畜产品冷冻干燥工艺优化及产品复水性研究
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摘要
食品加工、保藏和运输中会发生各种物理变化及生物化学变化，这些变化不仅会改变食品本来的颜色和结构，而且使芳香物质变质，营养成分下降，最终导致食品品质降低。选择有效的保藏方法能够防止食品品质降低。干燥是保藏食品的一种古老的方法，但是用风干等传统方法干燥的制品通常会使食品品质降低。冷冻干燥是基于升华现象的一种重要的干燥方法。相比于传统干燥方法，冷冻干燥能保持物料原有结构，含水物料中的水分在低温下脱除相对彻底，多种降解反应被减少到最低程度。但高耗能使真空冷冻干燥的成本高出热风干燥的4-8倍，其中升华用去了总能量的一半。优化升华过程操作条件，对改进热传递，缩短干燥时间，减少真空能耗有着十分重要的意义。同多数多变量过程一样，在冻干中涉及大量的显性或隐性影响因素，但只有物料厚度、干燥室压强及加热板温度可以控制。冷冻干燥实验属于高耗时、高耗资的工作，而且并不是在任何可能的操作范围内都可进行。长期以来，许多学者及工程技术人员都希望能大量减少实验量，以数学模型模拟冻干过程。数学优化是降低过程耗能、增大生产率、降低加工成本的重要途径。本文通过冷冻干燥的数学模型、统计模型与条件实验研究干切牛肉、酸乳、熟制鹌鹑蛋冷冻干燥的工艺优化，跟踪冷冻干燥过程水分、物料中心温度、物料表面温度随时间的变化，建立模型预测干切牛肉、酸乳冷冻干燥过程的动态参数。冻干制品浸入水中复水，检测其复水后的食用品质。具体内容与结果如下：
1．冷冻干燥过程数学优化模型的建立
本文基于Lichtfield＆Liapis模型，建立了干切牛肉、酸乳冷冻干燥能耗的确定型模型，计算了当物料厚度、干燥室压强、加热板温度在三因素五水平设计时，干燥周期、生产率及能耗的模拟值。采用统计软件SPSS 13.0将模拟值进行非线性回归，得出干燥周期、生产率及能耗的统计型模型，采用统计软件LINGO 4计算了干切牛肉、酸乳冷冻干燥的最低能耗。计算结果为：当干切牛肉物料厚度10mm，干燥室压强10Pa，加热板温度78℃时单位水分脱除能耗最低，为19164 KJ·Kg~(-1)(H_2O)，其相应干燥周期6.52h，生产率172.29 g·m~(-2)h~(-1)。当酸乳装盘厚度10mm，干燥室压强10Pa，加热板温度51℃时单位水分脱除能耗最低，为27522 KJ·Kg~(-1)(H_2O)，其相应干燥周期14h，单位面积为生产率77.89 g·m~(-2)h~(-1)。
2．畜产品冷冻干燥工艺优化的实验研究
通过测定干切牛肉、酸乳、熟制鹌鹑蛋的共晶点、共熔点，确定了预冻终点温度。通过单因素试验研究预冻速率与干燥速率的关系，确定了优化的预冻工艺。干切牛肉、酸乳、熟制鹤鹑蛋的优化预冻速率分别为-0.33℃／min、-0.62℃／min、-0.77℃／min。通过单因素实验研究干燥室压强、加热板温度、物料厚度与干燥速率的关系。干切牛肉、酸乳冷冻干燥过程中操作变量物料厚度(L)、干燥室压强(P)、加热板温度(T)与目标函数干燥时间(t)、单位面积生产率(Pr)、单位水分脱除能耗(E)的交互关系已通过数学优化模型确定．通过实验确定了干切牛肉、酸乳冷冻干燥的最佳组合参数：厚度10mm、干燥室压强10Pa，加热板温度分别为78℃、52℃，预冻速率分别为-0.33℃／min、-0.62℃／min。开展三次干切牛肉、酸乳的冻干重复实验，结果表明：干切牛肉干燥时间、单位面积生产率及单位水分脱除能耗的实验值与数学优化值的绝对误差分别低于0.13h，3.5 g·m~(-2)h~(-1)，383 KJ·Kg~(-1)(H_2O)。相对误差分别小于1.63％、1.78％及1.1％。酸乳干燥时间、生产率及能耗的实验值与计算值的绝对误差分别低于0.23h、1.5 g·m~(-2)h~(-1)、0.278 KJ·Kg~(-1)(H_2O)，相对误差分别低于2.0％、4.5％及1.4％。实验值与计算值很接近，说明本文建立的干燥过程优化模型可以确定千切牛肉、酸乳的冷冻干燥优化工艺。通过单因素实验确定熟制鹌鹑蛋的优化参数为：预冻速率加热板温度85℃，干燥室压强10Pa，干燥时间10.2h。
3．冷冻干燥过程的动态预测与验证
假设干切牛肉、酸乳冷冻升华过程中冻结层温度T_i由预冻终点温度T_f经过每K温度上升到熔点温度T_m，以气体分子运动论及物质、能量平衡原理为基础，推导出冻结浓缩酸乳经过T_i时的升华层厚度d_(is)、升华量w_i、升华时间t_i及冻结物料T_i时升华所需物料表面温度T_(is)的计算模型；假设解吸干燥过程中水分含量由升华结束水分百分含量经过每0.5％w／w下降到0.0％w／w，成功模拟了预冻终温-28℃，物料厚度为7mm的干切牛肉、酸乳在干燥室压强p_s=10Pa，加热板温度T_h=42℃的操作条件下开展的冷冻升华干燥实验。并预测与验证了预冻终温-30℃、-28℃，物料厚度10、4mm的干切牛肉、酸乳冷冻升华干燥过程c_i、T_i、T_(is)的动态值及干燥周期S_(ti)。结果表明：预测c_i、T_i、T_(is)与实测值很接近。水分含量的相对误差小于10％，温度误差不超过±5℃。说明模型能有效预测干切牛肉、酸乳冷冻干燥过程的动态参数。
4．冷冻干燥产品复水性
将冻干产品在不同温度的水中浸泡复水，观察它们的形状、色泽、口感等复水特性。样品可复水到冷冻干燥前水分含量的90％，复水速率与产品类型、冻结条件等多种因素有关，在最初5min迅速吸水，随之减速，最终停止吸水．冷冻对物料微观结构、挥发性成分影响甚微，复水样品总体结构的弱化由干燥阶段引起，可能是与水混合时所需机械能引起。然而，样品的物理特性被保留，通过调节复水量，样品原来的强度能够恢复。冷冻干燥对乳酸菌的存活有影响，冻干后活菌量下降2～3个对数单位。
