EntranceThe use of cavitation water in the food industry. Method for obtaining fodder molasses
The phenomena of cavitation are known in hydrodynamics as phenomena that destroy the structures of hydraulic machines, ships, and pipelines. Cavitation can occur in a liquid when the flow is turbulent, as well as when the liquid is irradiated with an ultrasonic field excited by ultrasound emitters. These methods of obtaining a cavitation field have been used to solve technological problems in industry. These are the problems of dispersion of materials, mixing of immiscible liquids, emulsification. But due to the high cost of equipment and the strength characteristics of the emitters, these technologies are not widely used in Russian industry.
The proposed solution to these technological problems is based on continuous hydraulic machines to create a cavitation field in the fluid flow. Unlike traditional methods obtaining a cavitation field with the help of ultrasonic devices and hydrodynamic whistles, these hydraulic machines make it possible to obtain a cavitation field in any liquid, with different physical parameters and with given frequency characteristics. This expands the geography of application of these machines for their use in industrial technological processes. These machines, conventionally called "cavitators" by the developer, can be used in such industries as the food industry to obtain liquid food products(for example: mayonnaise, juices, vegetable oils, dairy products, feed additives, animal feed, etc.); as a chemical industry (production of paint and varnish products), obtaining fertilizers for agriculture; in the construction industry (for the enrichment of clay, improving the quality of concrete, obtaining new building materials from conventional composites).
Some studies have also been carried out on the cavitation effect of these machines when used as heat pumps. The production of thermal energy is based on the release of energy when the intermolecular bonds of the liquid are broken during its passage through the navigation field. Full-scale research in this matter can result in a new generation of heat units that will have autonomy and a wide range of applications for heating buildings and structures of small volume, remote from heating mains and even electric lines.
On the issue of energy, these machines were used to produce new types of fuel: artificial fuel oil, briquetted fuel with environmentally friendly binders from natural peat, as well as in technologies for the use of conventional fuels (oil, solar oil, fuel oil) to save 25% of the consumption of these fuels. 30% of existing expenses.
- The use of a cavitator for obtaining juices, ketchups from vegetables and fruits, berries, which contain small seeds that are difficult to separate during the manufacture of the product. The cavitator makes it possible to produce juices from such berries as raspberries, currants, sea buckthorn, processing berries without separating seeds, which are dispersed up to a particle size of 5 microns and are a foam component in products.
- The use of a cavitator in the technology of obtaining vegetable oils allows you to increase oil yield and equipment productivity. This technology makes it possible to obtain oil from any oil-containing plant structures, as well as to obtain foamy feed additives for farm animals.
- Technological line for the preparation of mayonnaise.
- Technological line for the production of oil and feed additives from spruce branches of coniferous trees.
- Cavitation plants make it possible to obtain new types of feed from peat and grain processing waste.
- From peat with the help of cavitators from vegetables and from grain crops, you can also get full-fledged fertilizers for agricultural producers, these are the so-called "humates".
II. Energy - Obtaining liquid fuel from waste coal production and peat. The fuel can serve as a substitute for fuel oil. (Peat-coal fuel).
- Technological line for the production of peat-sawdust briquettes and building materials.
- Production of sorbents for oil products.
- There are preliminary studies on the use of cavitators for the production of motor fuels and oils from crude oil without cracking directly on non-commercial wells.
- The use of cavitators for automonopoly space heating as a coolant heater of low power up to 100 kW.
III. Construction - The technology for obtaining a high-quality paint and varnish material is being tested in view of the fine dispersion of fillers and dyes.
- Technological line for the production of drying oil, dispersion and water-based paints.
- The use of cavitators for obtaining new building materials may be promising:
- concretes and mortars of increased strength;
- enrichment of clays for the production of bricks. - Cavitators can be used to clean metals and parts from rust, scale, etc.
- Cavitators can be used as mixers for normally immiscible components and obtaining homogeneous structures in the food and chemical industries.
IV. Other - A unit for generating steam using electricity has been developed. The steamer can be used for the production of feed, building materials, sterilization, etc.
- Wastewater treatment with fuel production from sedimentary materials. Purification of water from oil products.
The method relates to the production of animal feed. The method consists in moistening, grinding and enzymatic hydrolysis of grain, while the ratio of grain to water is 1:1, the water temperature is 35-40°C, and α-amylase 1.0-1.5 units/g of starch and xylanase are used as enzymes 1-2 units/g of cellulose. The method allows to obtain a product containing easily digestible carbohydrates. 1 tab.
At present, molasses obtained from sugar production waste is used in animal husbandry. This molasses, obtained by acid hydrolysis, contains 80% solids and has a high concentration of glucose.
The use of beet molasses as animal feed is well known. Due to the high calorie content of these products, their use in feed is constantly increasing. However, molasses is a viscous liquid and therefore difficult to handle. When making it into feed, it has to be heated. In addition, molasses contains very little nitrogen, phosphorus and calcium and does not meet the protein needs of farm animals.
Therefore, in the last 20 years, molasses obtained from grain or starch by enzymatic hydrolysis has been used in animal husbandry.
At present, the enzymatic hydrolysis of starch-containing materials is carried out with pre-treatment raw materials at a high pressure of 4-5 kgf/cm 2 for 120 min.
With such pretreatment of grain, swelling, gelatinization, destruction of starch grains and weakening of the bond between cellulose molecules, the transition of some cellulases and amylase to a soluble form occur, as a result of which the surface available for enzymes increases and the hydrolyzability of the material increases significantly.
The disadvantages of this method include high temperatures and duration of treatment, which lead to the destruction of xylose with the formation of furfural, hydroxymethylfurfural and the degradation of part of the sugars. There is also a method of preparing feed, for example, according to A.S. No. 707560, which involves moistening the grain in the presence of amylase, and then flattening, tempering and drying the finished product. With this method, only up to 20% of the original starch content is converted into dextrin and up to 8-10% into reducing sugars (such as maltose, glucose).
