欧李果实加工利用及其标准体系构建
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摘要
本文在分析欧李果实的营养成分、加工适宜性、加工利用现状及存在问题的基础上,从加工专业的角度提出欧李果实加工利用的思路与策略,按照既定的思路和策略,攻克了欧李仁综合利用的关键技术,实现了欧李仁中欧李仁油、苦杏仁苷和欧李仁蛋白的全利用,对欧李加工标准体系展开了研究,确定了欧李加工标准体系框架图、构建了欧李加工标准体系。此外,本文还概述了包括功能栗仁加工、板栗粉低碳节能工艺开发、板栗酒加工产业化示范和超临界CO2制备辣椒红色素的酶法脱辣技术在内的作者在博士后工作期间的其他研究成果。
     本文的主要结论是:
     1.欧李果实加工利用应着力抓好如下几个方面的工作:(1)开展欧李品质评价技术的研究,高起点规划欧李产业布局。针对药用、制汁、鲜食、制脯和生态用等产品或用途,构建品质评价模型和评价标准,进行不同欧李品种(系)的不同加工或用途的适宜性评价,筛选专用品种。(2)开展欧李贮运保鲜技术研究,研发适合不同规模、不同用户的贮运保鲜技术。系统研究欧李的采后生理病理,明确采收成熟度、采收方法、预冷方式、包装形式、防腐保鲜处理、贮运环境条件等对贮藏生理、贮藏期限和贮藏品质的影响,在此基础上集成开发冷藏、气调及简易气调贮藏、自发气调贮藏、冰温保鲜、冷链物流以及超市配送等技术。(3)研发适于欧李加工的特色技术与产品,坚持精深加工与综合利用相结合。以最大程度保留钙质为原则,改进现有果肉加工产品,或开发新的产品花色品种;通盘考虑果肉精深加工与综合利用的技术路线,产品研发过程中要坚持精深加工与综合利用相结合;欧李仁加工要实现苦杏仁苷、欧李仁油和欧李仁蛋白的全利用,同时开发三种成分的深度加工产品;开发适于不同用途的欧李核壳粉、核壳活性炭等核壳加工产品。(4)明确欧李加工标准体系结构,建立与国际接轨的相关标准。专用标准目前几属空白,需要对欧李加工标准体系展开研究,为相关标准的制修定等提供指导。欧李作为我国特有的第三代水果资源,应以发展外向型产品为主,所定标准的技术指标应与国际接轨。
     2.攻克了欧李仁综合利用的关键技术,实现了欧李仁中欧李仁油、苦杏仁苷和欧李仁蛋白的全利用。抑制欧李仁油、苦杏仁苷和欧李仁蛋白分离提取过程中苦杏仁苷酶的催化活性是实现三者全利用的关键。在欧李仁破碎和欧李仁油萃取时,通过控制水分活度抑制其催化活性,适宜的水分活度为0.67;继而在苦杏仁苷和欧李仁蛋白分离提取时,通过控制乙醇的浓度和温度抑制其催化活性并防止欧李仁蛋白过度变性,浓度和温度以75%、45℃为最佳;采用以上条件对欧李仁油、苦杏仁苷和欧李仁蛋白进行分离提取,得率分别可达到96.98%、73.04%和90.29%,其中蛋白的氮溶解指数为69.86%,工艺条件由每批次处理1-5g欧李仁放大到每批次处理100g,两者实验结果相互接近;欧李仁储藏过程中,苦杏仁苷在其内源苦杏仁苷酶的作用下可发生水解,因此供制备苦杏仁苷的欧李仁需要在适宜的水分活度下储藏,储藏时适宜的水分活度为0.67。此外,将上述三种成分全利用的技术路线用于苦杏仁中苦杏仁苷、苦杏仁油和苦杏仁蛋白的分离提取,苦杏仁油得率为97.68%,苦杏仁苷得率为75.38%,苦杏仁蛋白得率为89.23%、氮溶解指数为71.05%,供制备苦杏仁苷的苦杏仁亦应于在0.67的水分活度条件下储藏。
     3.确定了欧李加工标准体系框架图、构建了欧李加工标准体系。欧李标准体系框架图是由欧李加工过程要素(x轴)、欧李加工产品门类(y轴)和标准层次(z轴)构成的三维框架结构。确定了9个一级加工过程要素:加工原料、设施环境、生产加工、包装标识、产品、检测及检验、贮藏运输、销售和综合;将加工产品门类分为四大类:综合、欧李果肉加工品(综合、鲜食、贮藏、制汁、制酒、糖制、罐藏、冷冻、色素提取及其他)、欧李仁加工品(综合、欧李仁油、欧李仁蛋白、中药郁李仁、苦杏仁苷及它们的深度加工产品)和欧李核壳加工品(综合、不同用途的欧李核壳粉及活性炭产品);将标准分为三个层次:基础标准、通用标准和专用标准。在此基础上,提出了包括原料分级标准及其加工品质评价标准、加工技术标准、产品质量标准和检验检测方法标准在内的应有或预计发展的欧李加工专用标准33部,同时收集了已经发布的相关标准479部(欧李专用标准1部,通用标准478部),构建了欧李加工标准体系。
     4.研究了功能栗仁加工、板栗粉低碳节能工艺和超临界CO2制备辣椒红色素的酶法脱辣技术,对板栗酒加工进行了产业化示范。(1)功能栗仁是在保持板栗仁形态完整的前提下,将其蛋白质酶解为具有生物活性的短肽,以强化栗仁的降压和抗氧化功能。目前短肽得率为43.62%,水解度26.27%,ACE抑制的IC50值4.70mg/mL,亚油酸氧化抑制的IC50值4.26mg/mL,清除超氧阴离子、羟自由基和DPPH三种自由基的IC50值分别为2.77、7.78和4.30mg/mL。(2)对渗透脱水和真空微波干燥两种技术进行集成,或将这两种技术和其他干燥技术进行集成,可开发不同品质板栗粉加工的低碳、节能工艺。以燕红为原料,采用渗透脱水,目前可脱除需去除水分的55.65%,固形物增加率6.72%,联合热风干燥,制品品质较好。(3)提出超临界CO2制备辣椒红色素的酶法脱辣技术。步骤1:低压连续萃取分离辣椒碱和辣椒红;2:加酶于介质,以水为夹带剂,将残留辣椒碱水解为无辣味、同辣椒红极性差异较大的香草基胺和脂肪酸;3:在线分离去除香草基胺和脂肪酸。目前1次循环脱辣率达到31.6%。(4)在北京怀柔对板栗酒加工进行了产业化示范。建设了生产车间、生产线,制定了技术规程,培养了技术人员,同时发明快速澄清技术,使澄清时间由通常的6个月缩短为20天。
The approaches and strategies of processing and utilization of cerasus humilis were put forward in the field of processing technology, on the base of analyzing the nutrition components, processing suitability, current situation and some problems. According to the approaches and strategies, the key technology of multipurpose use of cerasus humilis kernel was studied, by which we could obtaine the oil, amygdalin and protein. The processing standard system construction frame and diagram of standard system were established. In addition, the other research results were briefly described, including functional chestnut kernel, low-carbon and energy-saving process of Chinese chestnut powder, enzyme-catalyzed elimination of capsaicinoids from capsanthin extracted by supercritical carbon dioxide, development and demonstration of Chinese chestnut wine. There were some main conclusions of this paper.