The physical, chemical and biological changes during food manufacturing, storage and transportation result in unsatisfactory changes of food color, structure, aroma components and nutrition substances. The choice of the right method of preservation can be the key for a successful operation. Drying is an old method for food' preservation, however, conventional methods such as hot air drying often make food quality inferior. Freeze-drying is an important drying process based on the sublimation phenomenon which has the following advantages compared to the conventional drying process: the material structure is maintained, moisture is removed at low temperature, product stability during the storage is increase, and the fast transition of the moisturized product to be dehydrated minimizes several degradation reactions. However, the cost of freeze-drying is 4-8 times as that of hot air drying. Especially, the sublimation operation needs 50% of the whole energy. Therefore, it is important to improve heat transfer, to shorten drying time, and thus to reduce vacuum energy consumption by optimizing operation conditions. The optimization is an important tool to maximize the amount of removed water and minimize the time of the freeze drying process with significant impact on the energy consumption and hence in the process costs. But the freeze-drying experiments are time consuming and are usually expensive to be carried out in all possible operating ranges. Because of that, expecting great reduction of experiments considerable increase in the development and use of mathematical models that can predict the behavior of the freeze,drying process satisfactorily is observed. Freeze-drying is a process affected by many factors, of which material thickness, shelf temperature, chamber pressure could be controlled. In this research, the freeze-drying processes of cooked beef slice, yoghourt and quail-eggs were optimized though the use of the statistical models and experimental study. The another objective of this study was to track the changes of the moisture content, frozen layer temperature and sample surface temperature with drying time, and establish the models to predict the dynamic parameters for primary freeze drying of cooked beef slice and yoghourt. Freeze-dried products were re-hydrated by dipping them in water and their rehydration characteristics examined. The contents and results are as follows.