A similar method of processing grain for feed is proposed (A.S. No. 869745), which involves processing grain like A.S. 707560, but differs in that, after tempering, the flattened grain is additionally treated with the enzyme preparation glucamorin in an amount of 2.5-3.0% by weight of starch for 20-30 minutes. The percentage of reducing sugars in the product increases to 20.0-21.3%.
We offer quality New Product with easily digestible carbohydrates - wheat (rye) molasses obtained by enzymatic hydrolysis.
Feed molasses is a product of incomplete hydrolysis of starch and cellulose (hemicellulose and fiber). It contains glucose, maltose, tri- and tetrasaccharides and dextrins of various molecular weights, proteins and vitamins, minerals, i.e. everything that wheat, rye and barley are rich in.
Feed molasses can also be a flavoring additive, because. contains glucose, which is necessary when growing young farm animals.
Taste, sweetness, viscosity, hygroscopicity, osmotic pressure, fermentability of hydrolysates depend on the relative amounts of the first four groups of carbohydrates mentioned above and generally depend on the degree of hydrolysis of starch and cellulose.
For the hydrolysis of cellulose and starch, complex enzyme preparations were used: amylosubtilin G18X, celloviridin G18X, xylanase, glucavamorin G3X.
We also offer a new method for processing grain (rye, wheat) and obtaining fodder molasses using cavitation with the simultaneous action of an enzyme complex.
The grain processing method takes place in a special cavitator apparatus, which is a rotating container with a perforated drum, in which the cavitation process takes place, based on high-intensity hydrodynamic oscillations in a liquid medium, accompanied by 2 types of phenomena:
hydrodynamic
acoustic
with the formation of a large number of cavitation bubbles-caverns. In cavitation bubbles, a strong heating of gases and vapors occurs, which occurs as a result of their adiabatic compression during cavitation collapse of the bubbles. In cavitation bubbles, the power of acoustic oscillations of the liquid is concentrated and cavitating radiation changes the physicochemical properties of the substance located nearby (in this case, the substance is crushed to the molecular level).
Example 1: The grain is preliminarily coarsely ground in a feed crusher with a particle size of not more than 2-4 mm, then it is fractionally mixed with water supplied to the cavitator. The ratio of grain and water is 1:1 parts by weight, respectively. Water temperature 35-40°C. The residence time of a suspension of grain and water in the cavitator is no more than 2 seconds. The cavitator is connected to an apparatus in which pH and temperature are maintained by means of automatic control. The volume of the reaction mixture in the apparatus depends on the power of the cavitator and ranges from 0.5 to 5 m 3 .
After feeding half the amount of grain, a complex of enzymes is fed into the cavitator: - bacterial amylase 1.0-1.5 units/g of starch and xylanase - 1-2 units/g of cellulose.
During cavitation, the temperature of the reaction mass is maintained within 43-50°C and pH 6.2-6.4. The pH of the mixture is maintained with hydrochloric acid or soda ash. After 30-40 minutes of cavitation, the thinned fine suspension with a grain particle size of not more than 7 microns is heated to a wheat starch gelatinization temperature of 62-65°C and maintained for 30 minutes at this temperature without cavitation. Then the clustered mass is again introduced into the cavitation mode for 30-40 minutes. The cavitation process is terminated by the iodine sample, the product is sent for saccharification into a larger container with a stirrer. For further saccharification of the reaction mass, add glucavamorin G3X at the rate of 3 units/g of starch. The saccharification process is carried out at a temperature of 55-58°C and a pH of 5.5-6.0. 43-50°C and pH 6.2-6.4, and further saccharification of the resulting mixture is carried out with glucovamorin GZH at a rate of 3 units/g of starch at a temperature of 55-58°C and pH 5.5-6.0.
PROCESSING: TECHNOLOGIES AND EQUIPMENT
UDC 664:621.929.9 V.I. Lobanov,
V.V. Trushnikov
DEVELOPMENT OF A CONTINUOUS MIXER WITH SELF-CLEANING WORKING BODIES
In the sausage and meat-packing industries, after grinding the raw material, it is mixed with the ingredients of the recipes to obtain homogeneous systems. The need for this operation may also arise when mixing various components, for mixing raw materials to a certain consistency, in the process of preparing emulsions and solutions, to ensure a homogeneous state of the product for a certain time, in the case when it is necessary to intensify heat and mass transfer processes.
In the meat industry, the most widely used mechanical mixing is used as the main (in the production sausage products, stuffed canned food and semi-finished products) or related (in the production of salted and smoked meat products, food and technical fats, glue, gelatin, blood processing) operations.
Mixers, meat mixers, meat mixers, etc. are used for mixing. The first two groups of machines are classified as batch equipment. Mixers can be either continuous or intermittent.
Having considered the designs of domestic and foreign mixers, we came to the conclusion that they all have significant drawbacks - sticking of materials
rial on the working bodies in the mixing process (adhesion) and low productivity.
An attempt was made at the Department of MSSP to create a continuous minced meat mixer with self-cleaning working bodies (application for patent No. workshop of the company CONVICE) and large subsidiary farms, which is important for the current stage of the economic development of our country, when up to 60% of all livestock products on the market are provided by subsidiary farms.
The proposed mixer for viscous materials consists of a housing 1 (Fig. 1), made on a frame 2, in which working bodies 3 are installed, each of which consists of a shaft 4 with two working blades 5, made along the length of the working body along a helical line with an angle lifting within 0 ° 30 "-0 ° 50", while the screw of one working body is twisted clockwise, and the other - counterclockwise. The drive 6 of the working bodies 3 is designed so that the bodies are synchronized with each other. The design is equipped with a loading tray 7 and an unloading tray 8.
