the ventilation lifting device drives the ventilation sleeve support to be positioned below the koji making disc, and the one-way air outlet valve is in a closed state; when the ventilation lifting device drives the ventilation sleeve support to move upwards to an upper limit, each air outlet vertical pipe can penetrate through the disc through hole on the koji making disc and push open the cross-shaped seam on the silica gel pad body, and each ventilation air blowing hole is positioned above the bottom surface of the koji making disc; the air inlet hole on the innermost ventilation ring pipe of the ventilation sleeve support is in butt joint with the air outlet hole on each disc rotating shaft, and the air pump is started at the moment, so that air flow meeting the temperature and humidity requirements enters the disc rotating shafts, enters the ventilation sleeve through the air outlet holes and is blown out outwards through the ventilation air blowing holes in the air outlet vertical pipe.
10. The process for producing the high-nucleotide ultra-fresh soy sauce as claimed in claim 9, wherein the lifting feeding device comprises a pre-storage bin which is fixed on the upper top wall of the outer bin body, the lower part of the pre-storage bin is provided with a discharge hole, and the lower end of the discharge hole is connected with the feed end of the spiral feeder through a flexible telescopic conduit; the discharge end of the spiral feeder faces the upper part of the koji making disc; the spiral feeder is fixed on a sliding nut through a fixer, the sliding nut is sleeved on a sliding lead screw, two ends of the sliding lead screw are horizontally fixed on a lifting support through a lead screw mounting bearing seat, a lead screw driven gear is fixed at one end of the lead screw, which is far away from a bending disc, a lead screw driving motor is arranged on the lifting support, a lead screw driving gear is sleeved on a motor shaft of the lead screw driving motor, and the lead screw driving gear is meshed with the lead screw driven gear; when the screw rod driving motor is started to rotate forwards or reversely, the screw nut can drive the fixer and the screw feeder to be close to the inner periphery or the outer periphery of the koji making disc by driving the screw rod to rotate forwards or reversely;
one end of the lifting support far away from the koji making disc is connected with a wheeled lifter, one end of the lifting support near the koji making disc is connected with the lower end of a lifting cable, the upper end of the lifting cable is wound on an electric winding wheel, and the electric winding wheel is hoisted on the upper top wall of the outer bin body; the belt wheel type lifter and the electric winding wheel are started to drive the lifting support to move up and down, and then the discharge port of the spiral feeder is aligned to the koji making discs with different heights to carry out feeding operation.
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