1. Development of optimization models during freeze-drying
The deterministic mathematical models for drying period, productivity and energy consumption during freeze-drying of cooked beef slice were development based on the models originally developed by Lichtfield and Liapis (1979). The drying period, productivity and energy consumption were calculated when the three main influential parameters (sample thickness, chamber pressure and shelf temperature) under five different levels of the other two. By nonlinear regression analysis of the calculation data, using statistical software SPSS 13.0, the statistical models for the drying period, the productivity and the energy consumption, with the freeze-drying sample thickness, chamber pressure and shelf temperature were also established and the optimal objective values were solved by statistical software LINGO 4. Finally, the freeze-drying process of cooked beef slices and yoghourts was optimized though the use of the statistical models LINGO 4. The results of the freeze drying of cooked beef were that: the minimum energy consumption 19164 KJ·Kg~(-1) (H_2O), the drying period 6.52h, the productivity 172.29 g·m~(-2)h~(-1), with sample thickness 10 mm, chamber pressure 10 Pa, shelf temperature 78℃. The results of the freeze drying of yoghourts were that: the minimum energy consumption 38263 KJ·Kg~(-1) (H_2O), the drying period 14h, the productivity 77.89 g·m~(-2)h~(-1), with sample thickness 10 mm, chamber pressure 10 Pa, shelf temperature 51℃.
2. Experimental study on optimization of freeze-drying process of livestock products
The eutectic and co-melting temperatures of cooked beef slices, yoghourt and quail-eggs were measured and their terminal freezing temperatures were determined. The relationship between the freezing and drying velocities of cooked beef slices, yoghourt and quail-eggs were studied through single factor experiments, and optimal freezing technologies were determined. The relationship between drying velocities and chamber presses, heating board temperatures and sample thickness were also studied through single factor experiments. The relationship between the drying time, productivities, energy consumption and the sample thickness, chamber pressure, of the heating board temperature have been determined through mathematical optimization previous mentioned. At last the optimal combination of the parameters for the freeze-drying technology of cooked beef slices, yoghourt, were determined through experiments. They are as follows: the temperatures of the heating board are 78℃and 52℃, respectively, the chamber pressures are 10Pa, the freezing velocities are -0.33℃/rain and -0.62℃/min, respectively, and material thickness are 10mm. The absolute errors of the drying periods, productivities and energy consumptions between calculated and experimental data for cooked beef slices were low than 0.13h, 3.5g·m~(-2)h~(-1) and 382.63 KJ·Kg~(-1) (H~2O), respectively, and for yoghourts were lower than 0.23h, 1.5 g·m~(-2)h~(-1), 278 KJ·Kg~(-1)(H_2O), respectively. The relatively errors between calculated and experimental data for cooked beef slices were low than 1.63 %, 1.78% and 1.1%, respectively, and for yoghourt, were low than 2.0%, 4.5% and 1.4%, respectively. It indicates that the optimization models established in the paper are feasible to optimize freeze drying process. The optimal parameters of cooked quail-eggs freeze drying was obtained through single factor experiment. They are as follows: the heating board temperature is 85℃, the chamber pressure is 10Pa, the freezing velocity is-0.77℃/min.
3. Prediction and validation of dynamic parameters during freeze drying
The predictive models were established, according to the kinetic theory of gases and heat and mass transfer principles, for quantifying changes of sublimation moisture c_i, sublimation time t_i, and sample surface temperature T_(is) with frozen layer temperature Ti. The predictive models during de-sorption were also established for quantifying changes of de-sorption time ti, central temperature in the sample Ti and the temperature on the sample surface T_(is) with de-sorption moisture ci. The changes of moisture content c_i, T_i and T_(is) in 6ram cooked beef slice with time during freeze,drying were simulated. Meanwhile, the models were used to predict the changes of c_i, T_i and T_(is) in 10mm and 4ram samples during freeze-drying. The results showed that the predicted c_i, T_i and T_(is) with time were nearest to the measured. Therefore, the established models could effectively predict the dynamicparameters for freeze drying of cooked beef slice and concentrated yoghourt.