Rice. 1. Scheme of the proposed mixer
Minced meat after grinding in a meat grinder enters the loading tray 8 and falls under specially designed working bodies 3 rotating towards each other with the same angular velocities (along a crossed trajectory), which self-clean during operation due to a certain shape of their cross section. In the mixer, the minced meat is actively mixed by working bodies 3 with blades 5 made along a helical line, is ground due to the gap between the shafts 4 and moves along the working bodies to the unloading tray 7. The translational movement of the material ensures
a helical line formed by a uniform displacement of the section of the working body along its entire length by a certain angle a. The rotation of the working bodies is carried out by means of the drive 6.
The proposed shape of the working bodies was taken from the German patent No. 1199737, where two blades rotate at constant speeds towards each other along intersecting trajectories. To build the profile of the working bodies of the proposed mixer, we use the scheme (Fig. 2), where the center distance is selected so that the working bodies engage at an angle of 45°.
Rice. 2. Scheme for building a profile of working bodies
Based on the above proposition, we can write
R+r = R-42 , (1)
where R is the radius of the working body, m; r is the radius of the shaft of the working body, m.
In order to define the SL curve, we need to know how the angle b and the distance OK change depending on the angle a. Thus, we will set the curve in the polar coordinate system with the angle β and the radius of curvature p = OK when changing the parent angle а in the range from 45 to 0°. So, let's connect the angle in and a.
From triangle NPK:
NK \u003d R - sina; (2)
ON \u003d r42 - NP \u003d R (4l - cos a) (h)
From triangle ONK:
t in NK R sin a sin a
ON R (J2 - cos a) (42 - cos a)
Consequently,
We connect the radius of curvature p angles in and a:
from triangle ONK:
on = r(V2 - cos a)
OK cos to cos to (6)
Thus, the curve in the polar coordinate system is given by the following system of equations:
r (V2 - cos a)
Considering that the cold air supply ducts are installed discretely, the material drying process is repeated several times and intensified, which is the achievement of the set technical result.
Analysis of drum dryers
Ho/yudiO air
Rice. The proposed scheme of the drum dryer
The proposed dryer (Fig.) consists of a housing 1, inside which a lifting-blade nozzle 3 is installed, and a fixed casing 2 is fixed on the console of the housing 1, on which a branch pipe 4 is installed for supplying hot air. Longitudinally-radial windows 5 are made along the circumference of the branch pipe 4, and a branch pipe for loading material 6, an unloading chamber 7 with pipes for removing hot air 8 and outputting material 9 are installed from the ends of the housing 1. Several boxes 10 are installed in series on the housing 1 under the fixed casing 2 with an inlet pipe 11 and outlet pipes 12 for supplying cold air. The lifting blade nozzle 3 has a special drive.
The drum dryer works as follows. The source material through the pipe 6 enters the housing 1. When the lifting blade nozzle 3 rotates, its blades capture the material and lift it. Falling off the blades, the material forms longitudinal jets that penetrate the heat fluxes that have passed through the nozzle 4 and the longitudinal-radial windows 5. Moisture is removed from the outer surface of the material. Then the material moves along the body 1 to the exit due to the inclination of the drum and the speed of the heat flow. At the moment the material moves along the inner surface of the body, it enters the fastening area of the boxes 10, through which cold air is supplied. Cold air is supplied
through the inlet pipes 11, cools locally part of the body 1 and is discharged through the pipes 12. In contact with the cooled part of the body, the surface of the material is cooled, while its middle remains heated. The moisture in the material will tend from the center to the periphery. Then, when passing through the casing zone, the material will again be on the hot surface of the casing, and the coolant air flow will remove moisture from the surface of the material. This process is repeated several times (depending on the number of boxes 10). Then the bulk material enters the discharge chamber 7, where it is separated from the coolant and removed from the drum dryer.
An experimental installation for drying grain and other bulk materials is currently being manufactured.
Bibliographic list
1. Energy-saving grain drying / N.I. Malin. Moscow: Kolos, 2004. 240 p.
2. Grain drying and grain dryers / A.P. Gerzhoy, V.F. Samochetov. 3rd ed. Moscow: Kolos, 1958. 255 p.
3. Wheat and evaluation of its quality / ed. and with preface. Dr. Biol. Sciences prof. N.P. Kuzmina and hon. worker of science of the RSFSR prof. L.N. Lyubarsky; per. from English. cand. biol. Sciences K.M. Selivanova and I.N. Silver. M.: KolosS, 1967. 496 p.
UDC 664.7 V.V. Gorshkov,
A.S. Pokutnev
EFFICIENCY OF GRAIN TREATMENT BY HYDRODYNAMIC CAVITATION IN BREAD PRODUCTION
Introduction
Currently, the issue of expanding the range remains relevant. bakery products. Of paramount importance is the increase in the taste and nutritional properties of bread while maintaining its low price. This is achieved by improving the technology of baking by changing the parameters of grain preparation, the degree and method of grinding it, the variety of recipes due to the inclusion of other grains and other components during kneading, improving the technology of loosening the dough and the conditions for baking bread.
One of the possible options for upgrading the grain grinding stage is the use of cavitation grinding mills. This eliminates the need for multiple runs of grain through grinders with subsequent separation into fractions. At the same time, due to the fact that wet grinding takes place in the cavitation mill, there is no harmful dust factor in the grain preparation shop. As a result, a homogenized suspension of crushed grain is fed to the baking.
Research methodology
The aim of the research was to study the possibility of obtaining grain bread based on a grain suspension obtained in the Petrakov disperser.
Chemical analysis of grain and suspension was carried out in the laboratory of the Altai State Agrarian University in terms of moisture, gluten and vitreousness. The quality of the resulting bread was determined at the Testing Center for Food Products and Raw Materials of the Altai State Technical University according to organoleptic indicators - shape, surface, crumb, porosity, smell, taste, color, and physicochemical - humidity, acidity.
slotting, foreign inclusions, signs of illness and mold, a crunch from mineral impurities. According to the results of the research, the calculation of the economic efficiency of production was carried out wheat bread based on grain suspension obtained by cavitation dispersion.