     1. To the processing and utilization of cerasus humilis, our main work includes three aspects as follows:(1) The processing quality evaluation should be developed, in order to program the cerasus humilis industrial layout from a high starting point. The evaluation model and evaluation criterion would be established; the processing suitability of different type cultivars (lines) would be evaluated, basing the different products and uses, including pharmaceutical product, fruit drink, table, preserved fruit, and ecological conservation; the special-purpose type cultivars (lines) would be elected.(2) The technology of storage and fresh-keeping should be developed, which suitable for different purposes. The postharvest physiology and postharvest pathology would be studied systematically; the effects of maturity degree, collecting methods, pre-cooling pattern, packaging type, environment condition on the storage physiology, preservation duration and storage quality would be studied; based this, the achievements would be integrated so as to develop technology of storage and fresh-keeping, such as cold storage, controlled atmosphere storage, convenience controlled atmosphere storage, modified atmosphere packaging, freezing-point storage, cold-chain logistics and logistic distribution for supermarkets, etc.(3) The characteristic technnology and products should be studied, which suit to the processing of cerasus humilis, and the intensive processing should be integrated with multipurpose use. In order to reserve the calcium in the product to the high degree, the present product would be improved, and the new products would be developed; the technical route for intensive processing and multipurpose use must be considered as a whole, and the former should be integrated with the latter in the course of product development; the technology should be resolved, by which we could obtaine the oil, amygdalin and protein, meanwhile, of which the deep processing products should be developed; the activated carbon and fruit shell powder product would be developed, using fruit shell as raw material.(4) It is essential to establish the standard system and formulate the standard with links to international level. At present, the specific standard belongs to blank still in processing and utilization of cerasus humilis, to establish the standard system was essential, in order to provide guidance to the formulation and revision of the standard concerned. Cerasus humilis, the third generation fruit, which was distributed only in China, was suitable to develop export-oriented processing product, therefore technical indexes of system should link to international levels.