4. Rehydration quality of freeze dried products
Freeze-dried products were re-hydrated by dipping them in water at different temperature and their rehydration characteristics, such as shape, color and taste properties were examined. The samples were found to restore up to 90% of their original moisture content, depending on the type of products and various other factors like the freezing condition. The water uptake happened rapidly during the first 30s and then slowed down with time until it finally stopped altogether. Microstructure and volatility component of freeze drying products were not seriously affected by freezing, while the drying step resulted in an overall structural weakening of the reconstituted products, possibly as a consequence of the mechanical energy required for mixing with water. However, its physical properties were retained and the original strength could be recovered by modulating the amount of water. The freeze-drying process affected survival of the lactic acid bacteria, resulting in a 2-3 log population reduction.
1．冷冻干燥过程数学优化模型的建立
本文基于Lichtfield＆Liapis模型，建立了干切牛肉、酸乳冷冻干燥能耗的确定型模型，计算了当物料厚度、干燥室压强、加热板温度在三因素五水平设计时，干燥周期、生产率及能耗的模拟值。采用统计软件SPSS 13.0将模拟值进行非线性回归，得出干燥周期、生产率及能耗的统计型模型，采用统计软件LINGO 4计算了干切牛肉、酸乳冷冻干燥的最低能耗。计算结果为：当干切牛肉物料厚度10mm，干燥室压强10Pa，加热板温度78℃时单位水分脱除能耗最低，为19164 KJ·Kg~(-1)(H_2O)，其相应干燥周期6.52h，生产率172.29 g·m~(-2)h~(-1)。当酸乳装盘厚度10mm，干燥室压强10Pa，加热板温度51℃时单位水分脱除能耗最低，为27522 KJ·Kg~(-1)(H_2O)，其相应干燥周期14h，单位面积为生产率77.89 g·m~(-2)h~(-1)。
2．畜产品冷冻干燥工艺优化的实验研究
通过测定干切牛肉、酸乳、熟制鹌鹑蛋的共晶点、共熔点，确定了预冻终点温度。通过单因素试验研究预冻速率与干燥速率的关系，确定了优化的预冻工艺。干切牛肉、酸乳、熟制鹤鹑蛋的优化预冻速率分别为-0.33℃／min、-0.62℃／min、-0.77℃／min。通过单因素实验研究干燥室压强、加热板温度、物料厚度与干燥速率的关系。干切牛肉、酸乳冷冻干燥过程中操作变量物料厚度(L)、干燥室压强(P)、加热板温度(T)与目标函数干燥时间(t)、单位面积生产率(Pr)、单位水分脱除能耗(E)的交互关系已通过数学优化模型确定．通过实验确定了干切牛肉、酸乳冷冻干燥的最佳组合参数：厚度10mm、干燥室压强10Pa，加热板温度分别为78℃、52℃，预冻速率分别为-0.33℃／min、-0.62℃／min。开展三次干切牛肉、酸乳的冻干重复实验，结果表明：干切牛肉干燥时间、单位面积生产率及单位水分脱除能耗的实验值与数学优化值的绝对误差分别低于0.13h，3.5 g·m~(-2)h~(-1)，383 KJ·Kg~(-1)(H_2O)。相对误差分别小于1.63％、1.78％及1.1％。酸乳干燥时间、生产率及能耗的实验值与计算值的绝对误差分别低于0.23h、1.5 g·m~(-2)h~(-1)、0.278 KJ·Kg~(-1)(H_2O)，相对误差分别低于2.0％、4.5％及1.4％。实验值与计算值很接近，说明本文建立的干燥过程优化模型可以确定千切牛肉、酸乳的冷冻干燥优化工艺。通过单因素实验确定熟制鹌鹑蛋的优化参数为：预冻速率加热板温度85℃，干燥室压强10Pa，干燥时间10.2h。
3．冷冻干燥过程的动态预测与验证
假设干切牛肉、酸乳冷冻升华过程中冻结层温度T_i由预冻终点温度T_f经过每K温度上升到熔点温度T_m，以气体分子运动论及物质、能量平衡原理为基础，推导出冻结浓缩酸乳经过T_i时的升华层厚度d_(is)、升华量w_i、升华时间t_i及冻结物料T_i时升华所需物料表面温度T_(is)的计算模型；假设解吸干燥过程中水分含量由升华结束水分百分含量经过每0.5％w／w下降到0.0％w／w，成功模拟了预冻终温-28℃，物料厚度为7mm的干切牛肉、酸乳在干燥室压强p_s=10Pa，加热板温度T_h=42℃的操作条件下开展的冷冻升华干燥实验。并预测与验证了预冻终温-30℃、-28℃，物料厚度10、4mm的干切牛肉、酸乳冷冻升华干燥过程c_i、T_i、T_(is)的动态值及干燥周期S_(ti)。结果表明：预测c_i、T_i、T_(is)与实测值很接近。水分含量的相对误差小于10％，温度误差不超过±5℃。说明模型能有效预测干切牛肉、酸乳冷冻干燥过程的动态参数。
4．冷冻干燥产品复水性
将冻干产品在不同温度的水中浸泡复水，观察它们的形状、色泽、口感等复水特性。样品可复水到冷冻干燥前水分含量的90％，复水速率与产品类型、冻结条件等多种因素有关，在最初5min迅速吸水，随之减速，最终停止吸水．冷冻对物料微观结构、挥发性成分影响甚微，复水样品总体结构的弱化由干燥阶段引起，可能是与水混合时所需机械能引起。然而，样品的物理特性被保留，通过调节复水量，样品原来的强度能够恢复。冷冻干燥对乳酸菌的存活有影响，冻干后活菌量下降2～3个对数单位。
The physical, chemical and biological changes during food manufacturing, storage and transportation result in unsatisfactory changes of food color, structure, aroma components and nutrition substances. The choice of the right method of preservation can be the key for a successful operation. Drying is an old method for food' preservation, however, conventional methods such as hot air drying often make food quality inferior. Freeze-drying is an important drying process based on the sublimation phenomenon which has the following advantages