Research results
For the experiment, it was planned to use whole unshelled wheat grain and drinking water in a ratio of 1:2.
For research, a prototype cavitation heat generator of a rotational type with an electric motor power of 11 kW, a fluid flow rate of 0.15-0.5 l/s and a pressure of 0.2-0.4 MPa was used.
Dough was obtained from the grain suspension by adding 35% flour. Kneading was carried out by hand, until a homogeneous dough consistency.
The fermentation of the dough lasted two hours with a double punching, which was carried out manually. The first stretch was made after 40 minutes. after the start of fermentation, the second - after another 40 minutes. (1 hour 20 minutes after the start of fermentation). Cutting was carried out mechanically in standard forms. The proofing time was 50 min. at a temperature of 40°C. Duration of baking - 25 min. at a temperature of 240°C.
To set up the experiment, wheat with weak baking properties was taken. Grain with such characteristics was not chosen by chance. This made it possible to evaluate the minimum possible quality of raw materials in the production of bread and reduce the cost of it to a minimum. At the same time, the baking properties of the dough are leveled by adding flour to it. Indicators, character-
teriziruyuschie quality of the original grain, are shown in table 1.
As evidenced by the data presented in Table 1, the analyzed grain samples had average quality indicators: in terms of protein and gluten they corresponded to weak varieties of wheat, and in terms of vitreousness - to strong ones. According to technical properties, medium grades are suitable for obtaining baking flour without the addition of improvers.
A recipe was developed for making bread. The difference between the recipe is that it is carried out not for 100 kg of flour, but for 100 kg of the mixture. This is due to the fact that the basis of the dough is not flour, but its mixture with grain suspension. The suspension was obtained from whole grain without the use of flour. The mixture included 65% grain suspension and 35% wheat flour of the 1st grade. For 100 kg of the mixture, 0.9 kg of food table salt "Extra" was added and
0.3 kg of yeast.
The organoleptic analysis carried out after baking showed that the finished product had a shape - a characteristic
for molded, it corresponded to the bread form in which baking was made; surface - without large cracks and explosions; crumb - baked and elastic; porosity - developed without voids and seals; taste and smell - characteristic of this type of product; Brown colour.
The assessment of physico-chemical parameters is given in table 2.
The results given in table 2 show that according to the physical and chemical parameters the resulting bread corresponds to: in terms of moisture - Darnitsky, in acidity and porosity - white bread 1st grade.
The economic effect of the introduction of technology was assessed by reducing the cost of bread and was determined taking into account the costs of the dispersion process and savings on raw materials. For comparison, bread was taken from wheat flour first grade. Economic efficiency data for the production of wheat bread based on a grain suspension obtained by cavitation dispersion are presented in Table 3.
Table 1
Wheat grain quality assessment, %
Parameter Experimental sample Weak varieties of wheat Strong varieties of wheat
Humidity 14.23 - -
Protein, % 11.49 9-12 14
Gluten 20.59 Up to 20 28
Vitreousness 59 Up to 40 40-60
table 2
Physical and chemical indicators of grain bread
Indicator Test result GOST 26983-86 "Darnitsa bread" GOST 26984-86 "Stolichny bread" GOST 26987-86 "White bread from wheat flour of the 1st grade"
Humidity, % no more than 48.0±0.71 48.5 47 45
Acidity, deg. no more than 2.0±0.36 8 8 3
Porosity, % not less than 68.0±1.0 59 65 68
Foreign inclusions Not detected - - -
Signs of disease and mold Not detected - - -
Crunch from mineral impurities Not felt - - -
Table 3
Economic effect of bread production per 1 ton
Production Cost Items Product
bread from flour of the 1st grade (basic version) grain bread (design version)
1. General production and general business expenses, rub. 7570 7809
2. Raw materials, rub. 6713 4335
3. Total costs for the production of 1 ton of bread, rub. 14283 12114
4. Economic effect, rub. - 2139
Savings occur due to a decrease in the cost of raw materials due to the replacement of part of the flour with a grain suspension. From table 3 it follows that the economic effect per 1 ton finished products(bread) will be 2139 rubles.
The data obtained make it possible to recommend the use of hydrodynamic cavitation at the grinding stage in the production of wheat bread based on grain suspension, which will make it possible to refuse from repeated passing of grain through grinders, followed by sieving into fractions, to eliminate losses from the formation of mill dust and obtain an economic effect of 2139 rubles / t.
Bibliographic list
1. GOST 5667-65. Bread and bakery products. Acceptance rules, sampling methods, methods for determining organoleptic indicators and mass of products.
2. Romanov A.S. Examination of bread and bakery products. Quality and safety: study guide. allowance / A.S. Romanov, N.I. Davydenko, L.N. Shatnyuk, I.V. Matveeva, V.M. Po-znyakovsky; under. total ed. V.M. Poznyakovsky. Novosibirsk: Sib. univ. publishing house, 2005. 278 p.