     2. The key technology of multipurpose use of cerasus humilis kernel was resolved, by which we could obtaine the oil, amygdalin and protein. Because amygdalin can easily be hydrolyzed by the amygdalase in the kernel, it's essential to inhibit the catalytic activity to obtain the three. In the process of crashing the kernel and extracting the oil, the catalytic activity was inhibited by controlling the water activity, with the optimal value of0.67. Then when we extracted the amygdalin and protein, in order to inhibit the catalytic activity and prevent the protein denaturation, meanwhile, the concentration and temperature of ethanol was controlled, of which the optimal value was75%and45℃, respectively. Under the optimized conditions, the yield of the oil, amygdalin and protein was96.98%,73.04%and90.29%, respectively, NSI of the protein was69.86%. Batch processing volume was enlarged from1-5g to100g, the similar results were obtained. The amygdalin of the kernel could be hydrolyzed by the endogenous amygdalase, so the cerasus humilis kernel, to be used as raw materials to produce amygdalin, should be stored at0.67of the water activity to prevent the hydrolysis. In addition, the strategy was applied to the extraction of the oil, amygdalin and protein of bitter almond, Under the optimized conditions, the yield of the oil, amygdalin and protein was97.68%,75.38%and89.23%, respectively, NSI of the protein was71.05%. Similarly, the almond, to be used as raw materials to produce amygdalin, should be stored at0.67of the water activity to prevent the hydrolysis.
     3. The standard frame structure chart of processing and utilization of cerasus humilis was designed, and then the standard system was established. The chart of3-dimension construction, which consists of three axis, x axis indicates the elements of processing industry supply chain, y axis indicates products range, z axis indicates hierarchical structure. There were9primary chain units, including raw materials, facility and environment, production and processing, label of package, product, test and measurement, storage and transportation, sales, and comprehension. Main products were divided into four series:comprehension, products from fresh fruit(storage, juice, wine, preserve and jam, canned food, frozen food, pigment extraction, etc.), products from cerasus humilis kernel(comprehension, oil, protein, semen pruni, amygdalin, and their deep processing products), and products from fruit shell(comprehension, activated carbon and fruit shell powder product). The standard type is divided into three hierarchies:basic, general, and individual character standard. Under the principle of the standard frame structure chart, a total of33standards as planned was proposed, including standards for grades of raw materials, processing quality evaluation, processing techniques, product quality, inspection and testing standard, etc. Meanwhile,479relative standards published were collected, in which there are1individual character standard and479general character standard. Based on these, we prepared diagrams of standard system for processing and utilization of cerasus humilis.
     4. The following4aspects were studied:preparation of functional chestnut kernel, low-carbon and energy-saving process of Chinese chestnut powder, enzyme-catalyzed elimination of capsaicinoids from capsanthin extracted by supercritical carbon dioxide, and development and demonstration of Chinese chestnut wine. The main conclusions were as follows:(1) the protein in chestnut kernel was hydrolyzed into activity peptide by proteolytic enzyme while the chestnut kernel was still kept the complete form, in order to intensify or endow the chestnut kernel with some health function and develop the functional chestnut kernel products. In the optimum conditions,43.62%of the peptide yield and26.27%of hydrolysis degree could be obtained. The chestnut kernel hydrolysate brought about a higher ACE inhibitory activity with IC50value of4.70mg/mL, and a stronger inhibitory activity to linoleic acid oxidation and scavenging effects on superoxide radical, hydroxyl radical and DPPH radical, of which the IC50value was4.26,2.77,7.78and4.30mg/mL, respectively.(2) By means of integrated technologies between osmotic dehydration and microwave drying or between each of two and other drying methods, the low-carbon and energy-saving process could be attained. For example, more than55.65%of the water needed to be removed could be removed from the Yanhong Chinese chestnut through osmotic dehydration in45%sucrose at40℃at60rpm for7h, and the solids gain was6.72%. The powder product qualities was good, to remove the remaining water by air-drying.(3)The method for elimination of capsaicinoids from capsanthin extracted by supercritical carbon dioxide was proposed. Step1: capsaicinoids were extracted and separated from capsanthin using the sequential extraction procedure under low pressure. Step2:Using water as entrainer, lipase was added to the medium, and the residue was hydrolyzed into fatty acids and vanillylamine, which there was a large difference to the capsanthin in polar. Step3: The fatty acids and vanillylamine were removed from the medium on-line. Capsaicinoids removal rate could reach31.6%through1-cycle reaction procedure.(4) The development and demonstration of Chinese chestnut wine was performed in Huairou district in Beijing. The production workshop and production line were constructed, the operational procedure was laid down, the technicians were trained, and the technique of high-speed clarifying the wine was invented, by which the time to clarify is shorten from6months to20days.
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