compared to the conventional drying process: the material structure is maintained, moisture is removed at low temperature, product stability during the storage is increase, and the fast transition of the moisturized product to be dehydrated minimizes several degradation reactions. However, the cost of freeze-drying is 4-8 times as that of hot air drying. Especially, the sublimation operation needs 50% of the whole energy. Therefore, it is important to improve heat transfer, to shorten drying time, and thus to reduce vacuum energy consumption by optimizing operation conditions. The optimization is an important tool to maximize the amount of removed water and minimize the time of the freeze drying process with significant impact on the energy consumption and hence in the process costs. But the freeze-drying experiments are time consuming and are usually expensive to be carried out in all possible operating ranges. Because of that, expecting great reduction of experiments considerable increase in the development and use of mathematical models that can predict the behavior of the freeze,drying process satisfactorily is observed. Freeze-drying is a process affected by many factors, of which material thickness, shelf temperature, chamber pressure could be controlled. In this research, the freeze-drying processes of cooked beef slice, yoghourt and quail-eggs were optimized though the use of the statistical models and experimental study. The another objective of this study was to track the changes of the moisture content, frozen layer temperature and sample surface temperature with drying time, and establish the models to predict the dynamic parameters for primary freeze drying of cooked beef slice and yoghourt. Freeze-dried products were re-hydrated by dipping them in water and their rehydration characteristics examined. The contents and results are as follows.
1. Development of optimization models during freeze-drying
The deterministic mathematical models for drying period, productivity and energy consumption during freeze-drying of cooked beef slice were development based on the models originally developed by Lichtfield and Liapis (1979). The drying period, productivity and energy consumption were calculated when the three main influential parameters (sample thickness, chamber pressure and shelf temperature) under five different levels of the other two. By nonlinear regression analysis of the calculation data, using statistical software SPSS 13.0, the statistical models for the drying period, the productivity and the energy consumption, with the freeze-drying sample thickness, chamber pressure and shelf temperature were also established and the optimal objective values were solved by statistical software LINGO 4. Finally, the freeze-drying process of cooked beef slices and yoghourts was optimized though the use of the statistical models LINGO 4. The results of the freeze drying of cooked beef were that: the minimum energy consumption 19164 KJ·Kg~(-1) (H_2O), the drying period 6.52h, the productivity 172.29 g·m~(-2)h~(-1), with sample thickness 10 mm, chamber pressure 10 Pa, shelf temperature 78℃. The results of the freeze drying of yoghourts were that: the minimum energy consumption 38263 KJ·Kg~(-1) (H_2O), the drying period 14h, the productivity 77.89 g·m~(-2)h~(-1), with sample thickness 10 mm, chamber pressure 10 Pa, shelf temperature 51℃.