3. GOST 26983-86. Bread Darnitsky. Introduction 12/01/86 to 01/01/92. M.: Publishing house of standards, 1986. 6 p.
4. GOST 26987-86. Bread white from wheat flour of the highest, first and second grades. Specifications.
480 rub. | 150 UAH | $7.5 ", MOUSEOFF, FGCOLOR, "#FFFFCC",BGCOLOR, "#393939");" onMouseOut="return nd();"> Thesis - 480 rubles, shipping 10 minutes 24 hours a day, seven days a week and holidays
Gorbyleva Ekaterina Viktorovna Study of the qualitative characteristics of grain suspensions and their use in the production of food products: dissertation ... candidate of technical sciences: 05.18.15 / Gorbyleva Ekaterina Viktorovna; [Place of protection: Kemer. technol. in-t food industry].- Kemerovo, 2008.- 175 p.: ill. RSL OD, 61 09-5/1247
Introduction
Chapter 1 Literature Review 9
1.1 Analysis existing species and grinding media 9
1.2. Theory of cavitation 17
1.2.1 Definition of the cavitation phenomenon 17
1.2.2 Types of cavitation 19
1.2.3 Occurrence of cavitation 21
1.2.4 Practical application of cavitation 23
1.3 Characteristics of the wheat grain used in the work 26
1.4 Ways to increase nutritional value grain food 30
1.4.1 Milk as a means of increasing the nutritional value of grain processing products 30
1.4.2 Grain soaking as a way to increase biological and nutritional value food 34
1.5 Conclusion of the literature review 36
Chapter 2. Objects and methods of research 39
2.1. Objects of study 39
2.2 Research methods 40
2.3 Statistical processing of experimental data 45
Chapter 3 Research Results and Discussion 47
3.1 Determining how to prepare grain for cavitation grinding 47
3.2 Obtaining grain suspensions. Determination of initial temperature, sampling intervals 49
3.3 Organoleptic evaluation of the resulting suspensions 54
3.4 Temperature change of grain suspensions during cavitation 54
3.5 Studying the effect of cavitation treatment on acidity 58
3.6 Investigation of the carbohydrate complex 59
3.7 Determination of protein content 64
3.8 Determination of lipid content 67
3.9 Study of the effect of cavitation treatment on the content of vitamin E69
3.10 Study of the effect of cavitation treatment on the content of macronutrients 70
3.11 Study of the effect of cavitation treatment on the microflora of grain suspensions 72
3.12 Study of the stability of the grain product during storage 75
3.13 Preliminary determination of the optimal modes of cavitation grain grinding 82
3.14 Assessing the safety performance of grain suspensions 83
Chapter 4 Examples of possible practical use of grain suspensions 87
4.1 Use of water-grain suspension in bread baking 88
4.1.1 Development of a recipe for grain bread 88
4.1.2 Results of laboratory baking. Organoleptic and physico-chemical evaluation of finished products 91
4.1.3 Production verification of bread production technology using water-grain suspension 95
4.1.4. Economic efficiency 98
4.1.4.1 Description of the enterprise 98
4.1.4.2 Investment plan 98
4.1.4.3 Production plan 101
4.1.4.4 Financial plan 109
4.2 Using a milk-grain suspension for making pancakes and pancakes 112
4.2.1 Development of recipes for cereal pancakes and pancakes 112
4.2.2 Results of laboratory baking. Organoleptic and physico-chemical evaluation 113
4.2.3 Industrial Approbation 119
4.2.4 Economic efficiency 122
Findings 125
List of used literature 127
Applications 146
Introduction to work
The urgency of the problem.
Problem healthy eating human being is one of the most important tasks of our time. Grain processing products meet the requirements of good nutrition as well as possible. In this regard, there is a need to create a wide range of new grain products that allow the rational use of all valuable natural components while significantly reducing production costs.
That is why in the practice of grain processing production, considerable attention is paid to the introduction of progressive methods and high-performance equipment in order to increase the efficiency of grain use during its processing.
One of the promising technologies that provides a significant intensification of production processes and opens up wide opportunities for expanding the range of grain, bakery and other types of products is the cavitation processing of raw materials, which makes it possible to obtain grain suspensions - products with a certain set of physicochemical and organoleptic properties.
The proposed technology is based on a physical phenomenon - cavitation, which is generated either by ultrasound (acoustic) or hydropulses (rotational). Acoustic cavitation units are already being used in various branches of the food industry. To date, the greatest practical results in this direction have been achieved by Doctor of Technical Sciences. S.D.Shestakov.
However, recently, for the dispersion of raw materials, a more powerful disintegrating agent is being used - hydropulse rotary generators, which have shown high efficiency in laboratory tests.
In the general case, the dispersion of solid particles in hydropulse rotary generators is accompanied by hydropercussion action,
cavitation erosion and abrasion in the annular gap between the rotor and the stator. However, the mechanism of the complex effect of hydropulse cavitation on food raw materials has not been studied enough.
Based on the foregoing, it is relevant to study the effect of hydropulse cavitation treatment on the organoleptic and physico-chemical properties of grain products.
Target and research objectives.
The purpose of this research was to study the qualitative characteristics of grain suspensions and their use in food production.
To achieve this goal, it was necessary to solve the following tasks:
determine the initial temperature, the ratio of solid and liquid components before cavitation grinding and the maximum possible duration of hydropulse cavitation treatment of wheat grain;
to investigate the effect of the duration of hydropulse cavitation grinding on the organoleptic and physico-chemical indicators of the quality of grain suspensions;
to study the microbiological indicators of grain suspensions;
determine the storage capacity of grain suspensions;
evaluate the safety indicators of grain suspensions;
develop recipes and technologies for food products using grain suspensions. Give a commodity assessment of finished products;
on the basis of all the above studies, to determine the optimal parameters of hydropulse cavitation treatment of wheat grain;
conduct pilot testing of a new grain product and evaluate the economic efficiency of the proposed technologies.
Scientific novelty.
Scientifically substantiated and experimentally confirmed the feasibility of hydropulse cavitation grinding of wheat grain in order to obtain grain suspensions, as a semi-finished product, in the production of food products.
The influence of the duration of the hydropulse
cavitation effect on the physicochemical and organoleptic characteristics of wheat grain processing products.
For the first time, the influence of hydropulse cavitation treatment on the microflora of processed grain raw materials was revealed.
An assessment of the safety indicators of grain suspensions obtained by the method of hydropulse cavitation grinding of grain was carried out.
The optimal parameters for obtaining a semi-finished grain product for baking were determined by the method of hydropulse cavitation grinding of wheat grain.
For the first time, the possibility of using a suspension of germinated wheat grain obtained by hydropulse cavitation grinding in the production of grain bread is shown.
For the first time, a technology has been developed for the preparation of grain pancakes and pancakes based on a milk-grain suspension obtained by hydropulse cavitation treatment of grain with milk.
The practical significance of the work.
On the basis of the conducted research, practical advice on obtaining grain suspensions by the method of hydropulse cavitation grinding and their storage.
Examples of the possible practical use of grain suspensions obtained by hydropulse cavitation grinding for the production of various bakery products are shown: a suspension of sprouted wheat grain for the production of grain bread, a milk-grain suspension for the preparation of grain pancakes and pancakes.
The developed method for the production of bread has successfully passed the production test in the bakery of PE "Toropchina N.M."; method of making grain pancakes - in the dining room of AltSTU "Diet +".
The expected economic effect from the introduction of grain bread will be 155,450 rubles. in year. The expected economic effect from the introduction of grain pancakes is 8505 rubles. in year.
A draft normative documentation has been developed for grain bread.
Approbation of work. The results of the work were reported at the 62nd scientific and technical conference of students, graduate students and young scientists "Horizons of Education" in 2004, at the 64th scientific and technical conference of students, graduate students and young scientists "Horizons of Education" in 2006. There are 10 publications, including 3 reports at conferences, 7 articles.
Structure and scope of work. The dissertation work consists of an introduction, a review of the literature, a description of the objects and methods of research, the results of the discussion and their analysis, a description of examples of the possible practical use of grain suspensions in baking, conclusions, a bibliographic list of 222 items, including 5 foreign ones, and 6 appendices. The work is presented on 145 pages of typewritten test, contains 23 figures and 40 tables.
Milk as a means of increasing the nutritional value of grain processing products
In world practice, work on the creation of bakery products, characterized by a high content of biologically active substances, is becoming more widespread. In the theory and practice of baking, two directions have been identified to increase the biological value of food products from grain.
One of these areas is the enrichment of products with raw materials containing a large number of protein, minerals, vitamins. It is realized through the creation of bread enriched with dairy products, soy concentrates, fishmeal, vitamins, etc.
The second direction is the use of all the potentialities inherent in nature in grain, since during varietal grinding a significant part useful substances grain is lost.
Milk and products of its processing are valuable protein and sugar-containing raw materials. In the process of making cream from milk, skimmed milk is formed as a result of separation. A by-product of the production of butter from cream is buttermilk. In the production of cheese, cottage cheese and casein, whey is formed. All listed products can be used in baking both in their natural form and after their special processing.
One of the most deficient components in the diet is calcium. Bread is a limited source of calcium. In this regard, dairy products are used to increase its calcium content.
Milk is a complex polydisperse system. The dispersed phases of milk, which make up 11 ... 15%, are in the ion-molecular (mineral salts, lactose), colloid (proteins, calcium phosphate) and coarse (fat) state. The dispersion medium is water (85...89%)). Approximate content of some components in cow's milk presented in table 1.1.
Chemical composition milk is unstable. It depends on the period of lactation of animals, breed of livestock, feeding conditions and other factors. The amount and composition of fat undergoes the greatest changes. During the period of mass calving in cows (March-April), milk has a reduced content of fat and protein, and in October-November - the maximum.
Fat in the form of balls with a diameter of 1 to 20 microns (the main amount - with a diameter of 2 ... 3 microns) forms an emulsion in uncooled milk, and a dispersion with partially hardened fat in cooled milk. Milk fat is represented mainly by mixed triglycerides, of which there are more than 3000. Triglycerides are formed by residues of more than 150 saturated and unsaturated fatty acids. Milk fat is accompanied by fat-like substances: phospholipids and sterols. Phospholipids are esters glycerin, high molecular weight fatty acids and phosphoric acid. Unlike triglycerides, they do not contain low molecular weight saturated fatty acids, but polyunsaturated acids predominate. The most common in milk are lecithin and cephalin.
Milk proteins (3.05...3.85%) are heterogeneous in composition, content, physicochemical properties and biological value. There are two groups of proteins in milk different properties: casein and whey proteins. The first group, when milk is acidified to pH 4.6 at 20C, precipitates, the other - under the same conditions remains in the whey.
Casein, which accounts for 78 to 85% of the total protein content in milk, is in the form of colloidal particles, or micelles; whey proteins are present in milk in a dissolved state, their amount is from 15 to 22% (approximately 12% albumin and 6% globulin). Casein fractions and whey proteins differ in molecular weight, amino acid content, isoelectric point (IEP), composition and structure features.
The elementary composition of milk proteins is as follows (%): carbon - 52...53; hydrogen - 7, oxygen - 23, nitrogen - 15.4 ... 15.8, sulfur - 0.7 ... 1.7; casein also contains 0.8% phosphorus.
Milk carbohydrates are represented by milk sugar (lactose), a disaccharide consisting of glucose and galactose molecules, as well as simple sugars(glucose, galactose), phosphate esters of glucose, galactose, fructose.
Milk sugar is contained in milk in dissolved form in a- and jB-forms, and the “-form is characterized by less solubility than /?-form. Both forms can change from one to the other. Milk sugar is about five times less sweet than sucrose, but it is not inferior to the latter in terms of nutritional value and is almost completely absorbed by the body.
Minerals are represented in milk by salts of organic and inorganic acids. Calcium salts predominate (content 100...140 mg%) and phosphorus (95...105 mg%). In addition, milk contains trace elements: manganese, copper, cobalt, iodine, zinc, tin, molybdenum, vanadium, silver, etc. The content of vitamins in milk depends on the breed of animal breed, lactation period and other factors.
Statistical processing of experimental data
To obtain a mathematical model of the process under study, which takes into account the change in several factors affecting the process, methods of mathematical planning of the experiment were used.