2. Experimental study on optimization of freeze-drying process of livestock products
The eutectic and co-melting temperatures of cooked beef slices, yoghourt and quail-eggs were measured and their terminal freezing temperatures were determined. The relationship between the freezing and drying velocities of cooked beef slices, yoghourt and quail-eggs were studied through single factor experiments, and optimal freezing technologies were determined. The relationship between drying velocities and chamber presses, heating board temperatures and sample thickness were also studied through single factor experiments. The relationship between the drying time, productivities, energy consumption and the sample thickness, chamber pressure, of the heating board temperature have been determined through mathematical optimization previous mentioned. At last the optimal combination of the parameters for the freeze-drying technology of cooked beef slices, yoghourt, were determined through experiments. They are as follows: the temperatures of the heating board are 78℃and 52℃, respectively, the chamber pressures are 10Pa, the freezing velocities are -0.33℃/rain and -0.62℃/min, respectively, and material thickness are 10mm. The absolute errors of the drying periods, productivities and energy consumptions between calculated and experimental data for cooked beef slices were low than 0.13h, 3.5g·m~(-2)h~(-1) and 382.63 KJ·Kg~(-1) (H~2O), respectively, and for yoghourts were lower than 0.23h, 1.5 g·m~(-2)h~(-1), 278 KJ·Kg~(-1)(H_2O), respectively. The relatively errors between calculated and experimental data for cooked beef slices were low than 1.63 %, 1.78% and 1.1%, respectively, and for yoghourt, were low than 2.0%, 4.5% and 1.4%, respectively. It indicates that the optimization models established in the paper are feasible to optimize freeze drying process. The optimal parameters of cooked quail-eggs freeze drying was obtained through single factor experiment. They are as follows: the heating board temperature is 85℃, the chamber pressure is 10Pa, the freezing velocity is-0.77℃/min.
3. Prediction and validation of dynamic parameters during freeze drying
The predictive models were established, according to the kinetic theory of gases and heat and mass transfer principles, for quantifying changes of sublimation moisture c_i, sublimation time t_i, and sample surface temperature T_(is) with frozen layer temperature Ti. The predictive models during de-sorption were also established for quantifying changes of de-sorption time ti, central temperature in the sample Ti and the temperature on the sample surface T_(is) with de-sorption moisture ci. The changes of moisture content c_i, T_i and T_(is) in 6ram cooked beef slice with time during freeze,drying were simulated. Meanwhile, the models were used to predict the changes of c_i, T_i and T_(is) in 10mm and 4ram samples during freeze-drying. The results showed that the predicted c_i, T_i and T_(is) with time were nearest to the measured. Therefore, the established models could effectively predict the dynamicparameters for freeze drying of cooked beef slice and concentrated yoghourt.
4. Rehydration quality of freeze dried products
Freeze-dried products were re-hydrated by dipping them in water at different temperature and their rehydration characteristics, such as shape, color and taste properties were examined. The samples were found to restore up to 90% of their original moisture content, depending on the type of products and various other factors like the freezing condition. The water uptake happened rapidly during the first 30s and then slowed down with time until it finally stopped altogether. Microstructure and volatility component of freeze drying products were not seriously affected by freezing, while the drying step resulted in an overall structural weakening of the reconstituted products, possibly as a consequence of the mechanical energy required for mixing with water. However, its physical properties were retained and the original strength could be recovered by modulating the amount of water. The freeze-drying process affected survival of the lactic acid bacteria, resulting in a 2-3 log population reduction.
引文
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