To implement one of the directions, it was necessary to first germinate a grain of wheat. Therefore, initially in the course of these studies, the optimal method for preparing wheat grain was determined. At the same time, the following requirements were imposed on this process: the method of grain preparation should not have a negative impact on its nutritional and biological value; the method should be simple and not particularly time-consuming, its implementation should not require complex expensive equipment and additional personnel, so that, if necessary, any enterprise can carry out germination with minimal re-equipment and at minimal financial costs.
As shown by the analysis of literature data, traditionally for dispersion in order to obtain a grain mass, the grain is subjected to soaking for 6-48 hours, which is accompanied by the initial germination of the grain. The main direction of biochemical processes in the germinating grain consists in the intensive hydrolysis of macromolecular compounds deposited in the endosperm and their transfer to a soluble state, available for feeding into the developing germ.
However, the formation of nutrients that increase the nutritional value of germinated grain does not occur immediately. The initial stage of germination (hidden germination, or fermentation) is accompanied by a decrease in low molecular weight substances consumed by the growing embryo. So, when soaking for 12 hours, the content of sugars in the grain is reduced by almost 1.5 times, and the content of dextrins by about 1.7 times. The content of vitamin C at the initial stages of germination is reduced by almost 1.5 times. But experiments show that after 12 hours of grain soaking, the content of sugars and dextrins in the studied samples began to grow.
Consequently, the next stage of grain germination is accompanied by the accumulation of low molecular weight substances, including vitamins, due to the growth of enzymatic activity, leading to the hydrolysis of high molecular weight compounds. However, too long soaking (more than a day) leads to intensive development of bacterial microflora, mold, and the appearance of a sharp sour smell. Therefore, after analyzing all the information, the following grain preparation parameters were adopted: soaking time - 24 hours; key water temperature - 25C.
Such soaking ensures the initial germination of the grain with the formation of nutrients and does not significantly increase the microflora of the grain. 3.2 Obtaining grain suspensions. Determination of initial temperature, sampling intervals
The primary task of experimental studies was to determine the possible duration of cavitation treatment of grain and to identify sampling intervals for further laboratory studies. To solve this problem, trial experiments were carried out to obtain grain suspensions.
Cavitation treatment of grain was carried out on the basis of the LLC "Technocomplex" enterprise, located at the address Barnaul, Karaganda street, house 6.
At the moment when the rotor hole is blocked by the side walls of the stator, there is a sharp increase in pressure along the entire length of the cylindrical holes of the rotor (direct water hammer), which enhances the “collapse” of cavitation bubbles in zone A.
In zone B, constant overpressure helps the intensive "collapse" of cavitation bubbles. As already discussed in Section 1.1, the closure of cavitation bubbles contributes to grain destruction.
The grinding process was carried out in recirculation mode. The ratio of solid and liquid parts was 1:2. An increase in the solid fraction in the mixture is impossible due to the technical features of the cavitation unit. An increase in the liquid phase is inappropriate from the point of view of the nutritional value of the resulting product.
For the experiments, ordinary cold tap water was used, the temperature of which was 20C. Changing the initial temperature is impractical, since it requires additional material investments and time spent on heating or cooling, which will significantly lengthen the technological process and increase the cost of the final product. Experimental studies have shown that the possible duration of cavitation treatment of wheat grain is 5 minutes for water-grain and milk-grain suspensions and 5.5 minutes for a suspension of germinated wheat grain. At the same time, the final temperature of grain suspensions reached 60-65C.
Further processing of the grain is impossible, since during cavitation grinding the viscosity of the product increases significantly, which by the end of the process acquires the consistency of dough, as a result of which the suction pipe of the installation is not able to draw in the processed mixture and the process stops.
Study of the effect of cavitation treatment on acidity
Change in the acidity of grain suspensions during cavitation Analyzing the results, we can conclude that as a result of cavitation, the acidity of products during the first minute of cavitation treatment increases sharply compared to the initial value by 2 - 2.5 times. But further in the course of the process it decreases to 1.6 degrees for a water-grain suspension, to 2.1 degrees for a suspension from germinated wheat grain and to 2.4 degrees for a milk-grain suspension.
This can be explained by the fact that the occurrence of cavitation is accompanied by the generation of free radicals OH-, NCb-, N-, as well as the end products of their recombination H2C 2, HNCb, HN03, which acidify the medium. But since, as a result of pulsation and collapse of one cavitation bubble, approximately 310 pairs of radicals, mainly OH-, are formed, and the hydrogen formed during the process partially evaporates, as the process proceeds, the number of hydroxyl groups increases, which leads to alkalization of the medium and acidity decreases.
Carbohydrates are the main energy resources concentrated in the cells of the endosperm of the caryopsis. According to the amount of easily digestible carbohydrates, products made from grain are in first place among other human foods. The value of carbohydrates in technological process grain processing and, especially, when using grain in the process of dough preparation is very large.
In this work, we studied the effect of hydropulse cavitation treatment on the change in the carbohydrate complex of wheat grain. To assess the ongoing changes, the content of starch, dextrins, sucrose and reducing sugars was determined.
Starch plays the most important role in the process of kneading dough and baking bread. The results of the research presented in Figure 3.5 indicate that hydropulse cavitation treatment of grain contributes to the destruction of the starch contained in it.
The maximum reduction in the amount of starch is observed in a suspension of germinated wheat grains. This is due to the fact that as a result of germination, the action of grain enzymes sharply increases, the process of dissolution of complex substances deposited in the endosperm begins with the formation of simpler ones. Accordingly, starch is converted into dextrins and maltose. Therefore, even before the germinated grain was supplied for cavitation treatment, the starch content in it was lower by 6-8% compared to the original wheat grain, and mass fraction dextrins - higher.
The content of sucrose in the grain is negligible, and glucose and fructose in the grain, normally matured and stored in conditions of low humidity, is negligible. It increases significantly only during germination. Therefore, a significant increase in sugars in suspensions during the cavitation process was especially important. The results of these changes are presented in Figures 3.7 and 3.8. 1.2 and 3 4 5
Changes in the content of sucrose Especially significantly during the cavitation process, the content of reducing sugars increased: 5-7 times compared with the initial values, while the amount of sucrose increased only 1.2-1.5 times. Firstly, this is due to the fact that reducing sugars are the end product of starch hydrolysis. Secondly, in parallel with the breakdown of starch, when heated in the presence of a small amount food acids hydrolysis of sucrose itself occurs with the formation of reducing sugars (glucose, fructose).
The main part of grain sugars is raffinose trisaccharide, glucodifructose and glucofructans, which are easily hydrolyzed oligosaccharides of various molecular weights. Apparently, it was they who, during hydrolysis during cavitation, ensured an increase in the amount of sucrose.
The increased content of sugars in the milk-grain suspension compared to the water-grain products, apparently, was influenced by the sugars contained in the milk itself.
Thus, cavitation treatment of wheat grain causes significant positive changes in the structure of its carbohydrate complex. The significance of this fact is due to the fact that with traditional grain dispersion, the degree of grain grinding does not provide the proper intensity of sugar and gas formation during dough fermentation. To improve the quality of grain dough, it is proposed to add sugar, phosphatide concentrates, surfactants (lecithin, fat sugar). It can be assumed that the use of this technology in baking will allow for intensive fermentation of the dough without adding additional additives, but only at the expense of grain's own sugars. 3.7 Determination of protein content
As you know, about 25-30% of the total need of the human body for proteins is covered by grain processing products. At the same time, it is the protein fractions that determine the technological properties of grain processing products, the ability to produce high-quality bread and pasta. It is quite clear, therefore, that the study of grain proteins in the process of cavitation is one of the most important tasks.
Studies on the effect of acoustic cavitation treatment on the content of total protein, conducted by S.D. Shestakov, indicate its increase. According to his theory, when cavitation-activated water interacts with a crushed mass containing animal or vegetable protein, an intense reaction of its hydration occurs - the combination of water molecules with a biopolymer, the termination of its independent existence and its transformation into a part of this protein. According to Academician Vernadsky V.I. water bound in this way becomes an integral part of proteins, that is, it naturally increases their mass, since it combines with them due to the action of mechanisms similar to those that take place in living nature in the process of their synthesis.
Since studies on the effect of hydropulse cavitation on the protein content in grain suspensions have not been previously carried out, it was necessary to determine the degree of this effect. To do this, according to the standard method, the protein content in the selected samples of the grain product was determined. The results of the determinations are presented in Figure 3.9.
Production verification of bread production technology using water-grain suspension
The results of complex studies on the use of a water-grain suspension from germinated wheat grain as a recipe component of bread showed that its use makes it possible to obtain bakery products with high nutritional value, with good organoleptic and physico-chemical parameters.
Production tests of the proposed technology were carried out in the bakery of PE "Toropchina N.M." (Annex 4)
Assessment of organoleptic and physico-chemical parameters ready bread presented in Table 4.5 were carried out according to the standard methods given in Chapter 2.
On the basis of the existing bakery, PE "Toropchina N.M.", located at the address Altai Territory, Pervomaisky District, with. Logovskoe, st. Titova, house 6a, the production of grain bread based on a water-grain suspension is being organized.
The bakery produces bread from wheat flour of the first grade, sliced loaves, and bakery trifles. The productivity of the bakery is 900 kg / day of bakery products. The area of this bakery allows you to place a line for the production of grain bread. Raw materials - flour are supplied by Melnitsa LLC, located in the village of Sorochi Log, grain - SEC "Bugrov and Ananyin".
Grain bread will be sold in the bakery shop and in a number of shops located nearby. There are no significant competitors to grain bread, as there are no enterprises producing such products.
Bakery PE "Toropchina N.M." during its work compensated for its initial cost. The residual value is 270 thousand rubles. The production of grain bread accounts for one sixth of the bakery's output. Thus, one sixth of the cost of the building falls on the line for the production of grain bread. This is 45 thousand rubles. For the production of grain bread based on a water-grain suspension, you must purchase the following technological equipment: cavitation plant for grinding organic materials (Petrakov disperser), Binatone MGR-900 disperser, locking bath. The rest of the equipment is at the enterprise and can be used in the production of grain bread.
Depreciation is calculated in accordance with the useful life of an item of fixed assets. Buildings and structures belong to depreciation group 6 with a useful life of 10 to 15 years, since the building is not new. The useful life of the building is 12 years. The equipment belongs to the 5th depreciation group with a useful life of 7 to 10 years.
For the preparation of grain pancakes and pancakes, it was proposed to replace milk and flour with a milk-grain suspension. The calculation of the recipe of grain products was based on the amount of milk 1040 g for pancakes and 481 g for pancakes. Since the cavitation treatment of wheat grain with milk is carried out in a ratio of 1: 2, the grains were taken half as much, that is, 520 g for pancakes and 240 g for pancakes. The rest of the raw materials were taken in the same amount as in the original recipe. However, the humidity of the dough for pancakes and pancakes should be 65-75%. Therefore, if necessary, it is possible to add a small amount of flour to obtain a dough of optimal consistency. The amount of additive was calculated based on the moisture content of the raw material. Thus, the recipe for cereal pancakes and pancakes is as follows.
Suspension, yeast and sugar were dosed onto the dough, the dough was kneaded and put in a thermostat for 90 minutes at a temperature of 32 C for fermentation. After the fermentation time of the dough, all the remaining raw materials were added to it according to the recipe and the dough was kneaded.
Next, pancakes and fritters were baked. Fritters and pancakes were baked on a laboratory stove, in a frying pan at an average temperature of 270 C. The baking time for one pancake averaged 1.5 minutes, the baking time for one pancake was 3 minutes.
As a result of baking, we found that it is impossible to make pancakes from the last suspension. When pouring the dough on these suspensions into the pan, it foams, spreads, sticks, and is not removed from the pan.